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Heat Sealer with Multiple Seal Widths

Multiple Seal Widths on the SAME Heavy Duty (HD) 120" Impulse Sealer (Spring 2023)

heavy duty LFIG heat sealer with multiple seal widths

This case study demonstrates one of the many specialty sealer modifications IMPAK has developed to add functionality for customers. In this example, the ability to quickly change seal widths on the same unit allows users to seamlessly switch between projects as needed, without the cost and space needed for a separate sealing machine. This modification also resulted in prodution time and material cost savings for the customer.

NEED: A global pharma company had to accomodate unique packaging requirements from several of their customers. One of those requirements was particularly challenging to meet - two of their customers required different heat seal widths (.25" and .375") for pouch packaging. To meet these requirements, the pharma company invested in different heat sealing machines and other costly methods. The company tasked the IMPAK Engineering Team for solutions to increase throughput and save on costly machine changeover.

PROPOSAL: The IMPAK Team accepted the challenge and presented the following solution:

  1. Each of the two seal bars contains a heat band with a different width: 6.35mm and 9.35 mm (1/4” and 3/8” respectively). Either heat band can be activated separately.
  2. Heat seal lengths up to 3048mm (120 inches)
  3. Siemens based, open source, validatable temperature controlled system to ensure seal integrity

SOLUTION: IMPAK chose to modify their industry-leading Heavy Duty HD horizontal heat sealer to have two separate nichrome element widths embedded in the heat bars, either one of which can be activated separately using our iS2 Intelligent Sealing System which includes Siemens-based PLC.

iS2 temperature control showing 3/8" element buttoniS2 temperature control showing 1/4" element button

sample screenshots: simply press the 1/4" or 3/8" button

RESULT: The final version of the customer-specific sealer incorporated the following specifications:

  • Seal Widths: This machine is capable of producing either 6.35mm or 9.35 mm (1/4” or 3/8”) without changeover
  • Seal Length: up to 3048mm (120")
  • Temperature Control System for Medical Validation – IMPAK’s Industry Standard, Siemens-based Intelligent Sealing System (iS2)
  • Pneumatically controlled low-pressure jaw close safety system with release if obstruction is detected
  • Foot pedal cycle activation
  • Air requirement (min): 100 psi
  • Electrical requirement: 220V
  • Made in USA
results show reduced material cost, packaging labor, freight costs, and increased truckload density
top element is 1/4 inch width bottom element is 3/8 inch width

close up showing two separate seal width options

The video below shows the digital display of the machine's iS2 Intelligent Sealing System, followed by a closeup of the seal bars at work.

Other customized solutions are available, including retrofitting. Below is an example of a previous retrofit project:

Large Frame Impulse Sealer Retrofitted to a Siemens temperature control system

Contact us today to discuss how the HD Series of Heavy Duty, High Performance equipment can work for you.