Svet Črnil

Description

Continuous induction welding machine DF-2100

When packing, most money is often not lost when buying packaging, but when small recurring errors occur. Poorly sealed cover means the possibility of leaking, complaint, product returns, additional work and lost customer confidence. According to a packaging industry survey, McKinsey found that more than 70 percent of the companies surveyed saw the possibility of more than 5 percent cost improvement through better digitisation and process optimisation. For serial production, savings can be very high by some percent.

This is why we designed DF-2100 as a machine for continuous induction welding of lids for production, where the result must be reproducible. The bottle comes under the induction head, the aluminium sealant foil in the cover is heated quickly due to the electromagnetic field, the sealant connects to the edge of the packaging and a protective seal is formed. Quick. No direct contact with the container heater.

DF-2100 is suitable for lids up to 120 mm wide and for bottles or containers from 50 mm to 300 mm high. If you need a different height, we can adjust it to your production process.

Favourable induction sealing for manufacturers and chargers

The largest user group DF-2100 are producers and bottlers of consumer products. The reason is simple. Several dimensions of bottles, several types of lids and several different products can be used in a single production. The machine should therefore allow fast adjustment and stable work.

• food producers and sauce
• food supplement fillers
• cosmetics manufacturers
• pharmaceutical and laboratory production
• cleaners and household chemistry producers
• producers of technical liquids and chemical products
• contract chargers with several different contracting entities
• companies wishing to automate manual closing and sealing of packaging

If you seal small quantities today, the manual procedure may seem cheaper. As production grows, seconds, repetitions, human mistakes and complaints begin to add up. Continuous induction welding is therefore primarily a question of the economy of the process.

Covers up to 120 mm and bottles from 50 to 300 mm

DF-2100 allows induction welding of lids up to 120 mm wide. This means a lot of use for different types of packaging, from smaller bottles to larger containers.

A lifting mechanism is fitted to adjust the height of the induction assembly according to the packaging. The machine can be customized from 50 mm to 300 mm in height. Thus, when changing the product, it is not necessary to change the overall production arrangement. Adjust height, set process and continue work.

You need packaging higher than 300 mm or a special production line. That's also possible. The height of the machine can be manufactured or adjusted according to your actual needs.

That's an important difference. We do not want you to adapt production to the machine. Where technically feasible, we prefer to adapt the machine to production.

Separate induction windings and electrical unit for even result

DF-2100 has induction windings separated from the electrical unit. The electrical unit provides the correct, even and proper power to the induction coils. This is not an insignificant design detail.

Induction sealing requires a controlled process. If energy is too low, the weld can be incomplete. If it is too much, we can damage the sealant, deform sensitive materials or heat the lid area unnecessarily. The target is not the most energy. The target is the right amount of energy at the right time.

Five things affect the quality of the induction weld:

• correct induction sealant in cap
• material and quality of bottle or container edge
• height or distance between coil and sealant
• the rate of movement of the packaging through the induction area
• correctly adjusted power of the induction system

Therefore, the lifting mechanism is so useful. At different levels of packaging, the induction head can be repositioned in an optimal position to maintain a more reproducible result.

Savings in leaks, complaints and ejection

The induction weld is not just a nice addition under the lid. Packaging World highlights the prevention of leakage, protection against tampering, maintaining freshness and the possibility of extending the product’s usefulness. These are properties that have a direct commercial value.

Benjamin Franklin wrote a thought that is surprisingly topical for production: Watch out for small expenses. A small hole can sink a large ship.

In the case of packaging, a small mistake can really cost a lot. One poorly sealed bottle in the carton can stain other products. One complaint may require a phone call, a new shipment, a credit card and an additional administration. Serial error is even more expensive.

Correctly configured DF-2100 can help reduce:

• possibility of leakage during transport
• number of incomplete seal products
• manual checking of each individual piece
• complaints about open or damaged packaging
• ejection due to unstable sealing process
• time spent by the operator for manual induction welding

That's real savings. Not only the lower price of the machine, but the lower cost per properly packaged product.

Local in Ljubljana also means easier adjustment

In an industrial machine, what happens after the purchase is important. If you buy equipment from the other side of the world, the starting price may look very good. But a special height, a different layout or a change in the production process can quickly become a problem.

At the World of Inks in Ljubljana we have the possibility to adapt the machine to concrete applications. Local cooperation makes special sense for the Slovenian buyer when standard implementation is not entirely correct.

For example, if you are using very high packaging, we do not need to complete the conversation at standard 300 mm. We check the requirements and we can adjust the machine height structurally. Here a locally designed or adapted solution can be cheaper in the long term than a seemingly cheap universal machine.

DF-2100 vs. normal competitive machine

The comparison is not intended to claim that every other machine is bad. Far from it. The purpose is to show what is really important in choosing. Buy according to the packaging, the desired process and the possibility of subsequent adjustment, not only to the first price on the offer.

How to get the best result from DF-2100

Before purchasing, send us some concrete information. This allows us to assess much faster whether the standard implementation is the law or whether it is better to make adjustments.

• cap diameter or width
• minimum and maximum packaging height
• material of the bottle or container
• cover material
• type of induction sealant
• photo of packaging and lid
• desired quantity of products through the production line
• whether the DF-2100 will be an independent station or part of an existing line

It's even better if we have samples of your packaging. In the case of induction sealing, it is not enough to say that the cover is 60 mm wide, for example. Material, the shape of the edge of the container, the type of foil and the way the lid is closed are also important.

This allows us to reduce speculation and get to useful settings faster before we start.

User experience after correct process setup

Illustrate user experience summarising the benefits of a properly configured system:

Previously, at different bottle heights, we lost time by setting and checking the seal. At DF-2100 we set the height of the induction head, determined the appropriate process parameters and obtained a significantly more reproducible result. The most important thing is that we can use the same machine for several packaging formats and that we can adapt it to our line if necessary.

That is our goal. The machine has to work in production, not just looking good in the photo.

Cheaper to measure the cost on a good product

When comparing machines, do not just look at the purchase price. See how much time you spend setting up. How many products do you throw away? How many complaints do you get? How many different packages can be processed on the same machine. And what happens if you introduce a higher bottle in a year.

The packaging industry is increasingly underscored by automation, more stable quality and reducing process costs. McKinsey also highlights automation in production and packaging as an important way to increase productivity, reduce waste and improve repeatability.

DF-2100 is therefore particularly interesting for a company that not only buys machinery but wants a more orderly process of closing packaging.

Send us your bottle and check the solution

If you use lids up to 120 mm and packaging between 50 and 300 mm, DF-2100 can be a very good basis for your production. If the packaging is higher, tell us the required measure. Adaptation is possible.

Send us a photo of the packaging, dimensions, material, type of sealant and desired production requirements. On the basis of actual data, we can significantly better assess the necessary implementation than from the general description alone. This helps you to find a solution faster, more favourable and less risky.

And finally, the unpleasant question: Is it really sensible to save some money from the machine if a single series of poorly sealed products can cost more than total savings when buying cheaper equipment?