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Break with convention, use induction technology to improve efficiency,
increase productivity, reduce downtime, and maximise your profitability.
Using a Relco 'Capless Induction Sealing System' all of this and more
is possible, let us explain why:
Energy Efficient - Relco capless induction sealers use approximately
10% of the total power required by an equivalent conduction system.
Energy is pulsed into the sealing heads as required to generate the
seal so that these are not permanently on. As all of the energy in
the sealing head is used to generate the weld none is wasted by convection
into the environment as found in conduction sealing systems. Not only
is this reducing your operating costs, it is also extremely environmentally
friendly and will assist with climate change levy minimisation.
Higher Output - Due to the extremely efficient thermal process
of induction heating, the energy being generated within the foil
rather than conducted into it, sealing times are typically between
0.3 seconds and 0.7 seconds. This means that higher outputs are possible
from the same size of machine or on new systems a greater number
of containers can be sealed for each head thereby reducing the number
of heads required to achieve the same production target.
Increased Reliability - All Relco capless induction sealing
heads are cold to the touch, this means that fatigue and wear on
the sealing heads is extremely low providing an enormous increase
in reliability when compared to conduction devices. Aside from minimising
spares costs, this has the advantage of greatly reducing the amount
of down-time needed and the associated costs leading from the loss
of production.
Clean Sealing - Conduction heads when descending on a container
where the foil is missing or not correctly aligned will melt the
plastic and cause the head to be soiled. Conduction sealing heads
can also attract dust and dirt which will bake on to the outside
of the head. Again, with the heads running at ambient temperature
they will not melt or damage containers where no foil is present
and do not accumulate dust and dirt.
Instant Energy - Induction power is available on demand, the
energy being transferred into the coil within the sealing head at
the speed of light. This means that the sealing system is ready to
work as soon as the first container reaches it, no warm up or cool
down time being necessary.
Operator Safety - Where conduction heating is used as the
sealing medium conventional interlocked guarding or emergency stop
can not prevent operators or maintenance personnel being exposed
to the danger from the temperature of the sealing head. Relco capless
induction sealing operate at or around ambient temperature thereby
completely eliminating this danger.
Total Control - The exact amount of energy transferred into
each seal and the precise amount of time to which the foil is subjected
to the induction field are controlled by the system PLC guaranteeing
perfect consistency. No longer is it necessary to rely upon the thermal
characteristics of different conduction sealing heads and hope to
remain within the sealing window, customers can now control the seal
quality and strength in every single container which goes through
the machine.
Induction sealing is universally accepted as being the most effective
and efficient means of hermetically closing bottles, jars and other
containers. The application of this technology requires a cap which
is lined with a suitable foil or heat-seal membrane. As the cap is
torqued on to the bottle, the foil is pressed hard against the sealing
land area of the container. After capping, the container passes through
the induction sealing machine and the foil is very rapidly heated,
melting the heat-seal layer. As the heat-seal material begins to cool,
still under pressure from the cap, a bond is formed between the membrane
and the container. For more details on this process please refer to
the section 'The Principles of Induction Sealing'.
There are a number of significant benefits associated with the use of induction
but these have traditionally been restricted to applications where a cap is
used as the means of locating the foil and providing the necessary pressure
for sealing to take place. With the desire of bringing to our customers who
do not have a cap or wish to apply a cap after sealing the benefits of conventional
induction sealing even though they do not have a cap or wish to apply a cap
after sealing, in 1999 Relco began developing capless induction sealing systems.
Working in partnership with a number of leading companies we have developed
a range of products which can meet any capless induction sealing requirement.
FCS Systems
Foil is fed from a reel and die-cut into the required seal profile, this membrane
is held on the sealing head by a vacuum pick&place device and transferred
directly onto the container where it is our under pressure and induction
sealed into place. Relco manufacture a range of machinery from bench-top
semi-automatic units (FCS-1) though to higher speed
in-line automatic systems (FCS-Auto) to cater for
all capless induction sealing requirements.
 See the FCS-1 machine work (requires flash player)
See the 3 Head machine work (requires flash player)
See the 5 Head machine work (requires flash player)
P-800
We can also supply OEM filler/sealer manufacturers with induction sealing heads
and generators (P-800) which can be used to replace
conduction heads on conventional rotary or linear sealers. These units can
either be installed to existing equipment as a retro-fit modification or
specified on new build systems. The sealing heads can be used in applications
where the foils are already located, being either profiled foils from a capping
press or flat foils which are tacked in place after application. Alternatively
the sealing heads can be provided with vacuum pick&place units mounted
inside for taking and locating foil from a magazine. Relco are pleased to
offer technical and design assistance to OEM companies who wish to introduce
the benefits of induction sealing into their own equipment.
Punch&Seal
A new patented device for punching foil from a web, locating on a container
and induction sealing in one single stroke. This system is available in Relco
sealing machines or can be supplied to OEM filler/sealer manufacturers for
incorporation into their own systems.
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