With more than 250 million film bags ultrasonically sealed on GEA SmartPackers around the world, GEA Food Solutions has demonstrated that it knows how to make this cost-saving sealing technology work reliably on an industrial scale. The key to this success is an innovative technique we developed to ensure the sealing jaws remain parallel as they close on the film, making this Zero Reject Sealing System a front-runner in salad and grated cheese packaging applications.
With a GEA SmartPacker, you can be confident of seal integrity
More than 250,000,000 bags have been successfully sealed on GEA SmartPackers using ultrasonic sealing, so you can be confident that we know how to make it reliably on an industrial scale. To make certain your products are bagged with consistent seal integrity, we have developed an innovative technique for ensuring the sealing jaws remain parallel as they close on the film.
Seal integrity is guaranteed!
Ultrasonic bag sealing on vertical form, fill and seal machines is a welcome innovation for fresh salad and grated cheese packaging applications. It delivers consistent sealing performance even with packaging films as thin as 30 microns. The technology uses extremely fast ‘ultrasonic’ vibrations of one of the sealing jaws (called the sonotrode) to bond the two layers of film together at a molecular level, so that even if moisture, a piece of leaf or a cheese particle remain in the seal area, a perfect seal is still made. With conventional thermal sealing, such obstructions in the seal area may prevent an air-tight seal being made. The resulting reject bag has to be identified and removed, and its contents returned to the product flow. This not only wastes film but it is also labour intensive and costly.
Ensuring the sonotrode and anvil remain parallel
The key to success is to ensure that the anvil remain as parallel as possible as they close on the two layers of film. This not only places extreme demands on the engineering tolerances, it also means that external factors such as climatic conditions influence the jaw positioning or movement, and therefore affect its ability to make a seal. Even if the jaws are a few microns out at one end, the seal integrity is at risk. The GEA technology (patent pending) for controlling the anvil alignment eliminates the influence of those external factors. This also means that bags of different widths can be sealed using a single-width anvil jaw. The result is a consistent seal over the full width of the bag. This unique GEA technology has been proven in practice around the world.