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Integrity Seal
Case Study
Drivers for change• Why does the fresh cut produce industry need
a superior seal system on bagged fresh produce?
Reduce packaging material useImprove product quality Longer shelf life to maximize profitsImprove operational efficiencies and lower manufacturing costs
Current sealing technology
Typical cross seal failures
• Creases and folds on crimp seals are not hermetic, so the film barrier is impaired
New Integrity Seal™ technology
• Bead weld cross seal which produces a hermetic seal
New Integrity Seal™ technology
• Produces a hermetic seal even when creases are present
• Control unit
• Jaw system
• Water chiller
The commercial system
New Integrity Seal™ technology• Extensive 3 year development programme• Engineering partners Ceetak Ltd
• System Engineering and Development• Bespoke Installation and Field Service
• Funding through WRAP’s Innovation Fund• Marks & Spencer• Tilmanstone Salads (Geest, Vitacress
Salads, Exotic Farm Produce)• United Biscuits (KP)
• Successful commercial trials• Technically proven to give longer shelf life• Positive consumer research and in-store
acceptance•••
Successful commercial trials• Over 600,000 packs made during the recent 3 month trial for Marks &
Spencer:• Products packed:
• Block Bottom - Iceberg and Summer Salad• Pillow pack - Spinach
• Machine used – intermittent motion Sandiacre bagging machine• Line speeds consistently 10 -15 % faster • No packs leave the factory with product trapped in the seal • Integrity Seal cuts through fleshy leaves and still makes an hermetic
seal• Integrity Seal does not make a seal if larger leaves or stalks are present
– the bag remains open so easily seen and removed from the line • Rework down to between 1 and 5 % depending on ingredient
characteristics•••
New Integrity Seal™ technologyNet Machine Efficiency Comparisons
Line 1 - Iceberg - Summer Salad - SpinachLine 2 - All other baggeds salads
0
10
20
30
40
50
60
70
80
90
09/10
/2007
16/10
/2007
23/10
/2007
30/10
/2007
06/11
/2007
13/11
/2007
20/11
/2007
27/11
/2007
04/12
/2007
11/12
/2007
Line 1 Integrity Seal Line 2 Crimp Seal
Benefits - Extended shelf life• Oxygen sensitive varieties
• 50 % increase• Iceberg - extended from 5 to 8 days• Potential for 10 days plus
• Baby leaf non-sensitive varieties• 30% increase• Spinach – extended from 7 to 9 days
Offers improved supply chain flexibility
Benefits- extended shelf life
Pack on left 5 days oldPack on right 11 days old
• Benefits - block bottom or pillow pack style
Benefits - a perfect seal
• Better appearance, no folds, no wrinkles or ripples
• The bag is shorter giving typically 10% - 15% saving in film usage
Benefits- less packaging
• 10 - 15% faster line speed and efficiencies• Less product reworking – potential savings > 10%• Easy to open• Reduced in-store spoilage and shrink• Improved appearance – no over heated seals• Easier maintenance and less down time
• Wipe clean jaws – no burn on• Ready to use – no preheat time required• IP 65 rated electrics - low voltage elements
Other benefits (1)
• Works on straight or gusseted seals• Works on all Polymer film types OPP, OPP/PE, metallised
PET, PLA• Gusseted bags stand better • Easily retrofitted to existing bagging machines• Can be fitted to any new bagging machines• Safer to operate – jaw cooling after every cycle
Other benefits (2)
Other applications
Thank you
