CONGEAL MEANS TO COOL UNDER PRESSURE.
Hand / Foot Impulse Sealers
The hand or foot sealer is a manual sealer. What this means is that the congeal step or dwell step needs to be added into your sealing process to make a proper seal. Hold the jaw down for a couple of seconds after the timer light has gone off to set the seal. This will ensure a proper seal and will also allow the sealer to cool down before the next seal. This will ensure longevity of the heating elements.
Auto Impulse Sealers
We recommend the congeal (cooling) setting to be at least 2x greater than the heat setting. This will ensure that the seal has ample opportunity to set and cool under pressure. This will also allow the heating element to cool as well. The most important step for the longevity of auto sealers is having the appropriate congealing time. Most customers skip the congeal setting in order to get a higher ppm (packages per minute) but this will only lead to problems – broken element and PC Board.
Posted in Best Practices for Dealers, Double Impulse Sealer, Hand Sealer, Impulse Sealer, Maintenance, Troubleshooting
Tagged Auto Sealer, congeal, Double Impulse Sealer, Hand Sealer, Heat Sealer, impulse, Impulse Sealers, maintenance, Sealer Sales, troubleshooting
What is Judy’s favorite sealer? Her go-to suggestion when customers call and ask for help? The KS-FS Automatic Foot Sealer Why we ask?
- Best of both worlds! A foot sealer with automatic function leaving your hands free to hold both bags
- Heavy duty solenoid allows for the strongest beautiful 5mm seal
- Digital display of your sealing and cool settings
We have created a couple of glossary reference guides for our distributors. There are so many terms to remember that we sometimes we forget too!
Click here for our A to Zs of Packaging
Click here for our Glossary of Flexible Packaging Materials
Posted in Automatic Sealer, Bags & FIlm, Band Sealer, Direct Heat Sealer, Double Impulse Sealer, Foot Sealer, Hand Sealer, Imprinting, Instruction, Sealing Bags, Troubleshooting, Vacuum Sealer
Tagged Auto Sealer, Band Sealer, Constant heat sealer, Direct Heat Sealers, Double Impulse Sealer, Hand Sealer, Heat Sealer, Heating Element, Impulse Sealers, microswitch, mounting spring, PTFE Adhesive, PTFE Cover, Replacement Kits, sealer repair, Sealer Sales, sealing gusset bags, vacuum sealer
We created this troubleshooting guide to help with our most frequently asked questions regarding sealers.
Impulse sealers (hand, foot, automatic) work in a similar manner – often, if you are having a problem with your sealer, the solution can be found in the following parts: heating element, PTFE adhesive, PTFE cover, microswitch, mounting spring, and/or timer. Let us know if you have a problem that isn’t listed in this guide and we can try and assist you.
- Check element and PTFE cover and adhesive.
- Element: This is the wire (flat or round) that heats up to seal or cut the bag/film. Remove the PTFE cover and check that the wire is not discolored, bent, or broken.
- PTFE Adhesive: This is the 1/2″ piece with an adhesive backing UNDER the heating element. It should extend past the seal area 1/2″ on either side because it is the barrier between the metal machine and the metal heating element. For the PTFE adhesive, you must replace the bottom sealing strip whenever you change the element. The adhesive serves as a barrier between the heating element and the sealer’s body. When the sealer’s heating element has burned through the bottom adhesive and arc’ed on the sealer’s body, the element will break as well as destroy the timer.
- PTFE Cover: The PTFE cover that goes over the heating element must be whole to prevent the plastic bags or film from sticking to the element. For the teflon cover, we recommend changing the cover BEFORE it burns through. As the cover wears, you will see a discoloration where it comes into contact with the element, you may also notice that your element is sticking to the thermoplastic material you are sealing. You can maneuver the cover back and forth to allow the element to come into contact with the unused portions of the PTFE cover. If you are sealing/cutting a thicker plastic material (higher amount of heat) you may go through a lot of PTFE covers.
- Listen for “click” from microswitch when pushing bar down. This click should occur right before the upper bar comes into contact with the lower. If there is no click try the following:
- Hand Sealer: Slightly bend metal switch lever so that when arm of sealer is brought down, the lever makes contact with microswitch and a click can be heard.
- Foot Sealer: Small bolt for limit switch must be tightened as needed to make contact with the microswitch.
- Auto Sealers: A 3.5″ screw that is mounted on upper jaw must be loosened so that it will make contact with microswitch which is mounted on left side of hinge bracket.
- Mounting Spring: Make sure that the spring the element mounts on is intact. Replace if damaged. Please check also that the mounting spring is not rusted or worn in any way as this will prevent the element from conducting heat.
- Timer Light: The light on the timer should come on briefly when the seal bar is brought down for sealing. If it does not come on, the timer PC board probably needs replacing.
Posted in Automatic Sealer, Foot Sealer, Hand Sealer, Instruction, Troubleshooting
Tagged Auto Sealer, Hand Sealer, how to fix a sealer, Impulse Sealers, Instruction, microswitch, mounting spring, PTFE Adhesive, PTFE Cover, Replacement Kits, sealer repair, Sealer Sales, timer, troubleshooting
When selecting a sealer, it is important to have a sense of the material which will be sealed. Try and have the material thickness and width available as this will make your selection process much easier. This will ensure the sealer you purchase is capable of sealing your material. If you want any sealer suggestions, fill out this easy questionnaire and we will provide you with some suggestions
This page discusses the four key characteristics of sealers to help you determine which best fits your application.
