Pouch Packaging: The Value of a Stable Process
Transcript of Pouch Packaging: The Value of a Stable Process
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Heat SealingThe value of a stable process
Scott A. FullerProduct Line Manager
CMD Corporation
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Have you ever tasted, seen or heard something from the past and thought . . .
“That’s just the way I remember it !”
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From DVD “Neil Peart: Taking Center Stage”Thanks to Neil Peart & Hudson Music, LLC for permission to use this clip
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Memorable Because It’s Consistent
• An epic drum fill, played by an iconic drummer
• Still as recognizable today, as it was in 1981
• Wouldn’t sound anything like that if I were to play it
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Consistency is the Goal
In Package Converting, success is achieved through consistency…
…package after package
…from lot to lot
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Consistency is Focused
Consistency in the ability to provide pouches that perform as specified…every time!
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Consistency is Valuable!
• Consistency in the way “Tom Sawyer” was played by Rush at every concert made the song one of the most recognized and replayed rock songs of all time…
Replays = Purchases = Value
• Pouches that perform as specified, every time = Repeat Business = Value
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The Purpose of the Pouch
• The Pouch has 5 main jobs to do:o To contain the product insideo To protect the product insideo To transport the product from one location to another intacto To identify the product and the brando To inform the consumer
• Our focus will be on the top three functions
• A consistent seal is vital to each of those three functions
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3 Why’s and a How
• Why is a stable sealing process valuable to the Consumer?
• Why is a stable sealing process valuable to the Brand Owner?
• Why is a stable sealing process valuable to the Converter?
• How can I achieve this stable sealing process?
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Value to the Consumer
Value is like a snowball rolling down a hill• To the individual Consumer, a failed seal is inconvenient
o Time consuming to clean the messo Relatively low monetary loss
• The greater loss is the loss of confidence in the product and possibly the brand itselfo Is the product safe?o Has it been tampered with?o Can I trust it in the future?
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Value to the Brand Owner
Now, the snowball gets a little bigger…• To the Brand Owner, a failed seal starts to get costly
o Seal failure in the retort chamber could contaminate the whole batch
o Seal failure in transport could result in rejection of a pallet, or even a full truckload
o In extreme cases, product spoilage or contamination due to seal failure could result in product recalls
o Much higher monetary loss• Loss of confidence is also an issue at this level
o Even if the failure doesn’t make it to the consumer, loss of confidence in a product at the store level can become very costly to the Brand Owner
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Value to the Converter
At the Converter level, the snowball can become devastating• The Converter has invested significant money to be able to produce a
pouch:o $2MM - $3MM USD for 3-layer extruder…$5MM - $6MM USD for 7-layero $2.5MM - $3MM USD for a 10-color presso $1.5MM USD for a laminator
• By the time the material reaches the pouch machine, it is the most expensive it can be
• To prevent the issues we spoke of earlier, it is critical that the pouch machine be consistent and efficient
• Yet, many Converters gamble on a pouch-making process that is neither consistent nor efficient. Some lose. That loss can be devastating, even resulting in bankruptcy
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Value to the Converter
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It All Comes Down to Confidence
The expectation is that a finished pouch will perform as specified
• How confident are you that it will?• In what are you basing that confidence?
o “The pouches have always performed well in the past.”o “That’s why we test and inspect.”o “We plan for a certain percentage of failures in the market.”
Technology is now available to Pouch Converters, which can provide a confidence that is fact-based, supported by data, and driven by the process
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The Trinity
• Temperature, Time and Pressure remain the key ingredients to creating a seal
• Temperature control in Fusion-Sealing has, historically, had the most profound impact on seal quality
• Today, remarkable control over temperature can be achieved
Time
TemperaturePressure
Seal
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The New Focus
• Structures are becoming ever more sophisticated • Time and pressure play a more important role
• Converters are now shifting their focus from simply ‘dialing-in’ the temps, to closely monitoring the effects of time and pressure
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Observed Performance
• Eight individual sealers
• Identical input pressures
• Different measureddownforce
• The operator is required to ‘tweak’
Input Pressure to Dow nforce Profile
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
1 2 3 4 5 6 7 8
Sealers
Dow
nfor
ce in
Pou
nds
25 psi 30 psi 35 psi 40 psi 45 psi 50 psi
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Inherent, seemingly insignificant, system differences combine to produce a significant force differential:
• Variability in gauges, regulators and air-cylinder condition
• Variability in spring force
• Variability in mechanical tolerances
Why the Difference?
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19Copyright 2010
The Solution
Intelligent Sealing Technology combines mechanical simplicity with advanced, closed-loop controls technology to provide a sealing process that minimizes variation, and provides access to real-time data to be used for process validation
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• Eliminate lost motion
• Minimize mechanical linkages
• Design for structural integrity under the mostdemanding conditions
Simple Mechanics
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Advanced Controls
• Precise, closed-loop position control
• Precise, closed-loop force control
• Real-time process data outputfor Time, Temperature, andPressure--each time the sealermakes contact with the substrate
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‘Intelligent’ Force Management
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• Simplified mechanics, like a fixed anvil design, can minimize sources of variation
• Sophisticated, recipe-based controls take much of the process out of the hands of the operator, providing lot-to-lot consistency, regardless of which operator ran the product
• Closed-loop feedback, coupled with newer controls applications, provide a more consistent sealing process from pouch-to-pouch and lot-to-lot
Consistency and Control Are Achievable
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• Consistency in the application of Temperature, Pressure and Dwell-Time has a profound value
• The heat-sealing of today’s substrates is becoming more and more complex
• Adopt the philosophy of improving and controlling the sealing process
• Reduce risk by minimizing reliance on the human element
• Never stop seeking ways in which to improve your entire process!
Take Aways
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CMD CorporationScott Fuller
Intermittent-MotionProduct Line Manager
2901 E. Pershing StreetP.O. Box 1279
Appleton, WI 54912-1279
+1 920 380 [email protected]
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