Author: claire

We are pleased to welcome Neall Massingham as our new Engineering Operations Manager. With over 15 years of experience in various manufacturing sectors, Neall brings a wealth of knowledge in driving improvement, efficiency, and growth within complex operational environments.

His extensive career includes senior roles in engineering, production, maintenance, and quality management, providing him with a comprehensive understanding of high-performing factories. Neall is known for his hands-on leadership style, having successfully built and led multidisciplinary teams, delivered major automation initiatives, and managed strategic capital projects and full-site transformations.

Neall’s expertise extends to modernising legacy facilities, strengthening quality systems, and embedding data-led decision-making across engineering and production functions. He is dedicated to fostering strong, people-first cultures that empower subject matter experts, encourage innovation, and create environments where teams can excel.

In his role as Engineering Operations Manager, Neall will focus on driving operational excellence and developing a world-class manufacturing system that enhances customer service and reinforces our core company values. His leadership will be instrumental in supporting continued growth, improving performance, and cultivating a culture of continuous improvement across the organisation.

Outside of work, Neall is a devoted husband and father to an energetic 11-year-old boy. He values lifelong learning and enjoys activities such as reading, golf, football, woodworking, 3D printing, and model building, while also keeping his son entertained and engaged.

We showcased a range of products including:your tickets to see what solutions we can offer for you.

Kenray is proud to sponsor the Market Bosworth Football Club (MBFC) Under 7’s football strips. We believe that these small gestures towards local causes can significantly contribute to the development and teamwork training essential for the young players’ futures.

Jack Hayes is often seen on the sidelines, cheering the team on and encouraging them to ‘Perform Better.’

Good luck to MBFC Under 7’s.

Kenray exhibited at PPMA 2025 last week where we were able to catch up with both new and current customers. It was great to see other members of the packaging industry and creating new connections.

PPMA is a great event with a range of processing and packaging manufacturers and is definitely an event to keep on your radar for next year. It always proves to be a great event for all staff from sales to engineering to marketing and helps everyone to get a feel of the environment we are competing within.

We showcased a range of products including:

• Snack Bag Formers
• DOY Formers
• Product Strippers
• Belts
• HFFS
• Jaws from our partner Greener Corporation

We all had a great time attending PPMA and are excited to be attending again next year and are also looking forward to out next exhibition in Dusseldorf at Interpack! Be sure to book your tickets to see what solutions we can offer for you.

In the world of packaging, efficiency is the difference between meeting production goals and falling short. While high-quality equipment and materials are essential, the skill and knowledge of your operators play an equally important role in achieving seamless operations. Investing in operator training is not just a nice-to-have – it’s a critical step toward maximising your packaging line’s performance and reducing costly downtime.

Here’s why training your operators should be a top priority for any packaging operation.

Minimising Downtime and Errors

Untrained or undertrained operators can inadvertently cause issues that lead to production delays. From incorrectly aligning forming sets to misconfiguring machine settings, small errors can snowball into significant downtime. These disruptions not only cost time but also waste materials and increase operational costs.

By ensuring your operators are fully trained on equipment use, troubleshooting, and maintenance, you can dramatically reduce the frequency of these errors. Skilled operators are quicker to identify and address potential issues before they escalate, keeping your production line running smoothly.

Improving Product Quality

Consistency is key when it comes to packaging quality. Poorly sealed bags, creases, or misaligned prints can tarnish your brand’s reputation and lead to product waste. Often, these issues stem from improper handling of machinery or a lack of understanding of how to adjust settings for different products or materials.

Operator training helps bridge this gap. When your team understands the nuances of your equipment, they can make precise adjustments to ensure every package meets quality standards. Whether it’s achieving a flawless back seal or eliminating film misalignment, trained operators are better equipped to deliver high-quality results consistently.

Extending Equipment Lifespan

Packaging equipment represents a significant investment, and protecting that investment is crucial. Improper use of machinery – such as over-tightening components or neglecting routine – can lead to unnecessary wear and tear, shortening the lifespan of critical parts like forming sets and tubes.

With proper training, operators learn the correct way to handle, clean, and maintain your equipment. They’ll also know how to spot early signs of wear or damage, allowing you to address issues proactively. This not only extends the life of your equipment but also helps prevent costly repairs and replacements.

Boosting Team Confidence and Morale

A well-trained team is a confident team. When operators feel equipped to handle their responsibilities, they’re more engaged and less likely to feel overwhelmed by the demands of a fast-paced production environment. Training also fosters a culture of continuous improvement, where team members take pride in their skills and actively seek opportunities to enhance their performance.

Additionally, investing in operator training demonstrates that you value your employees and their development. This can lead to improved morale and retention, creating a more stable and skilled workforce over time.