A heat sealer (ex: bag sealer, heat impulse sealer, direct heat sealer, hand sealers) is a machine used to seal plastic material using heat. There are many types of sealers and choosing the right sealer may be overwhelming without a few basic points.
There are two main types of sealers: (1) impulse heat and (2) direct heat.
Impulse sealers require no warm up time and seal by applying a pulse of energy to the sealing area, followed immediately by cooling. Impulse sealers only use power when the jaw is lowered. We recommend an impulse sealer for any thermoplastic material such as polyethylene (PE) or polypropylene (PP) which requires a lower seal temperature. Materials for impulse sealers: Polyethylene, Polyurethane, Polyvinylchloride, Pilofilm, Polyvinyl Alcohol, Saran, Nylon, bubble packs, padded mailers, foil, coated bags, Kel-F, Polyflex, Mylar, Tyvek, and other thermoplastic material. Impulse sealers are easy to use (no warm-up time), economical (electricity used only during sealing process), and safe (no component is always hot).
There are different types of impulse sealers based on type of material and usage:
- Hand sealers can seal poly material up to 10mil thickness
- Pedestal Type / Foot sealers can seal poly material up to 15mil in thickness
- Auto sealers can seal poly material up to 15mil in thickness
- Double impulse sealers (automatic and foot options) can seal poly material up to 20mil in thickness (We recommend double impulse for heavy duty applications)
- Sealers w/cutters seal and trim excess material (tubing) in order to make customized bags
Direct heat (constant heat) sealers maintain constant heat in both jaws. Direct heat sealers use power as long as the machine is turned on. As a result, direct heat sealers possess better heat penetration in roder to seal thicker materials. We recommend a direct heat sealer for materials such as coated aluminum foil, poly cello films, gusset bags, coated Kraft papers, waxed paper, cellophane, mylar, coated PP, and other thicker materials.
We also include other types of sealers used for more specific types of applications:
Vacuum sealers remove air from the product before sealing into an impermeable package. We recommend vacuum sealing in order to prevent oxidation, spoilage or corrosion. Barrier bags are used because PP and PE bags are both porous and cannot be used for long term storage.
Clam shell sealers are ideal for welding clam shell packaging.
The size of the sealer depends on the width of the material to be sealed. We usually recommend adding one inch to the width of material to be sealed for easier handling. Cutters on the sealer usually trim at slightly less than width of the sealer arm.
- Portable sealers are lightweight, handy and versatile. Sizes, however, are limited.
- Hand sealers are the most simple and economical unit. The sealing bar is lowered manually. Sizes are available from 4” to 40” and approximately 6-20 packages can be sealed per minute.
- Foot sealers provide a faster seal than hand sealers. The sealing bar is pedestal controlled leaving your hands free. Sizes are available from 12” to 35” and approximately 8-20 packages can be sealed per minute.
- Automatic sealers provide even faster sealing than foot sealers and are ideal for high production jobs. Automatic sealers are usually tabletop sealers whose jaws are activated automatically by a dial-controlled sequence timer. Automatic sealers feature a pre-set time cycle to allow for a fully continuous automatic operation. Automatic sealers can also be used with a foot pedal for semi-automatic operation. Sizes are available from 12” to 47” and approximately 20-50 packages can be sealed per minute.
- Continuous band sealers provide the fastest sealing operation with an unlimited length. Bags are simply fed into sealer while resting on a conveyor belt. Several models are available with features such as horizontal seal head, vertical seal head, tilting seal head, left or right feed, gas purging, and/or coding and imprinting.
Width of Seal / Packaging Material
Heating elements are made of nichrome (nickel-chromium) and determine the width of the seal. There are two types of heating elements: round or flat which are interchangeable in most sealers. The round wire is mainly used to cut and seal with no excess material above the seal. Depending on the width of the flat wire element, sealers are available in 2-3mm, 5mm, 8mm, or 10 mm. Some sealers are equipped with two heating elements for faster heat penetration making them ideal for sealing thicker materials.
Standard Features of our Impulse Sealers
The all-metal construction of our sealers provides industrial quality strength and ensures lasting durability. The body is formed out of rugged cast aluminum while the pivot is an all-steel construction. Most sealers are equipped with a plug-in electronic timer and built-in microswitch. No warm-up time is needed. The variable timer let you seal various types and thickness of plastic films. A signal light and “beep” indicates the heat cycle is complete and the seal is done.
The number in the model number usually indicates the size of the sealer in mm; so 200 points to an 8″ sealer while 1000 points to a 40″ sealer. The letter in the model number is used to designate the manufacturer and type of sealer. For example, “H” signifies a hand sealer while an “A” suggests auto sealer.
Posted in Automatic Sealer, Band Sealer, Direct Heat Sealer, Foot Sealer, Hand Sealer, Introduction
Tagged Auto Sealer, Band Sealer, Choosing the Right Sealer, Direct Heat Sealers, Heat Sealer, Impulse Sealers, Instruction, Sealer Sales, vacuum sealer