FL-2000 Aluminum Foil Sealer

Aluminum Foil Sealer: The Ultimate FAQ Guide

This guide has all information you’re looking for about aluminum foil sealer machine.

Whether you want to learn about parts, working principle, features, quality standards or support equipment, every information is right here.

Keep reading if you want to bean an expert in this foil sealing machine.

What is an Aluminum Foil Sealer?

An aluminum foil sealing machine is equipment that seals containers using aluminum foil.

It hermetically seals the containers.

Aluminum foil sealing machine

What are the Advantages of Aluminum Foil Sealer?

An aluminum foil sealing machine has many advantages.

Here are some of the advantages of an aluminum foil sealing machine:

· Provision of a Barrier

The machine will produce a complete barrier to light, oxygen, moisture, and bacteria to the containers.

This will increase the shelf life of products.

· Packaging Solution

The machine will provide a tamper-evident packaging solution to your products.

This will enable consumers to trust your products hence satisfying them.

· Brand Strategy

An aluminum foil sealer will ensure your products are in good condition and quality.

This will have a great impact on brand recognition and the image of the company at large.

· Streamline Packaging Process

One advantage of an aluminum foil sealer is that you can integrate it into the production line with other equipment.

· Ease of Operation

The machine is easy to use as most of the sealing is automatic.

What are the Challenges in Aluminum Foil Technology?

There are some problems you may encounter while using an aluminum foil sealer.

These issues are easy to troubleshoot to identify and sort out the problem.

Here are some of the disadvantages of using aluminum foil technology:

· Inadequate Impedance

Impedance is the measure of the total opposition of a circuit to a current.

The causes of an inadequate impedance in an aluminum foil tester may be due to:

1. Inaccurate wiring on the main power supply.
2. The input voltage being low.

Here are some ways on how to correct the above issues:

1. Measure the voltage to confirm if it is the main cause of the issue.
2. Adjust the voltage is it is below 205 VAC.
3. Ensure to adjust the voltage according to the specific aluminum foil tester manual.

· Output Current and Over Vault Flaws

An output current and over vault flaw in an aluminum foil tester may happen due to:

1. The transformer having loose connections.
2. Power obstruction from the power interface.
3. The sealing coil may have a loose connection, which will not allow power to flow accordingly.

Here are some solutions to the above problems:

1. Replace the power interface platform.
2. Tighten all loose connections to the sealing coil.

· Under Voltage Flaw

Some of the causes of an under-voltage flaw in an aluminum foil tester may include:

1. Problems with the sealing coil.
2. A faulty inverter
3. An open bus fuse.
4. Loose wire connections.

Here are the solutions to the above problems:

1. Make sure to change faulty components with new legitimate ones.
2. Ensure all wire connections are proper.
3. Inspect all the electrical components and repair or replace them with the help of a certified technician.
4. Ensure the fuse component is in the right position and fix it if it is not in the proper position.

· Increasing Temperature Flaw

The causes of a high temperature in the aluminum foil tester can be due to:

1. An inadequate cooling system.
2. A high environmental temperature.

Here is how to combat the increasing temperature flaw:

1. Inspect the thermal switch and the main control board.
2. Ensure the cooling fan is rotating as it should with no blockages to airflow.
3. Relocate the aluminum foil tester to a cooler environment.
4. Use compressed air to blow blockages out of the system.
5. Replace or repair faulty thermal switches.

· Stalling Containers

When sealing the containers using an aluminum foil sealer, some of the containers may fail to move.

This can be due to:

1. Improper system setup.
2. Power interference.
3. Improper alignment of the containers with the exit bracket.

Here are some ways of solving the above issues:

1. Install a fiber optic sensor that will sound an alarm when the containers stall.
2. Properly orient all sensors.
3. Replace or repair any power interference issues.
4. Properly program the aluminum foil sealer to eliminate the stalling problems.

What are the Applications of Aluminum Foil Sealer?

Aluminum foil sealing technology

Several industries use an aluminum foil sealer.

Here are some of the industries:

Beverage Industries

Examples of these beverages include:

1. Carbonated beverages
2. Coffee
3. Tea
4. Wine
5. Water
6. Soda
7. Cider
8. Juice
9. Canned beer

Chemical Industries

Examples include:

1. Cooking oil
2. Cleaning liquid
3. Ink and lacquer
4. Lube oil
5. Glue
6. Paint
7. Nuclear waste
8. Radioactive substances
9. Automotive fluids like diesel oil, petrol, etc.
10. Farm chemicals

Food Industries

Examples include:

1. Nutrition powder
2. Dry foods such as rice, cereals, nuts, etc.
3. Meat
4. Tuna
5. Jam
6. Soup
7. Seafood
8. Vegetables
9. Sauce
10. Fruits
11. Honey

Pharmaceutical Industries

Examples include:

1. Medical supplies
2. Powders
3. Pills
4. Veterinary supplies
5. Pharmaceutical raw materials

What is the Coating on the Aluminum Foil?

