What exactly is Induction Sealing Method?
Induction sealing is a simple process in which an aluminum seal liner is sealed on the opening of a bottle. This will provide leak free packaging as wee as the product safety. The manufacturer should insert the foil seal liners inside the cap and allowing the bottle to pass under the induction sealer after the filling and capping process. This is possible to apply both on Plastic (PET, PE, PP, PVC) & Glass bottles and jars. There are so many benefits for using induction foil seal liners. We will discuss them later on this page.
The majority of the manufacturers are into Induction Sealing these days to seal those products that are packed in bottles with screw caps to ensure the product safety from spillage and contamination. The induction seal can evenly seal the rim of the container while the cap is applied on the container and the seal liner is electronically heated. This ensures proper and uniform adhesion of the seal to the bottle mouth. In this method only the aluminum will be heated an no heat will reach the product and this will guarantee that the product wont affected by the heat.
Induction Seal Benefits
The induction sealing method has so many upsides that we are going to discuss some the them below:
The induction seal is a high-performance barrier that will prevent ingress or egress of moisture and gases. Therefore due to the airtight seal, it will maintain the aroma & freshness of the product hence will increase consumer satisfaction and confidence.
Induction foil seals will significantly increase the shelf life time of products due to the strong sealing they provide. They will keep the quality of the products for a longer period of time which is always a great bonus for manufacturers. More shelf life time means more time to sell.
The other great advantages of using aluminum foil seal is leakage prevention. As far as the seal liner is on the bottle or container mouth it will avoid leakage. This would give the manufacturers the confidence that their product will reach the stores safe and leakage free. This eliminates product recall costs due to leakages in containers
After the induction sealing process, the induction foil will show evidence that the product has been tampered with or any other substances has entered into the container during post packaging processes. It is possible to print or emboss the logo of the manufacturer on the seal liners to provide more security and confidence.
How Strong is the Induction Sealing?
This is indeed a strong seal when the proper seal liner with a quality equipment is applied to the bottle. This works on the principle of understanding what is the parameter of the induction seal such as:
- The bottle or container material. It is crucial to know if the bottle is a Plastic (PET, PE, PP, PVC) or a Glass bottle.
- Foil thickness,
- Sealing layer thickness
- A pharmaceutical product indeed need a different seal liner than a industrial lubricant
We always encourage our clients to conduct a test to check of sealing strength before placing their orders. This strength of seal is very important, so we always provide free samples for our clients to test and ensure about the liner they are choosing to order before they confirm their orders. This is vital as if a product leaks, the entire batch has to be recalled incurring additional transportation and handling charges resulting in substantial losses.
Induction Sealing Facts
There are a few basic facts we need to know about induction cap sealing and that is the factors that are vital to the sealing process. These factors are:
- Foil Structure
- Neck Surface
- Neck Diameter
- Dwell Time
- Closure Torque
Many induction wads have different types of layers for basic and special applications. These layers contain an aluminum foil that is vital as this is the medium of heat transfer from the sealer to the poly-laminate sealing film. There different ranges of gsm of the foil available in the market.
To achieve a perfect and uniform sealing, the plane surface of the mouth of the container must be uniform and smooth. This will ensure that when the induction seal lands on the mouth surface, it lands with uniform contact to the mouth. Otherwise it won’t result in a 100% perfect sealing.
The sizing of the induction sealer depends on the diameter of the induction seal. This means that the larger the diameter, the more heating is required.
The induction sealing process is done when the aluminum foil is heated by the electromagnetic flux lines from the induction sealer and that heat is transferred to the sealing layer that touches the bottle mouth. This melts the sealing layer forming a weld. This is done within seconds and the time needed for the process is called the Dwell Time. It is crucial to adjust a proper dwell time. A shorter time will lead to a weak sealing and if this is overtime it may result in burning the sealing layer polymer and the smoked will imprisoned inside the bottle. It also may deform the bottle mouth due to over heating.
This is the amount of pressure needed to be applied by the cap to the bottle in order to make sure the foil is perfectly landed on the bottle mouth. The liner inside the cap must be completely in touch with the bottle mouth, thus assisting the sealing process.
What can be Induction Sealed?
Induction sealing can be done on any type of container that has a screw cap. Hence induction sealing is also known cap sealing. Container mouth surface must be uniform. This ensures a proper and even seal. The cap of the container must close fully and apply proper pressure or torque to the wad on the container mouth after closure.
List of Type of Containers that can be Induction Sealed:
- HDPE Bottles & Jars
- LDPE Bottles & Jars
- PET Bottles & Jars
- Polypropylene (PP) Bottles & Jars
- Polyvinyl Chloride (PVC) Bottles & Jars
- Glass Bottles & Jars