We believe there is no better value Basic Induction Sealing Equipment on the market today.

We believe there is no better value medium priced “High End” Induction Sealing Equipment. There are unique features to allow process validation and adjustable width sealing head tunnels are available.

MeRo Induction Systems feature:

1. An Air cooled system (Absolutely no need to water cool the induction head).
2. Compact construction for easy integration into the filling line.
3. High power efficiency thanks to the configuration of the power circuits and the use of IGBT modules.
4. Sinusoidal output waveform (Not Square or chopped).
5. Constant and Precise Output power due to the configuration of the regulation circuits.
6. Easy to use controls that display operating parameters and alarm signals.
7. Remote control Start-Stop interface.
8. Power variation monitor which can be set by the user to activate an alarm.
9. Manufactured in accordance with EN-60204-1 standards, Electromagnetic (EMC) compatibility in accordance with EN-5511 and EN50082-2 standards.
10. Motorized height adjustment
11. Set-Up Validation providing an Energy absorbed reading- A key advantage over Nearly Every other make

Depending on the range of product and cap/lid/closure shapes, different sealing heads can be supplied.

Options include:

1. Missing Foil Detection with Bottle Eject Mechanism or Signal
2. Bottle Accumulation Detection to avoid the situation where bottles are stalled under the active sealing head.
3. Pressurized Cabinet version to work in dangerous areas.
4. Fieldbus connection to the production process ASI/PROFIBUS/CAM OPEN/DEVICE NET
5. Integration of power regulation proportional to the speed of the conveyor via feedback from your existing conveyor’s speed controller. This is another key advantage that MeRo are able to offer over nearly other make.

Material Liner is what we call that piece (or pieces) of what looks like paper inside product caps. It is also referred to as induction foil, induction sealing material, foil seals and induction seals among others. Many people are unaware of the purpose they serve to the product aside from being a protection seal or a tamper proof seal.

Material Liner Purpose

Material liner within caps can be one piece or two pieces depending on the expected purpose of the lining material.

Single piece cap liners are often present in smaller sized containers in which the product is likely to be consumed after opening. Its packaging is regarded as being one time use packaging.  In this instance, the liner functions as protection until the product is opened. No other material is left inside the cap.

Larger packs or bottled items are not likely to be completely consumed right after opening. The consumer is more anticipated to reclose the container and store the product. The caps used on these conditions have demands for caps that reseals effectively. Upon close examination, the caps used on these kinds of merchandise have laminated foam within. This lamination enables the cap to reseal the container upon closing to maintain product freshness.  The laminations within the cap as well as the removed tamper evident seal on the product are referred to as two-piece cap liners.

Deciding on the best components and structure of your foil seal is essential to guarantee the proper amount of protection for your merchandise. We can help you in selecting the type of material as well as the construction suitable to your application.

We have induction sealing materials available in many variants to fulfil almost any standard or individualized product packaging requirement which are safe and meet the strict specifications set by the Food and Drugs Authority.

Effective for products that must be kept free from contamination, oxidation and moisture, tamper evident hermetic seals are best suited for use in the following production:

1. Food & Beverage
2. Drugs
3. Alkalies
4. Acids
5. Oils
6. Organic solvents and products
7. Flammables,
8. Powders
9. Pellets
10. Other products

Induction foils are generally supplied to the closure manufacturers. Developed over 35 years ago, induction sealing, in the beginning, was designed to eliminate leakage of chemicals from plastic bottle caps. At present, this method works extremely well with most style container and closure.

Induction Sealing Process

The caps are supplied with an induction foil waiting to load into the capper. The container is then filled and capped, using the caps that are pre-lined with the induction foils.

The capped container is then transported down the conveyor line and travels underneath the induction sealing head. The electromagnetic field generated by the sealing head penetrates the cap and the aluminum foil layer. When the field permeates the foil, it causes an electrical current which melts the liner’s sealing film. The foil cools down as it leaves the induction field causing the heat seal film bond to the container. Once the cap is removed, the aluminum foil remains bonded to the lip of the container.

You can trust our team of experts to provide you the best solution to your application requirement. Contact us today!

