Fin Wheels Archives - Greener Corporation https://greenercorp.com/tags-resource-block/fin-wheels/ Just another WordPress site Wed, 22 Apr 2026 16:40:30 +0000 en-US hourly 1 https://wordpress.org/?v=7.0 https://greenercorp.com/wp-content/uploads/2023/02/cropped-greenercorp-favicon-32x32.png Fin Wheels Archives - Greener Corporation https://greenercorp.com/tags-resource-block/fin-wheels/ 32 32 Maintain Efficiency on Flow Wrappers with Systematic Preventative Maintenance https://greenercorp.com/resource-blog/maintain-efficiency-on-flow-wrappers-with-systematic-preventative-maintenance/ Tue, 11 Nov 2025 16:46:06 +0000 https://greenercorp.com/?post_type=resource-blog&p=29808 https://www.youtube.com/watch?v=ltvzBM9keJ4?rel=0 A Tech Bite from Greener Technical Service Manger Jeff Fouche Due to production demands and a shortage of experienced mechanics, maintenance on flow wrappers is often reduced to immediate problem solving. In the rush to restore production, this reactive maintenance relies on short-term fixes that don’t fully resolve the underlying cause of the problem and […]

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Jeff Fouche Greener Corporation Packaging Solutions

A Tech Bite from Greener Technical Service Manger Jeff Fouche

Due to production demands and a shortage of experienced mechanics, maintenance on flow wrappers is often reduced to immediate problem solving. In the rush to restore production, this reactive maintenance relies on short-term fixes that don’t fully resolve the underlying cause of the problem and fail to restore peak efficiency. Repeat problems require additional quick fixes and further erode efficiency.

This Greener Tech Bite details systematic preventative maintenance practices for flow wrappers that sustain peak efficiency and production levels.

If you and your team don’t have the required time or experience to implement preventative maintenance, Greener’s Technical Specialists can provide regularly scheduled onsite visits to perform line evaluations, make necessary updates, and provide training on these procedures.

Systematic Preventative Maintenance 

The following flow wrapper components and adjustments—from the product feed through to the package discharge—should be evaluated and updated at least every three months.

Product Infeed

On the product infeed, stretched or worn components cause product misalignment and create timing problems. Replace worn or stretched infeed flight chains. Inspect the belts—even those with automatic tensioners—and replace them if they are stretched, worn, or frayed and can’t hold the proper tension.

The product infeed should be level and aligned with the flow wrapper.

Rails – Deck Plates – Forming Box

Check the rails, deck plates, and the forming box for misalignment or damage and readjust, repair, or replace them as needed.

When not level, smooth, or properly positioned, these components inhibit movement of the product and packaging material, causing malformed packages that delay production.

Packaging Material Unwind

Replace the bearings of shafts and rollers on the packaging material unwind that don’t spin freely; they create excess tension that causes tracking problems.

Adjust rollers to create the proper tension on the packaging material as it moves throught he forming process.

Fin Wheels

Fin wheel issues can cause slippage, poor tracking, and seal problems. Make sure that the tension between the fin wheels is correct and adjust their tilt to prevent slippage and create tighter packages.

Replace fin wheels that are worn, damaged, or have sharp edges. Check the condition of the fin wheel bearings and replace them if needed.

Cutting and Sealing Head

The cutting and sealing head requires frequent inspection and updating.

Backlash

Check for and remove backlash between the upper and lower sealing jaws.

Gears

Inspect the gears and replace them if necessary.

Springs or Compression Washers

Assess the condition of the springs or compression washers and adjust or replace them as needed.

Bearings

Worn bearings cause chronic problems that can be difficult to diagnose. To determine if new bearings are needed, follow this bearing evaluation process. 

Carbon Impression

Next, remove the knives and anvils and, with the sealing jaws at operating temperature, run carbon impressions to evaluate their condition and setup.

Sealing Jaws and Adjustments

Replace worn or damaged sealing jaws. Check and, if needed, readjust the clearance, phasing, serration alignment, and pressure.

Clean the slots to ensure that knives and anvils can be firmly and accurately seated. To prevent cutting problems, always replace the anvil when installing a new knife.

