Innovative focused ultrasound-based sealing method of flexible packaging films—Principles and characteristics

A key process to package goods is the closure procedure. It ensures the good protection against the environment and vice versa. Ultrasonic sealing presents the advantage of converting locally ultrasound into heat, which is optimal for temperature sensitive goods. The disadvantages remain, however, the equipment cost, the noise generation, and the process sensitivity to materials. It is necessary to develop a sealing process to decrease the acquisition cost of the sealing equipment and cover a wide range of polymer films. This paper focuses on a new sealing method based on high-intensity focused ultrasound. The principles and characteristics of this process are discussed and underpinned with experimental results. Both the acoustic and thermal effects of the sealing process are summarized. A study of the process parameter impact on the seam strength in static and dynamic operating is proposed. Low-density polyethylene films with a carrier layer of bi-oriented polypropylene and polyethylene terephthalate are used. A first test bench generates point-shaped seam. The heat generation is recorded with an infrared thermography system. A second test bench, a horizontal form fill and seal machine, produces longitudinal seams. The seam quality is controlled by tensile test and tightness test. A quick heating of the polymer films is found. Point seams and longitudinal seams are successfully generated. The seams behave similarly to the ones generated with ultrasonic sealing process. However, the sealing velocity is limited to 3 m/min. This work provides a summary of the characteristics and principles of the new sealing method in packaging applications.     

Experiments and Simulations on the Cleaning of a Swellable Soil in Plane Channel Flow

ABSTRACT

The cleaning behavior of a soil with physical properties that depend on the wetting time is studied experimentally via the local phosphorescence detection method and simulated numerically in fully developed plane channel flow for Reynolds numbers up to 30,000. A computationally inexpensive general cleaning model is proposed, adopting an existing removal model and coupling it to the turbulent flow field. The influence of the soil on the flow is neglected and the transient behavior of the soil during cleaning is modeled in the form of a transient Dirichlet boundary condition. This approach is innovative for computational fluid dynamics of this phenomenon. The way of determining the model parameters from the experiment is described. The comparison of the simulation results with experimental data reveals very good suitability of the model in the case of a starch soil. A similar good agreement is found for data for a model protein foulant in tube flow from the literature.     

Pulsed flow for enhanced cleaning in food processing

The use of slow (～1 Hz) flow oscillation imposed on a stationary flow of liquid has been shown to enhance shear stresses imposed on a surface and to mitigate fouling or enhance cleaning. Examples of the application of pulsed flow are presented in this paper. A new measuring technique in combination with tailored CFD simulations was developed for monitoring the cleaning of complex piping equipment with pulsed flow. A time-independent and isotropic approach to model the wall shear stress is introduced. The optical monitoring procedure uses a model food soil consisting of starch as matrix material and phosphorescent zinc sulfide crystals as optical tracer. Investigations of pulsed flow cleaning published prior to this work focused on tests with straight pipes, whereas difficulties in industrial cleaning operations more often arise while operating piping systems and plant components with complex geometries. Therefore cleaning experiments were performed in a CIP test rig simulating industrial cleaning processes. The results with pulsed flow show an enhancement of cleaning efficiency at locations difficult to access using stationary flow.     

Sensitivity of photon-counting based K-edge imaging in X-ray computed tomography

The feasibility of K-edge imaging using energy-resolved, photon-counting transmission measurements in X-ray computed tomography (CT) has been demonstrated by simulations and experiments. The method is based on probing the discontinuities of the attenuation coefficient of heavy elements above and below the K-edge energy by using energy-sensitive, photon counting X-ray detectors. In this paper, we investigate the dependence of the sensitivity of K-edge imaging on the atomic number Z of the contrast material, on the object diameter D , on the spectral response of the X-ray detector and on the X-ray tube voltage. We assume a photon-counting detector equipped with six adjustable energy thresholds. Physical effects leading to a degradation of the energy resolution of the detector are taken into account using the concept of a spectral response function R(E,U) for which we assume four different models. As a validation of our analytical considerations and in order to investigate the influence of elliptically shaped phantoms, we provide CT simulations of an anthropomorphic Forbild-Abdomen phantom containing a gold-contrast agent. The dependence on the values of the energy thresholds is taken into account by optimizing the achievable signal-to-noise ratios (SNR) with respect to the threshold values. We find that for a given X-ray spectrum and object size the SNR in the heavy element's basis material image peaks for a certain atomic number Z. The dependence of the SNR in the high- Z basis-material image on the object diameter is the natural, exponential decrease with particularly deteriorating effects in the case where the attenuation from the object itself causes a total signal loss below the K-edge. The influence of the energy-response of the detector is very important. We observed that the optimal SNR values obtained with an ideal detector and with a CdTe pixel detector whose response, showing significant tailing, has been determined at a synchrotron differ by factors of about two to three. The potentially very important impact of scattered X-ray radiation and pulse pile-up occurring at high photon rates on the sensitivity of the technique is qualitatively discussed.     