Caps and Closures

As we deal with so many cap manufacturers we are able to source and supply you with the cap and cap lining material combination you are looking for without the need to separately supply you with cap lining material. The caps are supplied from cap manufacturers for whom we have an established trading relationship.

These cap manufacturers will almost always sell through third parties and we have qualified with many cap manufacturers to be that third party. We insure the pricing we supply is equal to or better than if you had gone to other third parties or EVEN the cap manufacturer themselves.

Our knowledge and involvement in the supply of Cap Lining Material, Lining Inserting equipment for the cap manufacturers and induction sealing equipment for the end user means we can help source “get-it right first time” combinations of caps with cap lining material and supply at very competitive pricing.

Often there are clients packaging a “pure” product which they are packaging in Glass.

The problem they face is that they are having leaking issues and also want some tamper evidence or freshness seal.  In the case of dry products like capsules or powders there are some good options.  Take for example coffee which is often packed in glass and has a foil freshness heat seal across the opening of the Jar.

In the case of wet and oily products the Induction Sealing option is not available.  The heat sealing process in induction sealing relies on a layer of material laminated to the foil becoming “wet” when it is heated and then setting or drying when the foil cools down.  In the case of plastics bottles this sealing layer is usually a plastic based sealing layer that “melts” into the existing plastic of the container.  For glass with very high melt temperatures the sealing layer never gets anywhere near hot enough to “melt” into the glass so this sealing layer is usually adhesive based.  Wet products and oily products tend to seep into this seal after the sealing process, eventually weakening or neutralising the adhesive and breaking the seal.

Another hurdle to get past with glass jars is that more often than not they are designed or supplied with metal caps.  The induction sealing process relies on an uninterrupted magnetic field to work on the foil layer of an induction seal to heat that seal.  Metal caps or closures interrupt the seal and the metal cap tends to absorb the heat sealing energy before the induction material receives this energy.

While often it is environmental or health based products packed into glass, ironically these manufactures are making a much larger impact on the environment in using glass packaging than their counterparts using PET packaging.

We will not enter into the argument about whether Glass or Plastic is best to package products but rather we will focus on the limitations lifted on induction sealing when using plastic packaging with plastic lids.

There are many products that transition from glass to plastic and are using plastic packs that look like glass yet still have metal lids.  These products can be induction sealed using Capless induction sealing.  This is a process where the open filled product passed under a sealing head that first cuts a disc of sealing foil, locates that sealing foil over the products opening and then heat seals that foil to the container.  After this sealing machine process the package has its metal cap put in place.

More recently plastic packs that look like glass packs are now having screw on sections enabling the development and application of plastic caps.  It is the combination of a plastic bottle and a plastic cap that best lend themselves to the induction sealing machine process.

For the pure products market that simply must have their product in glass ,not all hope is lost for induction sealing as development of adhesives for the induction sealing layer that are suitable for glass and resistant to wet and oily products is still taking place.  There are definitely some glass sealing foils that perform better than others and the best way to know if your product will suit will be via trials.  The longer you can conduct your trials and the more varied conditions, such as temperature ranges and pressure ranges the more certain you can be that the induction sealing process is suited to your application.

Cap Liners

Often found yet still rarely realized, inside of many high quality container caps is a material that was placed into the cap prior to the cap being applied on the container or jar.

Sometimes, the end user discover this material.They ask themselves what is the goal of that seal and just how was it put in place? To the astonishment of many, that security seal or freshness seal was put in place with the aid of the cap or lid itself.

Single Piece and two Piece Cap Liners

Individual Piece Cap Liners

Several bottled goods are smaller packs where their contents are required being consumed or used as soon as they are opened. The buyer is not

anticipated to reclose this product or keep product within the container and this kind of product packaging is referred to as one time use packaging. The expected purpose of the lining material or sealing material, in such cases, would be to provide tamper evidence as a protection up until it is opened up. Induction sealing is realized with the aid of single piece materials welded to the peak rim of the jar. Any time you open up a product like this you will observe the aluminium foil across the top of the bottle and when you look into the cap or lid there will not be any other material left from the cap.

