Steps to Achieve Perfect Induction Cap Sealing

Induction sealing of containers is essential to prevent pilferage and leakage and also to increase shelf life of products. It makes bottles tamper proof and assures the consumer that the product is safe to use. However, achieving a perfect seal is not a one-size-fits-all process. There are nuances to take care of and steps to follow in order to achieve the perfect seal that will achieve the desired result.


It all starts with selection of the type or types of sealing needed. While sealing of the cap is necessary you may also need to have a liner in the cap. These materials act as a barrier against various impurities as well as enhance the effectiveness of the seal. They also make tamper evident cap seals


Deciding On Liner Use


So, the first step is to decide if you need a liner inside the cap or not. Liners are used in pharmaceutical, processed food, cosmetics, liquor, petroleum products    etc. If you are working for any of these you need to have a wad inserting machine in order to insert liners inside caps. In fact, most plastic or metal continuous thread bottle caps come with a liner.


Deciding On The Type Of Liner


In case you need wad inserting, think about the material to be used. There are different materials available to make liners depending on the application. So, you need to use different liner materials for liquids, powders, essential oils, carbonated beverages, food etc. You need to understand what kind of material is to be used for the product in question.


Common materials used as liner are –


  • PE foam and F217

This white coated foam material is commonly used to seal containers with liquids and have plastic continuous thread caps.


  • Pulp & Poly

This too is a white foam type liner used mostly for sealing liquids in plastic continuous thread.


  • Pulp & Foil

This material has a layer of foil facing the product instead of PVC. This is mostly found in bottles containing powders. It looks silvery and shiny.


  • HS035

Induction sealing machine is used to apply this liner to render a tamper evident assurance for consumers. It is often printed ‚Äúsealed for your protection‚ÄĚ.


  • Plastisol

This is useful in glass bottles and jars containing food products.


  • PS22

This is a pressure sensitive liner having tamper evident properties but does not need induction sealing equipment to work. It is put in place just by pressure.


  • PE cone

These are mostly used to seal glass bottles containing essential oils or carbonated products. This cone shaped liner makes a good seal on the lip of the bottle.


Deciding On The Type Of Equipment


If you need a liner insertion, you probably need Wad insertion equipment. However, there are liner insertion techniques which can also be done with an induction cap sealer. So make sure the type of equipment you need.


Getting The Right Induction Cap Sealer


There is a huge variety of induction sealers. You need to choose one depending on the speed of sealing required, the process of sealing required, i.e inline or otherwise, the type of operation desired such as manual, semi automatic or automatic etc. You need to decide on the equipment depending on the process followed in the floor, level of automation as well as production numbers. If you are a small time business where sealing 4-6 caps per minute is a good one, you can go for the manually operated Sigma Flex from Sigma CapSeal. This is a leading manufacturer (1974) of sealing machines of a wide variety, ranging from tardy manual sealers to inline Cap Assembly sealing machines. 


If you need higher capacity and semi automatic machines, you can go for Sigma Pro from Sigma CapSeal. This piece of equipment can seal 15 to 20 bottles per minute.


For high capacity in-line operation, you can go for Sigma I Neo, Sigma II Neo, Sigma III Touch or Sigma Touch depending on your requirement of speed and level of automation.


Choosing The Wad Inserting Equipment


If you need liner insertion you can go for wad inserting systems. The company Sigma CapSeal also produces wad inserting equipment which are used by a number of internationally reputed corporations around the world. For inline operation you may need vision inspection systems. This particular company also manufactures these products.