Optimizing Hot Sealing Parameters: Maximizing Efficiency and Material Performance in Form-Fill-Seal (FFS) Applications

Hot tack testing plays an important role in selecting optimal hot sealing parameters for Form-Fill-Seal (FFS) lines. Hot tack refers to the initial seal strength of packaging materials immediately after heat sealing, before they cool down. It is crucial for FFS lines where product filling follows hot sealing with minimal cooling time.

FFS lines are widely used in packaging industries for products like food, medicine, and cosmetics. In these lines, packages are formed and filled simultaneously. Since the filling process creates an impact on the package bottom, sufficient hot tack strength is essential to prevent breakage and ensure filling efficiency. While ultimate seal strength, measured after cooling, is a valuable quality metric, it's not applicable in FFS due to the short time frame.

A case study is presented hereunder, Labthink C632B Hot Tack Tester was used to evaluate two film materials (A and B) for an East Asian food producer. Both films had similar performance parameters, but the goal was to select the material that would optimize the FFS line's efficiency. The client's requirements specified a maximum sealing temperature of 133°C and a minimum hot tack strength of 2N. Other sealing parameters like sealing pressure and film side for sealing were fixed.

Labthink C632B Hot Tack Tester is applicable in hot tack and heat seal performance tests for plastic films, laminated films and other packaging materials. It is applicable in peel test, tensile at break test, and other tests for adhesives, adhesive tapes, laminated films, plastic films, paper and other flexible materials.

The test results revealed that both films exhibited an optimal hot sealing temperature around which hot tack strength decreased. Film A achieved the client's minimum hot tack requirement only at higher temperatures (127°C - 133°C) and with longer sealing times (above 0.5s). In contrast, Film B surpassed the requirement at a wider temperature range (118°C - 133°C) and even with shorter sealing times (as low as 0.3s).

Based on the test results, Film B was recommended due to its superior hot tack performance at lower temperatures and shorter sealing times. This translates to increased production efficiency as it allows for faster sealing cycles with lower energy consumption. The report acknowledges the need for further testing to fine-tune the sealing temperature for optimal and consistent sealing across the production line. It also emphasizes considering material cost alongside hot tack performance for a holistic cost-efficiency analysis.

Hot tack testing plays a critical role in selecting optimal hot sealing parameters for FFS lines. By identifying materials with superior hot tack properties, manufacturers can achieve higher production efficiency through faster sealing cycles and lower energy usage. This report highlights the importance of hot tack testing in optimizing production line performance within the packaging industry.

As the demand for functional packaging materials grows, testing methods are evolving to ensure a more comprehensive evaluation of packaging films.

Labthink encourages collaboration with packaging industry companies for quality control! Visit the website www.labthink.com to learn more!

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Advanced Packaging Test

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