After adjusting the knife with shims or adjustment screws, re-check your sealing setup with another carbon impression.

Cleaning

At any point in the packaging process, insufficient cleaning can degrade efficiency.

Clean components such as belts, formers, deck plates, fin wheels, and both the upper and lower sealing jaws during scheduled production breaks and whenever time allows—before problems occur.

Regularly Scheduled Preventative Maintenance with Greener Corporation

Relying on reactive maintenance erodes package quality and output levels.

If you don’t have a systematic preventative maintenance program for your flow wrappers, consider partnering with Greener Corporation for regularly scheduled Technical Service visits. Our Technical Specialists will perform line evaluations, make necessary updates, and provide training to keep your flow wrappers running at peak efficiency.

To learn more contact Greener Corporation. We provide integrated parts and technical service solutions worldwide.

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]]> Align Flow Wrapper Packaging Processes on the Centerline https://greenercorp.com/resource-blog/align-flow-wrapper-packaging-processes-on-the-centerline/ Wed, 18 Jun 2025 09:34:35 +0000 https://greenercorp.com/?post_type=resource-blog&p=26325 https://www.youtube.com/watch?v=UFKtQ-QF85c?rel=0 A Tech Bite from Greener Technical Service Specialist Jeff Fouche As product moves along the infeed and through your flow wrapper, each packaging process should accurately align on the centerline. This Greener Tech Bite explains how to detect and fix even small, seemingly insignificant misalignment of flow wrapper packaging processes that degrade package quality and […]

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Jeff Fouche Greener Corporation Packaging Solutions

A Tech Bite from Greener Technical Service Specialist Jeff Fouche

As product moves along the infeed and through your flow wrapper, each packaging process should accurately align on the centerline. This Greener Tech Bite explains how to detect and fix even small, seemingly insignificant misalignment of flow wrapper packaging processes that degrade package quality and delay production.

Symptoms of Misalignment

Symptoms of centerline misalignment include loosely wrapped packages, uneven fin seals that easily pull free from the fin wheels, and package wrinkles and pleats that cause sealing problems.

Package wrinkles and seal problems caused by forming issues on a flow wrapper
Fin Seal problem on package from a flow wrapper

Assess Your Alignment

Flow wrapper packaging processes aligned on the centerline

1. Align the Product Feed

First, make sure the product infeed is inline with your wrapper. Infeeds often get moved out of position and deliver the product at an angle, causing a number of chronic problems.

Product feed misaligned off center on a flow wrapper

2. Center the Forming Box

Forming box adjustments can often be improved, especially if they have been moved off-center to compensate for product entering the wrapper at an angle. Ensure that the forming box is level, centered, and aligned with the product feed.

Forming box on horizontal flow wrapper

The packaging material tube should form evenly around the product, without wrinkles or gaps, and should help maintain the inline spacing between products to prevent them from interfering with the cutting and sealing process.

Product centered side to side in package from horizontal flow wrapper
Product centered end to end in package from horizontal flow wrapper

3. Center the Fin Wheels

Also make sure each pair of fin wheels is on the centerline.

Adjust Fin Wheels on Flow Wrapper Centerline

Misaligned fin wheels create loosely wrapped, wrinkled packages that are more difficult to cut and seal.

Fin wheels with package

4. Center the Sealing Jaws

On some flow wrappers the shafts have multiple mounting hole options. Make sure both the upper and lower sealing jaws are installed on center in relation to the package.

Easy Seal™ QUICK-CHANGE Jaw Assembly on shaft centerline

5. Center the Packaging Material Roll

Now check the packaging material roll and align it on center. The material may have been mounted off center to compensate for misalignments in other areas of the packaging process.

Flow wrapper flexible packaging material roll on center
Flow wrapper flexible packaging material roll off-center

Once the first four processes and the packaging material roll are centered, the edges of the fin seal should meet evenly and create a clean, parallel edge.

Fin wheels and tightly wrapped package on flow wrapper

6. Center the Product Rails

With the material on the center line, you can center the product rails so that they guide the product correctly into the forming box.

Flow wrapper product feed and product rails on centerline

Remember to align flow wrapper packaging processes on the centerline as part of your preventative maintenance program and to resolve packaging problems.