Aluminum foil has a coat of lacquer or water-based latex or laminated to a film of polymer

The laminated film sticks through, extrusion coating, lamination, or adhesive.

Many lidding applications use vinyl-based lacquer-coated aluminum.

What is Induction Sealing?

Induction sealing involves a non-contact method that bonds material.

Thermoplastics make up these materials.

Induction sealing happens via electromagnetic induction that produces eddy currents to heat these materials.

Packaging industries use this process to hermetically seal a container cap that has a laminate sealable foil.

The heat will bond the foil to the container.

Also, the foil seal in induction sealing is an aluminum heat induction sealing liner foil.

Induction sealing

How does Conduction Sealing compare to Heat Sealing?

In conduction sealing, you will use a conduction sealer to hermetically seal the containers.

On the other hand, in heat sealing, you will use both thermal pressure and heat pressure to seal two thermoplastic materials.

In conduction sealing, you will pass the containers beneath a hot conduction heat.

The conduction heat will use heat and pressure to seal the aluminum foil to the containers.

Also, the conduction heat has to get in contact with the aluminum foil seal in a conduction sealing process.

In both a conduction sealing and heat-sealing process, you first have to heat the conduction head before the process begins.

A conduction sealing process will use a lot of power as it heats the sealer head at all times to laminate the materials.

Again, in heat sealing, you will seal the products with no caps of lids in place.

On the other hand, in heat sealing, a heat source has to melt and dissolve the seal when it comes in contact with the sealing materials.

In both a conduction and heat-sealing process, the sealing may delay as the sealing components must be hot.

 Aluminum foil sealing machine

Which Side of the Aluminum Foil should Touch the Product?

An aluminum foil has a shiny side and a matte side.

Several sources recommend that the shiny side face away from the food as it is more reflective than the dull side.

New studies mention that the side does not matter at all.

This is because the two sides are different due to manufacturing processes.

The side that comes into contact with the rollers in the manufacturing process comes out shiny.

This means that it is a by-product of the manufacturing process and is not purposely there.

What Components of Aluminum Foil Sealer?

Many parts make up an aluminum foil sealer, which enables it to seal products.

These parts have their specific functions, but all work together in the sealing process.

Here are the components of an aluminum foil sealer

· Pneumatic Unit

The pneumatic unit will help in pressing the aluminum foil and seal to the containers.

It also assists in guiding parts of the machine, such as the lubricating unit.

· Sealing Plugs

The sealing plug does the job of bonding the sealing material to the different containers.

Sealing plugs come in a variety of shapes and sizes.

Also, the shape and size of the sealing plugs are dependent on the seal you prefer to use.

· Handle Springs

The handle springs automatically assist in moving components of the aluminum foil sealer.

For instance, it moves the sealing plugs back and forth.

· Electrical Units

The electrical unit provides the power that runs the automatic or semi-automatic aluminum foil sealing machine.

Also, the electrical unit has parts such as switches, transistors, inductors, capacitors, resistors, integrated circuits, etc.

· T-bar Holders

T-bar holders are available in manual aluminum foil sealers.

It assists in guiding the mechanical press in the machine.

· Blades

The blades in an aluminum foil sealer will carve the sealing material in the right shape and size.

This ensures the seals fit perfectly on the containers.

· Lubrication Unit

The lubrication system ensures the moving parts of the aluminum foil sealer does not heat up.

It greases all moving parts.

This will assist in preventing the tear and wear of the machine.

· Heating Element

The heating element is also known as the induction coil.

The heating element provides an oscillating electromagnetic field.

Besides, the electromagnetic field will heat the aluminum foil before the sealing process.

This will hermetically seal the containers.

· Conveyor Belt Unit

The conveyor belt unit assists in moving the containers from one point of the aluminum foil sealer to the next.

· Coolers

The coolers decrease the temperature of the polymer to create the bond.

It will also lower the temperature of the heat sealing layer.

· Motors

The motors will control the moving parts of the machine.

It can control the speed by either increasing or decreasing the sealing process.

· Programmable Logic Controller [PLC]

The PLC is an interactive part of the machine where you can control, program, and monitor the machine.

It is in a central position, and you can also input commands to guide the sealing process.

· Sensors and Alarms

Sensors and alarms are available in automatic aluminum foil sealers.

They help in identifying any mishaps in the aluminum foil sealer.

The sensors will automatically stop the sealing process, and this minimizes any damages or losses.

The alarms will sound a warning to the operators to initiate the repairing of the problem.

· Printing Unit

In automatic aluminum foil sealers, the printing units embed logos on the seals.

The logos identify the specific company and further improves the brand image.

· Circular Wire Conversion Unit

The circular wire conversion units will help in shaping the sealing material following the shape of the containers.