2 Piece Cap Liners

Other bottled products and bigger packs usually are not likely to be totally consumed once they are opened. The end user of the product is quite likely going to reclose and store the bottle or container, and thus there is a requirement for a cap the reseals effectively.

As soon as the induction seal has been taken away, there really should still be a material that could result in “friction seal” after the package is closed again. Normally, this is achieved with compressible laminated foam that is around 1 to 2 mm thick.

The soft quality of the foam permit compression as the cap or lid is tightened on the bottle or container. This offers the sort of friction fit tightness which can be kept regardless if the cap or lid is not screwed to its highest possible pressure. Although it is not as effective as a heat induction welded foil, the foam cap inserts supply a resealable seal, permitting the cap or lid can be removed and then replaced and tightened to create a high integrity seal.

Larger sized juice bottles frequently have both a foil lining material and a independent foam lining material. Freshness assurance is justified by the foil while the foam liner provide the resealable capability. For the duration of heat sealing process, the foam element ensures even contact of the foil layer.

When the bottle caps turn loosened while transporting or expand and contract due to temperature or perhaps failed to properly apply, in any case the merchandise integrity and packaging is damaged. With the application of the foil seal on the top of the container, spillage and spoilage are a uncommon occurrence regardless if the caps become loose.

Induction Sealers

To understand this question of the sealing head shape we must first understand how an induction seal is achieved. 

The sealing head is the part of the machine that is placed over the path of the product cap/lid.  Within the sealing head is usually long oval shaped coils of thick wire that carry high current that changes direction many thousands of times a second.  This creates a magnetic field at right angles to the coil that also changes direction many thousands of times a second.  The magnetic field can travel through air and plastic but it does get weaker as it travels away from the coils that generated the magnetic field.  When the magnetic field comes across metal, it will act to generate current in the metal.

In the case of the heat sealing machine, it waits for a product that has a metal laminated foil in its cap.  The magnetic field from the sealing head acts to generate current in the laminated foil and the laminated foil gets hot.  Laminated to the foil is a layer that will melt or become “wet” with heat.  When the product has completely passed from under the induction machine the foil will begin to cool and the layer that became “wet” will set to bond the laminated foil across the opening of the product.

From the above “theory” it can be understood that the sealing of a bottle or product using induction machines will depend on how long the product is under the magnetic field and how close it gets to that origins of the magnetic field.

There are two distinct shapes of sealing heads for cap sealers being Flat profile and Tunnel profile sealing heads.

The Flat profile sealing head is suitable for “Standard Flat Caps” . A “Flat Cap”, generally speaking, refers to a cap where the plane of the induction liner is within 4.0 mm of the plane of the Cap’s top surface.

The Tunnel profile sealing head is suitable for “Specialty Caps”. A Tunnel Induction Sealing Head lets you seal caps where the foil sits a distance greater than say 4 mm from the top surface of the cap; this is often the case with twist top spouts, flip top lids, sports drink caps, sipper caps or shaker caps.

The Tunnel sealing head concentrates the magnetic field to an area within the tunnel profile and hence provides stronger magnetic fields over a generally smaller width path for the products passing underneath.  A Tunnel sealing head also allows the coils within the sealing head to have a path lower than the top of the product caps.  This brings the magnetic field closer to the plane of the foil within “specialty caps”.  The drawback to this Tunnel profile sealing head is that it is usually not very good for large caps and it does limit the range of cap sizes that can be efficiently sealed.  There is a small exception to this rule with the MeRo™ brand induction sealer with an adjustable width tunnel profile.  This machine can typically cater for a range of specialty caps with an adjustment of 30mm which would mean a typical cap diameter range of 30mm to 60mm could be very efficiently sealed.

Efficient cap sealing means that less time is needed under the sealing head and hence higher production speed is possible.

A Flat profile sealing head will allow for a greater range of cap sizes and even allows for that Sealing head to be placed at an angle across the product’s path to achieve sealing of cap diameters that are even wider than the coil winding pattern within the sealing head.  It is quite possible to have a Flat profile sealing head that can seal caps from 30mm to 110mm wide.  The trade-off for the versatility of this profile sealing head on a heat sealing head is lower speed throughput and an inability to seal specialty caps.