Ultrasonic Sealing of Flexible Packaging Films – Principle and Characteristics of an Alternative Sealing Method

The closure process for packaging is a key process. It ensures the protective function of packaging and assures the packaged goods a long life. In this context, efficient and reliable sealing processes are essential for the production of sustainable packages. In this paper, several characteristics of the ultrasonic sealing process will be discussed and accompanied by experimental results. The introduction provides an insight into the ultrasonic sealing process, its heating mechanisms and the process steps. A comparison is made with conduction sealing. Furthermore, basic principles of heating and energy dissipation are related to the influences of the sealing parameters on the seam strength. The experimental studies were carried out on typical packaging films, such as polyamide‐polyethylene laminates. The seam strength in ultrasonic sealing is compared with that in conductive sealing. A lower seam strength was found for ultrasonic sealing in all the tested films. Furthermore, the sealing behaviour of the packaging films contaminated with different kinds of foods was analysed for both sealing methods. Although the ultrasonic sealing method has marginal advantages for bulk materials such as wheat flour, conduction sealing was shown to be better for other products. A comparison of the energy consumption during the ultrasonic and conduction sealing verified the advantages of ultrasonic sealing. In particular for thick packaging films, the amount of energy required for bonding is significantly lower than for conduction sealing. In summary, this paper provides a survey of the characteristics of the ultrasonic sealing method in packaging applications – its advantages and limitations. Copyright © 2011 John Wiley & Sons, Ltd.     

Characterization of the material elongation in the deep drawing of paperboard

In this paper, deep‐drawn paperboard cups are characterized in terms of their elongation along the cup wall. For this purpose, a method for the non‐destructive determination of the elongation was developed and tested. Using the presented method, a parameter study of the process parameters blank holder force, forming temperature, material moisture content, drawing velocity, and clearance ratio was performed. The influence of the process parameters on the cup wall elongation was determined by statistical design of experiments. Using the determined relationships between the process parameters, it was possible to achieve a shape‐specific characterization of the elongation along the cup wall. The parameter study showed a significant influence of the blank holder force, the forming temperature, and the material moisture content to the elongation along the cup wall.     

Examination of the Transferability of Technological key Features of Paperboard Deep Drawing Towards the Application in Fast‐Running Packaging Machines

The deep‐drawing process of paperboard has experienced essential improvement in the recent past; however, the technological advancements have not been transferred to packaging machines yet. Two of the most important issues with regard to the reliable production of high quality 3D shapes are the use of elevated moisture and defined blank holder force profiles. This paper examines a roll preparation method for applying additional water to the paperboard and analyses a spring‐loaded blank holder solution with regard to its achieved accuracy and reliability of the force characteristics. A two‐sided roll application of water on the paperboard using a sponge rubber cover on one of the rolls produces a water intake of up to 12%. The effect of moisture applied by roll preparation is higher compared to conditioning under controlled climate conditions, and the preparation time is reduced to a few seconds. The spring‐loaded blank holder introduced in the paper completely works in position control and avoids the switch over to force control as well as the problem of small position steps, which were necessary during force control. A harmonic oscillation of the blank holder while the material is drawn out of it could not be observed up to an output of 150 cycles per minute. An application of a roll‐based moisturization unit and a spring‐loaded blank holder force in modern packaging machines appears feasible and favourable according to the results of this paper and maintains the capabilities of this 3D forming technology to a large part. Copyright © 2016 John Wiley & Sons, Ltd.     

Method for Fast Quality Evaluation of Deep‐drawn Paperboard Packaging Components

The visual and mechanical quality of paperboard packaging components formed by deep drawing closely corresponds to the wrinkle distribution within the material wall section. Assessing this quality of paperboard packaging components currently relies on very slow or even subjective methods. Therefore, counting the number of wrinkles and measuring the mean distance between wrinkles proved to be a sensitive strategy for the evaluation of quality levels in deep drawing formed paperboard containers like cups or trays. A method introduced by Hauptmann proposes the measurement of the distances between 10 wrinkles in machine direction and 10 wrinkles in cross direction for each sample. However, this method is unsatisfactory because it can only observe a small part of each sample and is subject to deviation through the individual judgement of the person carrying out the survey. Further methods, as well as their respective application range, are listed in Table  1 . Hence, it is desirable to automate the wrinkle survey to be carried out without operator influences to the measurement. This paper introduces such an automated measuring method. The given method relies on recording the sample surface topography through laser‐distance measurement. An evaluation algorithm, which enables the detection of wrinkles in the topographic data, is proposed. Furthermore, it is shown that the method yields feasible results and is capable of generating reliable quality information in considerably reduced time frames.     

Reinigbarkeit von Oberflächen in der Lebensmittelindustrie durch Flüssigkeitsstrahlen

The influence of properties of product contact surfaces on cleanability is widely discussed in the food processing and pharmaceutical industry. In the present work stainless steel surfaces of different surface roughness, surface energy and electrokinetic properties were subject to organic soiling in order to study the influence of surface properties on cleanability. As food model test soils gelatinized starch and whey protein were chosen. The cleaning was realized by means of water jets from a flat fan nozzle.