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“Packaging that is altered in order to reduce food losses can lessen the total environmental impact and lead to large environmental gains, even if it is necessary to increase the environmental impact from the packaging itself,” according to Swedish researchers. Brands need to know that heat sealing helps to prevent the top cause of food waste in the world! It takes a good degree of familiarity with packaging materials and processes to select the right heat sealer. The good news is that product packaging is exponentially more secure when the proper method of heat sealing is used. No, choosing a heat sealer for your packaging needs should never feel like a guessing game. Yes, you can learn how to make a smart choice with just a little research into the different types of heat sealers. Take a look at how to turn up the heat on product integrity using the right heat sealer.

What Is Heat Sealing?

Heating sealing is a process that uses an electric current to heat and seal packaging openings to create a totally sealed unit. During the process, a heating bar is placed over the packaging to create a melting effect. Once the two sides of the opening have melted together, a cooling phase that creates a perfectly formed seal activates. Here’s a step-by-step look at how it happens:

• The operator pushes the heat sealer’s sealing bar down manually.
• Once the bar is lifted, the heat is turned off. This allows the cooling period to begin.
• During the cooling period, the seal becomes firm.
• The product then has an airtight seal!

While this is the general process used with all heat sealers, the truth is that there’s quite a bit of variety when it comes to the methods used to achieve flawless seals. There are actually dozens of different heat sealers available. Some even come with special features that allow you to perform quality control on the spot. Next, dive a little deeper into heat sealers.

What Industries Need Heat Sealers for Their Products?

Heat sealers can be used in packaging for essentially any product. However, they are commonly used in the food industry because they help to create airtight seals around products. This is important for both tamper-proof protection and freshness. The simple act of using a heat sealer can prolong shelf life by months!

Heat sealers are also commonly used in the pharmaceutical and medical industries to ensure safety and sterility. For instance, surgical equipment, examination tools, bandages, and dressings are often manufactured using heat sealing to ensure that there is no risk for contamination. In addition, placing medications in packaging that has been heat sealed helps with both safety and accountability. Finally, some product manufacturers simply prefer to use heat sealing because of the benefits this process offers for keeping products safe against dust, moisture, and markings caused by handling. Small, loose objects that can range from screws to doll accessories are also frequently packaged in heat-sealed containers simply to avoid product loss.

How to Choose the Right Heat Sealer

Impulse heat sealers and direct heat sealers are the two options to pick from when shopping for modern heat sealers for product packaging. The first detail to consider when beginning the search for the right heat sealer is the material that is being sealed. Thickness is quite important. In fact, it’s essential to have stats and dimensions regarding material thickness readily available when browsing sealers.

All heat sealers generally feature metal construction using materials like cast aluminum or steel. You’ll also see that plug-in timers and microswitches are standard on heat sealers. All heat sealers generally operate the same way. There’s no need to try to “guess” when a seal is complete. The operator is notified of each completed seal by a beep with an accompanying light.

Impulse Sealers

The impulse sealer is considered the most popular option. It is a better choice if you are seeking a sealer to seal thermoplastic materials. The list of materials suited for impulse sealers includes:

• Bubble packs.
• Coated bags.
• Foil.
• Kel-F.
• Mylar.
• Nylon.
• Padded mailers.
• Pilofilm.
• Polyethylene.
• Polyflex.
• Polyurethane.
• Polyvinyl alcohol.
• Polyvinylchloride.
• Saran.
• Tyvek.

If you’re planning to complete large-volume sealing jobs, you’ll appreciate the fact that impulse sealers are extremely economical during usage. Impulse sealers only draw electricity when they are actively sealing. They also heat up instantly with no need for a warmup period. However, impulse sealers don’t require you to lock into a one-size-fits-all solution. There are actually different styles of impulse sealers that are designed for use with specific packaging types. Here’s a rundown of how to shop for heat sealers based on what you’re sealing:

• Hand Sealers: Ideal for poly materials with thicknesses up to 10 mils.
• Pedestal/Foot Sealers: Ideal for poly materials with thicknesses up to 15 mils.
• Auto Sealers: Ideal for poly materials with thicknesses up to 15 mils.
• Double Impulse Sealers: Available in both foot/pedestal and automatic models, these sealers are ideal for poly materials with thicknesses up to 20 mils.

You can also source heat sealers with special features that assist with quality control. For instance, many impulse sealers come with built-in cutters that allow you to cut away excess material. This can help to ensure uniformity.

Direct Heat Sealers

Direct heat sealers are also called constant heat sealers. Unlike impulse sealers that heat up “as needed” after being turned on, direct heat sealers maintain constant heat. They also draw energy whenever they are turned on. As a result of the stronger heat output, direct heat sealers are actually better for sealing thicker packaging materials. Direct heat sealers are ideal when sealing:

• Cellophane.
• Coated aluminum.
• Coated PP.
• Gusset bags.
• Kraft paper.
• Mylar.
• Poly-cello films.
• Waxed paper.

Generally, direct heat sealers are necessary for coated packaging materials because seals add thickness and heat resistance to packaging. It’s important to have your packaging chosen before choosing a heat sealer for this exact reason. While direct heat sealers can be effective for sealing many of the materials that are compatible with impulse heat sealers, impulse heat sealers can’t often handle the materials that are ideal for direct heat sealers.

Specialty Sealers

Some packaging requires specialty sealing. Vacuum sealers are used with perishable products because they help to prevent spoilage and oxidation by “sucking” the air from the product prior to sealing. Special barrier bags are needed with this sealer because common bags are simply too porous. Brands that use clamshell packaging must use special clamshell sealers. These highly specialized sealers actually “weld shut” the packaging.

Do All Heat Sealers Use the Same Type of Heating Element?

There are actually two different types of heating elements built into heat sealers. A heating element can either be round or flat. Generally, the shape of the sealer used doesn’t have a big impact on performance. However, the number of heating elements does impact performance. It’s important to know that some sealers actually contain two heat elements instead of one as you’re shopping for a new heat sealer. While sealers with double heating elements are more expensive, they provide faster heat penetration that makes it possible to seal thicker packaging materials.

How Many Packages Can You Seal With Heat Sealers?

The answer depends on the style, size, and model of the heat sealer you ultimately choose. Standard commercial heat sealers are typically capable of sealing anywhere from six to 50 packages per minute. Automatic sealers generally produce the greatest output. A typical automatic heat sealer can seal anywhere from 20 to 50 packages per minute. The average foot sealer can finish between eight and 20 packages per minute. Finally, manual hand sealers can seal between six and 20 packages per minute. That number is impressive when you consider that hand sealers are extremely simple, affordable, and easy to use.

Get All of Your Questions About Heat Sealers Answered

A heat sealer is an important investment in your brand’s ability to put the finishing touches on products before sending them out to customers and retailers. Choosing the wrong heat sealer can result in poor product integrity. It can even become a liability if you’re sealing perishable food products. Mid-Atlantic Packaging is here to answer all of your questions about sealing products for freshness, safety, and product integrity. We can also help you find the best packaging materials for getting your product sealed in the cheapest, easiest way possible. Reach out today for your free custom packaging quote.