If you have questions about preventative maintenance or packaging problems on your flow wrappers or vertical baggers, contact Greener Corporation. We provide integrated parts and technical service solutions worldwide.

Greener Corporation logo

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]]> Optimizing Fin Wheel Performance on Flow Wrappers https://greenercorp.com/resource-blog/optimizing-fin-wheel-performance-on-flow-wrappers/ Sun, 26 Jan 2025 19:29:27 +0000 https://greenercorp.com/?post_type=resource-blog&p=23441 https://www.youtube.com/watch?v=8e1g3FZRDrw?rel=0 When poor tracking, slippage, and other problems occur on flow wrappers, fin wheel pressure or temperature is often increased to get the machine up and running again. These adjustments, however, may only be a temporary fix that could cause more severe problems in the future. This Greener Tech Bite presents a systematic approach you […]

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When poor tracking, slippage, and other problems occur on flow wrappers, fin wheel pressure or temperature is often increased to get the machine up and running again.

These adjustments, however, may only be a temporary fix that could cause more severe problems in the future.

This Greener Tech Bite presents a systematic approach you can use to:

  • Optimize Fin Wheel Adjustments
  • Troubleshoot Problems 
  • Implement Preventative Maintenance 

Follow these procedures to ensure consistent package quality and productivity.

Fin Wheel Adjustment on Flow Wrapper

Most wrappers utilize at least two, and often three, pairs of fin wheels. The first pair, typically unheated, works primarily to draw the packaging material tube forward through the wrapper. The second and third pairs seal the fin and guide the tube forward.

The same four steps can be followed to solve fin wheel problems and for preventative maintenance, which should be performed every six months.

  1.  Inspect
  2. Check Bearings
  3. Test Sealing Pressure
  4. Check Adjustments and Design
Three pairs of fin wheels on a flow wrapper

1. Inspect

Begin by removing the cover plates and making a visual and physical inspection.

Damage, Wear, Sharp Edges

Rotate each pair of fin wheels and check the sealing surface for damage and wear. Make sure their top edges have not grown sharp from rubbing against the cover plate.

Fin Wheel Inspection on Flow Wrapper
Clean

Clean any packaging material or product that has built up on the sealing surface.

Flow wrapper fin wheels contaminated with packaging material and product

Replace fin wheels that are worn, damaged, or that can’t be properly cleaned with a new, matched pair; never replace just one fin wheel.

Pair of new fin wheels for a flow wrapper

2. Check Bearings

Even with new fin wheels, slippage and poor tracking can continue if the bearings are worn. Bearing failure is often caused by excess pressure and heat adjustments that were made to compensate for worn fin wheels.

Using protective gloves if the fin wheels are hot, grasp and try to rock each fin wheel backward and forward, between the product feed and the product discharge. Any freedom of movement indicates worn bearings that should be replaced.

Checking fin wheel bearings on a flow wrapper

3. Check Sealing Pressure

Fin wheel wear that was not detected during the visual inspection can still cause problems.

Bring the fin wheels to operating temperature, and engage each pair together with a doubled piece of packaging material between them.

fin wheel bearing test engage fin wheels with packaging material between them
fin wheel bearing test check tension by pulling packaging material

If the material can easily be pulled out, make sure the tension between the fin wheels is within normal operating parameters. If pressure is too low, make corrective adjustments to increase it. If pressure settings are correct, the fin wheels are likely worn and need to be replaced.

Worn bearings will also yield this result, so be sure to follow step 2 before doing this test.

4. Check Adjustments and Design

If problems continue after following the first three steps:

Temperature

Make sure that fin seal temperature settings are within the proper range for your flexible packaging material. Excess heat causes slippage problems and can distort and even melt through the fin seal.

Fin seal slippage problem shown on package from flow wrapper
Fin seal slippage and temperature problems shown on package from flow wrapper
Tilt

Next, check the tilt adjustment of the fin wheels. Additional tilt, where the infeed end of the fin wheel is slightly higher than the discharge end, gives the fin wheels more “bite” and helps them draw the tube forward.

This tilt also pulls the material downward to create tighter packages.

Side view of fin wheel tilt adjustment on a flow wrapper

Make this adjustment with care.

