Automated systems that hermetically seal pre-formed trays (plastic, pulp, or fiber) with a top film to extend shelf life. Essential for food processors, meal kit companies, and pharmaceutical manufacturers.
Core Components & Functions
Component | Function | Technical Specs |
|---|---|---|
Tray Infeed | Automated conveyor positions trays | Adjustable guides (100–600 trays/hour) |
| Gas Flushing System | Replaces air with preservative gases (N₂/CO₂) | O₂ residual: <0.5%; Flow: 10–50 L/min |
Film Unwinding | Feeds top film (PET/PP laminates) | Roll diameter: ≤800mm; Tension control |
Heating Platen | Activates film sealant layer (heat-sensitive adhesives) | Temp: 150–220°C; Pressure: 1–3 bar |
Cutting System | Die-cuts film to tray contour | Servo-driven knives; ±0.2mm precision |
Outfeed Conveyor | Transports sealed trays to labeling/boxing | Variable speed: 2–30 m/min |
Sealing Technologies
Type | Mechanism | Best For | Seal Strength |
|---|---|---|---|
Heat Seal | Thermal activation of adhesive layer | Wet products (meat, produce) | 15–25 N/15mm |
Ultrasonic Seal | High-frequency vibrations fuse materials | Dry goods (salads, nuts) | 20–35 N/15mm |
Cold Seal | Pressure-activated adhesive (no heat) | Heat-sensitive items (chocolate, cheese) | 10–18 N/15mm |
Tray Compatibility
Tray Material | Max Depth | Sealable With | Product Applications |
|---|---|---|---|
APET/CPET | 150mm | PP, PET films | Ready meals, sliced meats |
Molded Pulp | 100mm | Biopolymer films | Eggs, fruits, organic produce |
Aluminum Foil | 80mm | Peelable lidding | Pet food, pharmaceuticals |
rPET Plastic | 120mm | Recyclable PP films | Meal kits, deli items |
Key Benefits
✓ Extended Shelf Life:
- MAP (Modified Atmosphere Packaging): 5–21 days extension
✓ Leak Prevention:
- Seal integrity tests withstand 0.8–1.5 bar pressure
✓ Automation:
- Integrates with filling/checkweighers (≤500ms cycle time)
✓ Customization:
Quick-change tooling for different tray sizes (swaps <5 min)
Operation Workflow
Tray Loading: Automatic or manual placement
Gas Flushing (MAP): 3–5 second purge cycle
Film Application: Pre-stretched over tray
Sealing: Heat/pressure applied for 1–4 seconds
Cutting & Ejection: Perforated lids for easy opening
Machine Types by Output
Type | Capacity | Footprint | Price Range | Best Fit |
|---|---|---|---|---|
Manual/Semi-Auto | 10–50 tph* | 1.5m² | $100–$25,000 | Small bakeries, farms |
Rotary Auto | 80–200 tph | 6m² | $50,000–$120,000 | Medium processors |
Inline Auto | 250–600 tph | 12m²+ | $150,000–$400,000 | Industrial food plants |
*tph = trays per hour
Top Brands & Models
Manufacturer | Flagship Model | Unique Feature |
|---|---|---|
Multivac | S 506 | AI-driven seal inspection |
Ilapak | Delta 320 | Zero-downtime film splicing |
Proseal | GT-360 | Patented "Twin Seal" technology |
ULMA Packaging | TSA 400 | Hygienic design (IP69K-rated) |
Critical Specifications
Seal Width: 3–10mm (adjustable)
Gas Mix Accuracy: ±0.3% for N₂/CO₂/O₂ ratios
Energy Use: 15–75 kW (depends on automation level)
Air Supply: 450–900 L/min @ 6 bar
Maintenance Requirements
Daily:
Clean sealing platens with food-grade alcohol
Inspect film/tray sensors
Weekly:
Calibrate gas flow meters
Lubricate conveyor chains
Annual:
Replace heating elements & cutting blades
Industry Applications
Food: Meat, seafood, produce, ready-to-eat meals
Pharma: Sterile medical devices, specimen kits
Agriculture: Seed packaging, biological samples
Retail: Meal kits, subscription boxes
Innovations
Self-Diagnostic AI: Predicts seal failures via thermal imaging
Sustainable Films: Compostable PLA laminates with O₂ barriers
Robotic Tray Loading: 3D vision-guided pick-and-place
Cloud Monitoring: Real-time O₂ tracking via IoT sensors
Cost Analysis
Expense | Manual | Automatic |
|---|---|---|
Machine Cost | $100-12,000 | $200,000 |
Labor (per shift) | 2 operators | 0.5 operators |
Film Waste | 8–12% | 3–5% |
ROI Period | 6–18 months | 2–3 years |
Regulatory Compliance
Food Safety: HACCP, FDA 21 CFR, EU Regulation 1935/2004
Certifications: CE, UL, ISO 9001/22000
Traceability: Serialized barcodes under each seal
Did You Know? Advanced tray sealers achieve <0.1% packaging defects – outperforming manual sealing by 15x.
Tray sealers are mission-critical for perishable goods, combining gas flushing, hermetic sealing, and precision cutting in one system. The global market will reach $1.8B by 2028 (CAGR 5.7%), driven by demand for fresh convenience foods.
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