CRH Case Study

CRH-Unit1-437x324
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tray-meat

Customer Profile

This particular customer is one of the market leaders in the manufacture of food packaging. Their range of products include specialist absorbent pads for use in packaging meat, fruit and fish to help protect and preserve the freshness of food when packaged for transportation and storage.

Application

The top layer of the pad is a non-woven Polypropylene (which allows moisture to soak through) with a bottom layer of moisture proof Polyethylene to contain the absorbent crystals within the middle of the pad. There are different size and shape combinations depending on the food product in question.


Sealing Challenge

Initially the customer used operators to create the individual absorbent pads by layering the materials and manually sealing them with hot seal technology.

This was time consuming and costly, so they commissioned a purpose built machine for their production line to automate the process.

Ceetak designed the QPH module of the machine for the cross seal phase but the customer was using Ultrasonic welding technology for the second phase to create the side seals.

They found this method of sealing to be problematic and they were not achieving the desired results.

Technology Supplied

Quick Pulse Heat (QPH) and Continuous Rotary Heat (CRH) Sealing Systems


Ceetak Solution

QPH seal technology was fitted to create the cross seal in the material and outstanding results were achieved from the outset.  The seal was of high integrity and the production line ran with no problems.

For the second phase of the (longitudinal) seal process the customer was looking for an alternative technology to the Ultrasonic process they were using. Ceetak designed a Continuous Rotary Heat Sealing (CRH) System which consisted of 20 wheels (on two sides of the unit), 10 lanes on each.

The CRH wheels could be easily re-positioned along the frame or even removed depending on the size of the pad being produced.

The unit was retrofit to the existing machine with little complications.

  • More efficient sealing process
  • Ability to easily seal up to 3 layers of film
  • Complete assurance of integrity of the seal during the steam process
  • The bag corners were also mitre joined to remove the sharp corners previously present which removed any potential weak spots and therefore any potential¬†leakage paths

Results

The customer saw immediate benefits from updating their sealing technology including:

  • Heat Sealing technology with the ability to seal two layers of different materials
  • Consistent, high integrity seals
  • More cost efficient sealing process by removing manual operators
  • Less downtime and associated costs with reliable sealing technology
  • Flexible technology with the ability to produce different sized absorbent pads on one production line
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