Pareto-based design of experiments for identifying and comparing optimum sealing parameters of heat sealing applications in packaging machines, TAPPI Journal June 2023

 


Application: This work describes a new design of experiments that may serve all engineers responsible for quality and productivity of packaging machinery and processes in the flexible packaging industry. It gives a step-by-step introduction on how to apply the new approach and gives three examples from industry and research. The new design of experiments may provide the basis for a new standard test method in addition to ASTM F88 “Standard test method for seal strength of flexible barrier materials,” for instance.

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Author: Peter A. Gellerich and Jens-Peter Majschak
Pareto-based design of experiments for identifying and compa
ABSTRACT: Sealing is one of the most important process steps in industrial packaging, because the sealed seam is the most sensitive section of a package in terms of quality. For this reason, a major focus in flexible packaging is the sealing process, and among this, heat sealing is the most frequently used technology. In detail, applications of heat sealing processes are confronted with four conflicting objectives: increasing seam quality, reducing dwell time, reducing sealing temperature, and increasing process robustness towards varying conditions. Typical problems, such as identification of the optimum process parameters or selection of the most appropriate packaging film, are subject to these conflicting objectives.This paper presents a recently published design of experiments for characterizing and comparing heat sealing properties of packaging films based on a multi-objective optimization algorithm. The approach provides easy-to-read charts showing all optimum sealing parameters with regard to the four essential objectives of heat sealing: seam quality, dwell time, sealing temperature, and process robustness. Three case studies show exemplary applications of the new approach: 1) analyzing transport damages of beverage powder packages; 2) identifying and comparing optimum sealing parameter of a standard, mono-material, and fiber based packaging film regarding tightness and visual properties of the produced sachets; and 3) analyzing the effect of additional aluminum layers on sealing characteristics regarding hot-tack.The new design of experiments may provide the basis of a standard test method for the identification of optimal sealing parameters in the heat sealing processes.
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