Too severe an angle can cause the fin wheels to rub against the cover plate and develop sharp upper edges that cut the package.

Fin wheels beneath cover plate on flow wrapper
Gripper Grooves

If problems still persist, install fin wheels with gripper grooves for the first, leading pair. Gripper grooves provide extra tension to prevent slippage and tracking issues.

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Fin Wheel for flow wrapper with Gripper Grooves for improved tracking
Dura-Therm

Some flexible packaging materials are poor thermal conductors, such as paper and some thicker structures.

For these applications, fin wheels made from Dura-Therm provide more consistent, responsive heat transfer to prevent temperature fluctuations that cause sealing and tracking issues.

Product Presentation & Package Formation

Problems that persist after following these troubleshooting steps are often caused by upstream issues.

Learn more from our post and video on Product Presentation and Package Formation.

Product Presentation and Package Formation on Flow Wrappers

If you’d like technical assistance with fin wheel or other packaging problems on flow wrappers or vertical baggers, contact Greener Corporation.

We provide integrated parts and technical services worldwide.

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]]> Flow Wrapper Fin Wheels: Problems, Maintenance, & Design https://greenercorp.com/resource-blog/flow-wrapper-fin-wheels-problems-maintenance-design/ Fri, 11 Feb 2022 23:00:13 +0000 https://gc.tdgrepo.com/resource-blog/flow-wrapper-fin-wheels-problems-maintenance-design/ https://vimeo.com/1185276628?share=copy&fl=sv&fe=ci Fin wheels on flow wrappers are often overlooked as the cause of poor package quality or reduced productivity. This Greener Tech Bite explains the problems caused by contaminated and worn fin wheels and reviews maintenance and design options that will help you prevent these issues. Most wrappers utilize at least two, and often three, […]

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Fin wheels on flow wrappers are often overlooked as the cause of poor package quality or reduced productivity. This Greener Tech Bite explains the problems caused by contaminated and worn fin wheels and reviews maintenance and design options that will help you prevent these issues.

Most wrappers utilize at least two, and often three, pairs of fin wheels.

The first pair, typically unheated, works primarily to draw the film tube forward through the wrapper.

The second and third pairs seal the fin and guide the film tube forward.

Fin Wheel Problems
Slippage

As fin wheels wear or grow contaminated with product, ink, or film residue they begin to slip against the film. This slippage distorts the fin seal with wrinkles and creases that channel leaks in the end seal and make the package unappealing to consumers.

Pressure

Increasing pressure between the fin seals may help get you through a production run, but they should be cleaned or replaced, if worn or damaged, as soon as possible.

Relying on excess pressure will further degrade the condition of the fin wheels and wear out the shafts and bearings.

Heat

Raising the temperature setting to compensate for poor seal quality can damage the film and further contaminate the fin wheels with film residue or product.

Fin Wheel Maintenance

Fin wheels should be regularly cleaned and inspected as part of your preventative maintenance program. Replace them when they begin to wear.

Fin Wheel Design

When you need new fin wheels, Greener will recommend the optimal design for your packaging film, product, and running conditions. Design options include serration profile, material, and seal width.

 

 

Serrations

We recommend gripper grooves on the first pair of fin wheels. This design draws the film with less pressure and helps prevent slippage.


Material

High Durability Stainless fin wheels provide excellent durability and prevent rust and corrosion without the need for plating.

Dura Therm provides consistent, responsive heat transfer to help maintain narrow temperature windows. This material also offers excellent corrosion resistance.

 
Seal Width

Opportunities may exist to reduce the fin seal width on your package and decrease film costs.


Standardization

Our Project Development team can help you standardize fin wheel designs across multiple makes, models, and lines of flow wrappers to achieve consistent performance.

Optimizing the design of your fin wheels and regularly inspecting, cleaning, and maintaining them will help you achieve peak package quality and productivity on your flow wrappers.