Adapting to New Challenges and Technologies

The packaging industry is constantly evolving, with new materials, machine designs, and technologies emerging regularly. Without proper training, operators may struggle to adapt to these changes, slowing down production and increasing the likelihood of errors.

Regular training ensures your team stays up to date with the latest advancements in packaging technology. Whether it’s learning how to use a new machine or understanding the unique requirements of a different product line, a well-trained workforce is better equipped to handle change with confidence.

Kenray Global’s Approach to Operator Training

At Kenray Global, we understand the critical role that operator training plays in packaging efficiency. That’s why we offer tailored training programmes designed to empower your team with the knowledge and skills they need to excel.

Our training covers a wide range of topics, including:

• Proper setup and alignment of forming sets and tubes
• Troubleshooting common issues like creasing and misalignment
• Routine maintenance to extend equipment lifespan
• Adjusting settings to optimise performance for different products and materials

Whether you prefer onsite training, remote sessions, or hands-on experience at our state-of-the-art Testing & Training Centre, Kenray Global provides flexible options to suit your needs.

Empowering Your Team for Success

Operator training is an investment that pays dividends in efficiency, product quality, and equipment longevity. By equipping your team with the skills they need to succeed, you can unlock the full potential of your packaging line while reducing costs and downtime.

If you’re ready to take your operations to the next level, Kenray Global’s expert training programmes are here to help. Contact us today to learn more about how we can support your team and optimise your packaging performance.

In the world of packaging, efficiency and precision are everything. However, even the most advanced production lines can encounter challenges that disrupt operations, waste resources, and impact product quality. From creasing issues to seal inconsistencies, these problems can feel like constant hurdles to overcome. Understanding the root causes and implementing targeted solutions can make all the difference.

Here are five common packaging challenges and practical ways to address them.

1. Creasing Issues

Creasing is one of the most frequent challenges faced by packaging professionals. Whether it’s caused by worn forming sets, incorrect adjustments, or incompatible materials, creased bags can lead to compromised product presentation and sealing failures. The issue often arises when forming sets are not properly maintained or aligned, leading to uneven pressure during bag formation.

To tackle this problem, regular inspection and maintenance of forming sets are essential. Worn or damaged components should be repaired or replaced promptly to prevent further disruptions. Choosing high-quality materials that are compatible with your equipment can also reduce the likelihood of creases. Additionally, ensuring that forming sets are correctly aligned during setup can significantly improve bag formation consistency.

2. Film Misalignment

Film misalignment is another common issue that can cause production delays and material wastage. Misaligned film can result in unevenly formed bags, irregular seals, or even equipment jams. This often occurs when rollers, guides, or forming sets are improperly adjusted, or when low-quality film is used.

Preventing film misalignment starts with a thorough setup process. Rollers and guides should be aligned with precision, and operators should be trained to recognise and correct potential misalignment during operation. Investing in high-quality film that is specifically designed for your machine can also minimise issues. Regular operator training can further enhance your team’s ability to spot and address these problems early.

3. Back-Seal Problems

A reliable back seal is critical for ensuring the integrity of your packaging, but achieving consistent seals can be tricky. Issues such as weak seals, wrinkles, or gaps often stem from poorly maintained forming sets or improper temperature and pressure settings on the sealing jaws. Back-seal problems not only impact product freshness but also lead to increased material waste.

The key to overcoming back-seal problems lies in precision. Regularly inspecting and refurbishing forming sets helps maintain the alignment and smoothness necessary for clean seals. Additionally, optimising the temperature and pressure settings on your sealing jaws can enhance seal consistency. Using forming sets tailored to your product type and packaging material can further reduce seal-related issues.

4. Tube Alignment Issues

When forming tubes are not correctly aligned, packaging lines can experience significant disruptions. Misaligned tubes can lead to uneven bag formation, causing irregular shapes or even product spillage. This problem is particularly common in fast-paced production environments where equipment is frequently adjusted.

To minimise tube alignment issues, it’s important to implement a routine inspection and calibration schedule. Operators should ensure that forming tubes are correctly positioned and securely fixed before starting production. Refurbished or high-quality forming tubes can also reduce the likelihood of misalignment and improve overall packaging performance. Training operators to handle adjustments with precision will further help maintain smooth operations.

5. Product Blockage

Product blockage can bring production to a grinding halt, particularly when dealing with sticky, irregularly shaped, or delicate items. Blockages often occur when forming tubes or other components are not properly calibrated or are incompatible with the product being packaged.

Addressing product blockage starts with understanding the specific characteristics of the product. Adjusting forming sets and tubes to accommodate product flow can make a significant difference. If blockages persist, consider working with experts to design custom forming sets tailored to your product’s unique requirements. Regular cleaning and maintenance of forming tubes can also prevent residue build-up that contributes to blockages.

