British Crisp Company: Overcoming Paper Packaging Challenges with Precision Engineering
As the packaging industry continues to explore alternatives to conventional plastic films, manufacturers face new challenges in maintaining pack quality, production efficiency and consistent performance.
The British Crisp Company, known for its paper-based crisp packaging, faced a particular challenge when producing its fin-sealed pillow packs. Repeated creasing was affecting the appearance of the finished packaging, requiring a more specialised approach to the forming process.
KENRAY’s engineering expertise helped overcome these challenges through a forming set specifically optimised for the paper packaging material.
The Challenge
The application involved a Vertical Form Fill Seal (VFFS) packaging machine producing fin-sealed pillow packs using paper-based packaging material. Unlike conventional flexible plastic films, paper-based materials can behave differently as they travel over the forming shoulder and into the forming tube. The characteristics of the material must be carefully considered to achieve consistent results.
In this case, repeated half-moon creases were proving difficult to eliminate using a conventional forming set.
These creases affected the smoothness and presentation of the finished packs, creating a challenge for the manufacturer as it worked to achieve the desired packaging quality. The objective was to eliminate the recurring creases while maintaining, or improving, production speeds.
The KENRAY Solution
KENRAY approached the challenge by focusing on the relationship between the packaging material and the geometry of the forming set. Rather than relying on a conventional former design, the team redesigned and optimised the forming geometry to suit the specific paper being used. By adapting the forming set to the material’s characteristics, KENRAY was able to improve how the paper travelled through the forming process, addressing the recurring creasing issues. This application demonstrates the importance of considering the packaging material when designing forming equipment, particularly when transitioning to alternative materials.
Results and Benefits
The redesigned forming set delivered significant improvements to the finished packaging and production performance.
Improved Pack Presentation
The optimised former geometry successfully eliminated the recurring half-moon creases, producing a smooth, crease-free finished pack.
Production Speed Improvements
In addition to improving pack quality, the forming solution enabled production speeds to meet and exceed the previous benchmark.
Optimised Paper Handling
By designing the forming set around the specific paper material, KENRAY achieved more effective material handling through the forming process.
Supporting Alternative Packaging Materials
The project demonstrated how specialist forming set design can help manufacturers overcome technical challenges associated with paper-based packaging applications.
Engineering Solutions for Changing Packaging Materials
As more manufacturers investigate paper-based and other alternative packaging materials, the performance of existing forming equipment becomes an important consideration.
A forming set that performs effectively with conventional plastic film may not necessarily deliver the same results when working with a material that has different handling characteristics.
At KENRAY, we understand that successful packaging performance depends on more than the machine alone. Our team combines forming set design, engineering expertise and an understanding of packaging materials to develop solutions tailored to individual applications. The British Crisp Company project is an example of how the right forming geometry can make a significant difference, overcoming a persistent packaging challenge while supporting improved production performance.
Helping Your Packaging Line Perform Better
Whether you’re transitioning to paper-based packaging, introducing new films or experiencing recurring issues with creasing, pack presentation or material handling, KENRAY can help.
Our team works with manufacturers to understand their specific packaging requirements and develop forming solutions designed to deliver consistent, reliable results.
Contact KENRAY to discuss your packaging challenges and discover how our engineering expertise can help your production line Perform Better.
British Crisp Co: Increasing Accuracy – Eliminating Half-Moon Creases