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]]> Preventative Maintenance Checklist for Flow Wrappers https://greenercorp.com/resource-blog/preventative-maintenance-checklist-for-flow-wrappers/ Wed, 21 Jul 2021 16:39:40 +0000 https://gc.tdgrepo.com/resource-blog/preventative-maintenance-checklist-for-flow-wrappers/ https://vimeo.com/1185279795?share=copy&fl=sv&fe=ci Changes on horizontal flow wrappers occur regularly—during sanitation, product changeovers, part installations and adjustments, maintenance, and from wear and tear. These changes can impact the success of your next production run, yet they often go unnoticed. This Greener Tech Bite presents our quick, Preventative Maintenance Checklist. By investing five or ten minutes to inspect these […]

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Changes on horizontal flow wrappers occur regularly—during sanitation, product changeovers, part installations and adjustments, maintenance, and from wear and tear. These changes can impact the success of your next production run, yet they often go unnoticed.

This Greener Tech Bite presents our quick, Preventative Maintenance Checklist. By investing five or ten minutes to inspect these four areas before starting production, you will be up and running more quickly and avoid hours of downtime.

1. Package Formation
2. Controller
3. Sealing Jaws
4. Cutting & Sealing

It’s easy to underestimate the value of these inspections, or to skip them when time seems too tight. But even details that may seem insignificant, such as a protruding screw in a deck plate, can cause problems.

Not everything you discover will require immediate action. But you’ll be able to track conditions such as backlash or jaw wear and know when its time to correct them—before they degrade package quality and disrupt production. When urgent problems do occur, you can compare current conditions with previous inspection results to recognize what has changed and resolve the issue.

1. Package Formation

Begin by checking the Package Formation components. Small, seemingly insignificant variations here can create wrinkles, pleats, and other deformities that cause leakers and other problems.

♦ Are the Deck Plates, Guards, and Rails properly installed, tightened, and adjusted for the product you are running?
♦ Make sure the Forming Box is the correct size or, if adjustable, has been set to the right dimensions. Is it installed and tightened properly?
2. Controller
♦ Moving to the Controller, confirm that the Recipe for package length, temperature settings, and other variables is set for the current product.
♦ Are the Fin Wheels worn, damaged, or contaminated with product?
3. Sealing Jaws
♦ Are the Sealing Jaws clean? Check the jaws for wear and damage.
♦ Is there excessive backlash, or free play, between the upper and lower shafts?
♦ Run a Carbon Impression for each pair of sealing jaws and check clearance and alignment. Look for additional evidence of wear or damage.
Be sure to date and save the impressions; over time they will help you document change and solve problems.
4. Cutting and Sealing

Lastly, inspect the Cutting and Sealing process. Even without product, you can check the basics. Mount the packaging material roll and run some film through the head.

♦ Is the Material Registration correct?
♦ Are the knives adjusted properly and Cutting cleanly, without banging?
♦ Are you getting good Seals?
♦ Make sure the Product Carriers and Discharge Guides, such as brushes and belts, are properly set and will not impede packages as they move through and exit the cutting and sealing head.

When you perform regular Preventative Maintenance Inspections, you’ll have time to make corrective adjustments before you are under the stress of production. Once product comes down the line, you will get up and running more quickly, with less scrap. And you’ll be able to keep running, with fewer problems and less downtime.

For more technical resources browse additional posts and videos and contact Greener Corporation. We develop and deliver Full Process Solutions, worldwide.

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]]> Product Presentation and Package Formation on Horizontal Flow Wrappers https://greenercorp.com/resource-blog/product-presentation-and-package-formation-on-horizontal-flow-wrappers/ Thu, 13 Dec 2018 22:31:29 +0000 https://gc.tdgrepo.com/resource-blog/product-presentation-and-package-formation-on-horizontal-flow-wrappers/ https://vimeo.com/1185280015?share=copy&fl=sv&fe=ci The ultimate quality of the packages produced on horizontal flow wrappers requires a complex series of events to form and fill each package and move it through the packaging process. In the following post and “Tech Bites” video we explore the many steps that occur before and after packages are cut and sealed—from the […]

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The ultimate quality of the packages produced on horizontal flow wrappers requires a complex series of events to form and fill each package and move it through the packaging process. In the following post and “Tech Bites” video we explore the many steps that occur before and after packages are cut and sealed—from the product feed and film unwind through to the discharge belt—that must be fine-tuned to optimize seal integrity, package appearance, and productivity.