Maintaining Operational Efficiency

Packaging challenges are inevitable, but they don’t have to derail your operations. By staying proactive with equipment maintenance, investing in operator training, and seeking expert support when needed, you can address these issues head-on. At Kenray, we specialise in creating tailored solutions for every stage of the packaging process, from refurbishing forming sets to providing bespoke training.

When you’re ready to optimise your operations and reduce downtime, Kenray is here to help. Contact us today to learn how we can support your packaging needs and keep your production line running at peak performance.

End seal leakage is one of the most common and frustrating challenges in packaging. It compromises product freshness, increases waste, and can cause significant downtime. Fortunately, with a proactive approach, this issue can be effectively managed. From equipment adjustments to material upgrades, there are many ways to ensure your packaging maintains its integrity.

Here are six proven solutions to minimise end seal leakage.

1. Schedule Regular Maintenance

Misaligned sealing jaws are a leading cause of end seal leakage. Over time, wear and tear can disrupt the alignment, resulting in inconsistent seals. Regular maintenance helps identify and resolve these issues before they escalate.

During inspections, focus on areas like jaw alignment, wear on components, and smooth operation of the sealing mechanism. Addressing minor issues early can save both time and money in the long run.

2. Optimise Sealing Parameters

Temperature, pressure, and dwell time are the three key parameters that determine seal quality. If any of these factors are off, the integrity of the seal can be compromised.

Ensure that the sealing temperature matches the requirements of your packaging material. Too little heat won’t bond the seal, while too much can degrade the material. Similarly, adequate and even pressure across the sealing area is essential for a reliable bond. Take the time to test and fine-tune these settings for each material and production run.

3. Check Jaw Profiles and Serration Patterns

The design of the sealing jaws, including their profile and serration pattern, plays a significant role in forming a strong seal. A poorly matched or worn profile can lead to weak seals or gaps.

Upgrading to a serration pattern optimised for your material and machine can improve seal consistency and reduce leakage. Regularly reviewing the condition of the sealing jaws ensures they maintain their effectiveness over time.

4. Use Quality Packaging Materials

Low-quality or incompatible materials can make it difficult to achieve a secure seal. Inconsistent thickness, poor heat resistance, or substandard film properties are common culprits behind seal failure.

Investing in high-quality materials specifically designed for your sealing equipment can significantly reduce leakage. Testing different materials under production conditions can help identify the best option for your needs.

5. Maintain Proper Film Alignment and Tension

Film misalignment or improper tension can cause wrinkles and uneven seals, leading to leaks. Ensuring that the film feeds smoothly through the machine is critical to achieving consistent results.

Regularly inspect rollers, guides, and tension settings to confirm that everything is aligned and functioning correctly. Training operators to recognise and address alignment issues quickly can also reduce the risk of seal problems.

6. Incorporate Regular Seal Testing

Even with well-maintained equipment and high-quality materials, periodic testing of seal integrity is essential. Tools like burst testers and peel testers can provide valuable data on the strength and reliability of your seals.

Incorporating these tests into your quality control process helps catch potential issues early, allowing for adjustments before defective products reach the market. Testing also ensures that your seals meet industry and customer standards for durability and freshness.

Partnering for Sealing Success

End seal leakage is a common challenge, but it can be effectively managed with the right combination of maintenance, adjustments, and expertise. From ensuring proper alignment and optimising sealing parameters to recommending advanced materials and designs, Kenray provides the tools and expertise needed to address these challenges head-on.

Our team can help you implement these solutions, perform detailed line assessments, and ensure your packaging operations run seamlessly. If you’re ready to minimise leaks and maximise efficiency, contact us today to discuss how we can support your packaging success.

It has been a fantastic week for the Kenray Research and Development (R&D) Team, headed by Phill Loxley and assisted by Ian Bonsall and Colin Bosworth who have finalised a 14-month project completing operational validation trials for paper packaging with Pepsico.

The Kenray Team have worked closely with the development team at PepsiCo and assisted them to become the first FMCG company to have a +90% paper content and carry the OPRL recycle compliance. This is a massive achievement across the board.

Thanks also for all the support and liaison from the back-office team at Kenray.

Kenray is celebrating the inauguration of our new plant in India & we were delighted to be joined by Alan Gemmel, Deputy High Commissioner & Her Majesty’s Trade Commissioner for South Asia who officially opened the new plant.

Our new facility will strengthen our services across Asia and beyond and will allow for further growth for Kenray products & services.

A big thank you to everyone who has helped make this move a success.

Mark Evans, Commercial Director and Andrew Dennis, Technical Director said:

“The opening of this new plant will allow Kenray to further expand into supplying formers and accessories across Asia to our wide client base and will allow our operations further room for our continued growth. This is a very exciting time for us and delighted to see the new plant up and running and providing jobs in the local region.”ion in Dusseldorf at Interpack! Be sure to book your tickets to see what solutions we can offer for you.