It can form various shapes depending on the input commands as it is flexible.

How does an Aluminum Foil Sealer Operate?

All components of an aluminum foil sealer work together to achieve the sealing process.

Here is how an aluminum foil sealer operates:

· First Phase

The first phase in operating the machine involves making sure the machine is in good working condition.

Ensure the machine has lubricants, the electrical components are functional, and that the machine is clean.

Once this verification is complete, load the sealing materials to the hopper.

The sealing materials include paper boards, heat sealing layers, and aluminum foils.

There is aluminum foil sealing processes that do not use a paper board.

Switch the aluminum foil sealer on to begin the sealing process.

· Assembling the Sealing Material

First, the aluminum foil sealer gathers the sealing materials each at a time.

Then, the first sealing material is the paper boards, which come into contact with the caps.

Consequently, the next layer is the heat sealing layer that will stick the paper board and the aluminum foil together.

Then, the last layer is the aluminum foil.

The aluminum layer bonds to the containers.

· Laying the Seal on the Caps

Different aluminum foil sealers work differently.

In some, you can first place the sealing materials on the caps before you proceed to seal it to the containers.

In others, you can place the sealing materials on the containers, seal it, then lastly cap the containers.

· Laying the Seal on the Containers

The container will pass beneath the sealing plugs.

Then, the aluminum foil sealer will place the seal on the container and seal it.

An electromagnetic eddy will heat the sealing plug to enable it to seal the materials on the containers.

Again, the heat sealing layer, which was in the middle of the sealing materials, will melt.

Thereafter, the paper board will absorb it and bond on the aluminum foil.

The heat sealing layer will also flow on the lips of the container to bond the aluminum foil to the container.

· Cooling Phase

A conveyor belt then moves the containers with the sealing materials to the cooling phase.

The coolers will lower the temperature of the bond hence forming a hermetic seal.

· Review Phase

The containers pass through a sealing test.

This test will establish if the bond is strong.

A seal strength testing machine conducts this process.

After passing the test, the containers are ready for packaging.

How does an Automatic Aluminum Foil Sealing Machine and Manual Aluminum Foil Sealing Machine Compare?

Fully automatic aluminum foil sealer

Manual aluminum foil sealer

An automatic aluminum foil sealing machine will automatically accomplish the whole sealing process with no human involvement.

A manual aluminum foil sealing machine requires human involvement in its operation.

Also, a manual aluminum foil sealing machine is affordable and readily available than an automatic foil sealing machine.

In terms of size, a manual foil sealing machine is smaller than an automatic foil sealing machine.

An automatic foil sealing machine is fast and reliable than a manual foil sealing machine.

This means you can meet large demands within a short time.

An automatic aluminum foil sealing machine has a PLC and HMI for easy operation and monitoring of the sealing process.

In terms of cost, an automatic aluminum foil sealing machine will cost you more than the manual aluminum foil sealing machine.

Despite the high cost, an automatic aluminum foil sealing machine will reduce your production cost as it requires no human involvement.

Integration of an automatic aluminum foil sealing machine in the production line is easy and cost-efficient.

This integration is not possible with the manual aluminum foil sealing machine.

An automatic aluminum foil sealing machine has an advantage over the manual one since it has sensors that automatically detect faults.

This enables the automatic machine to reduce damages and losses.

Both the automatic and manual aluminum foil sealing machine can handle various types and sizes of containers.

An automatic aluminum foil sealing machine is suitable for commercial industries due to its large production capacity.

The manual aluminum foil sealing machine is suitable for small scale sealing processes since it has a low production capacity.

An automatic aluminum foil sealing machine can operate for a long time as long as all the sealing materials are available.

On the other hand, when a human operator is not available, a manual aluminum foil sealing machine will not operate.

What Quality Standards should an Aluminum Foil Sealing Machine conform to?

An aluminum foil sealing machine should conform to quality standards for health and safety reasons.

Sone of the quality standards that the machine should conform to include:

· Good Manufacturing Practice [GMP] Quality Standard

Good Manufacturing Practice quality standard ensures that an aluminum foil sealer:

1. The production of the machine is consistent.
2. The machine conforms to the quality standards.
3. Produces reliable and accurate sealing.

· CE Mark Quality Standard

All companies in the world accept this quality standard even though it applies majorly to European Economic Areas.

· Food and Drug Administration [FDA] Requirements

Food and Drug Administration controls all medical equipment and supplies sold in the USA.

· International Organization for Standardization [ISO] Quality Standard

ISO ensures an aluminum foil sealer operates according to the set industry standards.

How can you Achieve the Perfect Aluminum oil sealing process?

The process of ensuring the perfect aluminum foil sealing involves:

· Matching the Materials

Matching the sealing material ensures that the cap, liner, and sealer are in line.