 

Film Roll Alignment
  • Center the film roll side to side so that the edges of the fin seal meet evenly and create a clean, parallel edge.
Fin Seal with Uneven Edge
Fin Seal with Parallel Edge
Film Tension
  • If the film wanders off center, check to make sure the film is making enough surface contact with the pivot rollers so that the resulting tension keeps it aligned side to side.
  • Adjust the spring tension and the angle at which the film enters the forming box so that the film tracks smoothly and evenly. Too much or too little tension can cause wrinkles and irregularities in the package.
Forming Box
  • The forming box should be correctly designed and adjusted for the product and film in use.
  • For products that are variable in size, make sure that the former size accommodates the largest possible product.
Product Centered Side-to-Side in Package
  • Adjust the product rails on the infeed so that as they guide the product into the forming box the film tube forms evenly around it, without excess space on either side.
  • In most applications the product, forming box, fin wheels, and the sealing and cutting head should all align on the same centerline.
Product Centered End-to-End In Package
  • Each product portion should sit against the flight pin as it is pushed into the forming box.
  • For the best results, the distance between the flight pins should correspond with the package length, and the film speed should be synchronized with the product speed.
  • Make adjustments so that the product is inserted as far into the forming box as possible.
  • Product that is too far forward or back in the film tube can be damaged by the crimpers and can contaminate the end seal.
Deck Plates
  • Deck plates that are not level and smooth can inhibit the movement of the film and the product.
  • Exercise care when removing and reinstalling deck plates—they can be easily bent or otherwise damaged.
  • Avoid using screws that protrude and inhibit package movement.
Fin Wheels

For optimal performance of the fin wheels, which draw the film through the former and create the fin seal, make sure that:

  • Their speed corresponds with the product feed and the film feed rates.
  • They apply enough pressure to draw and seal the film properly, but not so much that they cut thought the film.
  • Their serration pattern is correctly designed for the film in use. In some cases a different pattern on each pair of fin seals is required to draw and seal properly.
  • The sealing faces are not worn, damaged, or contaminated with product.
  • Temperature settings (if applicable) are not too high. Excess heat can distort the film and cause film slippage.
Vacuum

If vacuum pressure is used, adjust it to properly remove air from the package without creating wrinkles and pleats that can cause channel leakers in the end seal.

Fin Seal Fold

Make sure that the fin folder wheels or other folding mechanism consistently fold the fin seal so that it will lie flat against the package. Irregularities in this process create wrinkles and creases in the fin seal that degrade package appearance and cause leakers at the end seal.

Tuckers and Gusseters

If your package requires the use of tuckers and gusseters, adjust them so that the extra layers of film they create at the end seal are as consistent in size and location as possible. Make sure that your crimpers are designed and set up according to these specifications to provide optimal sealing pressure and heat transfer (if applicable).

Cutting and Sealing Head

Packages should maintain speed and remain on the same horizontal plane as they move from the infeed deck plate, through the cutting and sealing head, and to the discharge belt. Impediments and alterations to this flow create distortions and pleats in the film that degrade package appearance and can cause end seal leakers.

Vertical Alignment
  • Adjust the cutting and sealing head vertically so that the crimpers come together midway between the top and bottom of the package, keeping it on the same horizontal plane.
  • When packages get pulled upward or downward by the crimpers they are more likely to develop wrinkles and creases, which degrade package appearance and can cause end seal leakers.
Product Carriers
  • Make sure the product carriers, mounted on the lower crimper shaft, are correctly sized so that they maintain the package along the same horizontal plane as it moves through the cutting and sealing head.
Package Discharge
  • Adjust package discharge guides such as brushes, belts, and rollers so that they do not impede the movement of packages as they exit the sealing and cutting head.
Pause / Dwell
  • To ensure proper presentation of the film tube and product to the sealing and cutting head, adjust the end seal pause, or dwell, so that the crimpers move at the same or at a slightly faster speed than the film.
Additional Resources

Please click on the links below for more information:

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]]> Troubleshooting Extra Layers of Film at the End Seal (Part 1 of 4): Refining and Eliminating Wrinkles and Creases on Horizontal Flow Wrappers https://greenercorp.com/resource-blog/troubleshooting-extra-layers-of-film-at-the-end-seal-part-1-of-4-refining-and-eliminating-wrinkles-and-creases-on-horizontal-flow-wrappers/ Tue, 14 Feb 2017 21:57:34 +0000 https://gc.tdgrepo.com/resource-blog/troubleshooting-extra-layers-of-film-at-the-end-seal-part-1-of-4-refining-and-eliminating-wrinkles-and-creases-on-horizontal-flow-wrappers/ Varying thicknesses of film at the end seal can cause sealing problems, especially at the transition point between two and four layers created by the fin seal, gussets, wrinkles and creases, as well at the corners. Applications of pressure and heat (if applicable) must be great enough to cause the sealant layer to flow into […]

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Varying thicknesses of film at the end seal can cause sealing problems, especially at the transition point between two and four layers created by the fin seal, gussets, wrinkles and creases, as well at the corners. Applications of pressure and heat (if applicable) must be great enough to cause the sealant layer to flow into and seal off these voids. Excess pressure can easily crush or split the end seal, while overheating distorts the seal and can cause poor hot tack, where the film springs back open, or “moons,” before the seal can set.

The operating window for creating quality seals can be elusive, resulting in packages that leak, are distorted, and have little appeal to consumers.

An important step in troubleshooting these issues is to eliminate unintended wrinkles and creases. This post, the first in a four-part series, will examine this process on horizontal flow wrappers; Part 2 considers these issues on vertical baggers.

Any impediment that disturbs the even flow of film can distort packages and cause leakers; a combination of factors is often to blame. To find the causes of these problems and fix them we recommend a comprehensive analysis, beginning with the film roll and following along sequentially as the film is unwound, formed, filled, and sealed.

Film Tension

Too much, too little, or uneven tension can cause wrinkles and creases.

  • Make sure the film coming off the roll is properly centered, side-to-side, over the forming box.
  • Check for bent rollers, worn bearings, or other impediments that can keep the rollers from turning freely.
  • Make sure the power unwind and the film tension rollers are adjusted properly.
  • Keep in mind that inadequate slip on the film creates extra tension that can cause wrinkles and creases.
Product Presentation

Inconsistent product size and off-center positioning of the product in the ultimate package can create or exacerbate film wrinkles in the end seals. This is especially true with round or irregularly shaped products. Variances should be monitored and eliminated whenever possible.

Fin Wheels

Problems forming the fin seal or drawing the film tube through the wrapper can create unintended wrinkles and creases.

  • Clean product contamination from the fin wheels.
  • Check the fin wheels for wear or damage.
  • On heat seal applications, make sure the fin wheels are not too hot.
  • Make sure the fin wheels are set-up properly, to ensure film tube consistency and quality seals.
  • Ensure that the serration pattern is optimally designed for drawing and sealing the film in use.
Deck Plates

Damaged or improperly installed deck plates can twist the package and lead to undesired wrinkles and creases.

  • Take care during frequent removal and reinstallation of deck plates—they may seem inconsequential but can be easily bent or otherwise damaged.
  • Install deck plates properly, and avoid using screws that protrude and inhibit package movement.

As the film tube, with the product inside, moves toward the sealing and cutting head there are a few additional considerations:

Tuckers
  • If tuckers are used, refine their adjustments to create smoother, more consistent folds.
Timing
  • To ensure proper presentation of the film tube and product to the cutting and sealing head, adjust the end seal pause, or dwell, so that the crimpers move at the same or at a slightly faster speed than the film.

Vertical Adjustment of the Sealing Head

  • The cutting and sealing head should be adjusted vertically so that the crimpers come together midway between the top and bottom of the package. Packages that get pulled upward or downward by the crimpers are more likely to develop wrinkles and creases.

Taking steps to minimize or eliminate end seal wrinkles and creases is an important step toward optimizing seal quality. Our next blog post, Part 2 of 4, will explore how to refine the package formation process on vertical baggers. The third and fourth installments in this series will review Machine Adjustment Procedures and Crimper and Sealing Jaw Designs that improve seal quality across multiple layers of film at the end seal.

Subscribe to Greener Corporation’s  Technical Resource Blog  to be notified when new items are posted.

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