This ensures that no gaps develop during the sealing process.

· Assemble the Operating Window

Setting up the operating window determines the types of seals such as:

1. No seal
2. Partial seal
3. Good seal
4. Overheated seal

This information will provide a foundational baseline for every application.

It also helps in establishing test methods that will identify a good seal.

How much does Aluminum Foil Sealer Cost?

The price of an aluminum foil sealer depends on various factors such as:

• Level of automation
• Production capacity
• Manufacturer
• Technological advancements

Considering all these, the price may range from 100 US dollars to 60,000 US dollars.

Can you Customize an Aluminum Foil Sealer?

Yes, you can customize an aluminum foil sealer.

Customization will depend on the following factors:

• Production capacity.
• Type of containers you are sealing.
• Size of your production plant.
• Machine needs such as single or multi-line machines.
• Other special requirements.

Taking all this into consideration, you can customize the following:

Aluminum foil sealer

· Sealing Head

The sealing head can come as a flat or tunnel type head.

This depends on the type of bottles you are sealing.

· Brand of the Electrical Parts

This allows you to select the brands you like for use in the electrical parts.

· Size of the Machine

This depends on the size of your production plant.

How does a Flat Seamer Head compare to a Tunnel Seamer Head?

A flat seamer head will scatter the electromagnetic field that comes from the head.

On the other hand, the tunnel seamer head will produce rich magnetic fields on top of and the side of the cap.

Also, a flat seamer can seal a wide area and can seal many sizes without changing the flathead.

Again, a tunnel seamer head produces uniform electromagnetic fields for a consistent seal.

Besides, a tunnel seamer head produces strong fields meaning it can seal thicker caps.

A tunnel seamer head has the disadvantage of not being able to handle a wide range of bottles.

The limitation of a flat head seamer is that the concentration of the electromagnetic field is not strong.

This means that it can produce inconsistent seals if the container is not at the center and under the seam head.

What are the Different Types of Sealers and Sealing Equipment available in the Market?

The different types of sealers and sealing equipment available in the market include:

Foil sealer machine

· Bands

Band sealers will seal pouches and can be vertical or horizontal.

· Clamshell

A clamshell is a handheld device.

It adds tamper-proof to self-locking clamshells on items such as salads, sandwiches, hardware items, etc.

· Blister or Tray

A blister will attach the thermoform blisters to paperboards or film backings.

· Vacuum

A vacuum sealer is common for food since it allows low oxygen levels to minimize spoilage of the products.

· L Bar

An L bar sealer uses film to establish three seal edges from a double-over length of the materials.

· Jaw or Crimp

A crimp sealer will apply heat and pressure to seal pouches one after the other.

· Cap and Bottle

Here, you will cap bottle them pass them via the sealer to provide a tamper-proof seal.

It seals the container from the cap to the neck of the bottle.

· Case and Carton

Case and carton sealers will use a taping head, which applies an adhesive to the flaps of the cartons.

What are the Features of Aluminum Foil Sealer?

The features will vary depending on if the machine is automatic or manual.

Here are some of the features of the automatic foil sealer:

• It comes with a PLC and HMI for easy operation and monitoring.
• The height is adjustable and comes with a removable truckle.
• It comes with sensors that will inhibit and detect malfunctions.

What should you consider when choosing an aluminum foil sealer?

Here are some factors to consider when choosing an aluminum foil sealer:

· Level of Automation

If you need to seal a large number of containers, it is best to go for a fully automatic aluminum foil sealer.

This is because it will perform all tasks with no human involvement consistently and reliably.

· Technical Parameters

The technical parameters of the machine will assist you to determine if it is suitable for your production needs.

For instance, you will get information such as size, power usage, sealing methods, etc.

· Price Range

The price of an aluminum foil sealer is no doubt a factor worth considering.

Also, the price, however, should not be the only determinant in choosing this machine.

The budget you have will influence the machine you will purchase.

· After Sales Service

It is vital to choose an aluminum foil sealer from a manufacturer who will provide after-sales services.

These services include installation, shipping, parts, etc.

Which Equipment can you Integrate with Aluminum Foil Sealer?

Some of the support equipment you can use with an aluminum foil sealer include:

• Bottle packaging machine
• Bottle labeling machine
• Bottle filling machine

How should you Maintain an Aluminum Foil Sealer?

Maintaining an aluminum foil sealer will ensure the machine lasts for a long time and meet its production capacity.

Regularly conduct inspections to ensure all components are in good working condition.

Clean the machine regularly to avoid the buildup of dust and mold.

Ensure the pneumatic unit has no blockages.

Repair and replace faulty electrical components to avoid the chances of fires breaking out.

Ensure the lubrication fluid is always in the machine to avoid tear and wear.

At SaintyCo, we offer a range of aluminum foil sealer machines.

Contact us now for all your aluminum foil sealer needs.