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When it comes to shrink film, manufacturers often prioritize cost and performance, unwittingly ignoring subtle quality issues that can significantly impact the final product. These issues not only compromise the integrity of the packaged goods but can also lead to added expenses in the long run.
The most common quality issues manufacturers face with shrink film include inconsistent shrinkage, film breakage, poor clarity, surface issues, and sealing problems. Knowing how to identify and address these issues can save you time, resources, and keep your production line running smoothly.
In the following article, we will delve deep into each of these five quality issues, providing practical solutions for manufacturers. It’s essential reading for anyone in the industry who wants to optimize their shrink film usage and sidestep potential pitfalls.
Understanding Shrink Film
Shrink film is a polymer-based material that contracts when exposed to heat, tightly enveloping the item it encases. This reaction results from the material’s unique molecular structure, which changes during the heating process. The film is commonly made of low-density polyethylene (LDPE) or polyvinyl chloride (PVC), among other materials. I’ve spent years in the packaging industry, and it’s remarkable to see how much this seemingly simple material can impact the entire production line.
Key Uses Of Shrink Film In Different Industries
Shrink film is incredibly versatile and widely used across various industries. Its primary function is to protect products from external elements like moisture and dirt, but it’s also vital for unitizing items and ensuring their safe transit.
Quality Issue #1: Inadequate Shrinkage
Inadequate shrinkage refers to the inability of the shrink film to tightly conform to the product it’s supposed to encase. This issue can result from various factors, such as improper heat settings during sealing or using a film type unsuitable for the item being packaged. I’ve encountered this issue multiple times in my years working in the packaging industry, and it can be a frustrating bottleneck in the production line if not addressed timely.
How It Affects The Manufacturing Process
Inadequate shrinkage can significantly undermine the effectiveness of your packaging. A loosely wrapped product can compromise its appearance and protective features, making it less appealing to consumers. It may also contribute to the risk of damage during transport or storage, thereby impacting the entire supply chain. These consequences can cost companies valuable time and resources, not to mention the potential damage to brand reputation.
Relevant Solutions
Based on my experience, the best approach to address inadequate shrinkage is a comprehensive one:
Quality Issue #2: Poor Seal Strength
Importance Of Seal Strength
Seal strength is arguably one of the most critical aspects of effective packaging. A strong seal ensures that the product within remains secure, protected from external factors like moisture, oxygen, and bacteria. It’s a topic I’ve frequently discussed with clients and colleagues alike, stressing that even the highest-quality shrink film would be ineffective if the sealing process is compromised.
How Poor Seal Strength Can Affect The Product
A poor seal can have immediate and long-term repercussions. In the short term, it can lead to package failure, causing the product to fall out during handling or shipping. This leads to an increase in damaged goods, customer complaints, and, ultimately, returns. Over time, poor seal strength can tarnish your brand’s reputation, impacting customer trust and sales.
Suggested Remedies
If you’re facing issues with poor seal strength, consider these steps to improve the situation:
Quality Issue #3: Uneven Film Thickness
Uneven film thickness is an issue where the shrink film does not have a consistent thickness across its surface. This usually occurs due to manufacturing defects or improper handling during the packaging process. Having dealt with this problem in various operational setups, I can say that it’s a subtle issue that can significantly impact the final product.
Its Implications In Manufacturing
The inconsistencies in film thickness can result in uneven shrinkage during the heat treatment, leading to a poorly wrapped product. Furthermore, thin areas are susceptible to tears and punctures, posing a product safety and integrity risk. These inconsistencies can be particularly problematic in industries like food and pharmaceuticals, where packaging plays a crucial role in product quality and safety.
Possible Solutions
Here are some steps to counteract the issue of uneven film thickness:
Quality Issue #4: Poor Clarity and Gloss
Why Clarity And Gloss Matter In Shrink Film
Clarity and gloss in shrink film are not merely aesthetic considerations; they play a vital role in the product’s marketability. Clear, glossy film allows optimal product visibility, enhancing consumer appeal and aiding branding efforts. I’ve seen how a simple switch to higher clarity, the outcome of a significantly more polished film, can dramatically affect the outcome. More polished cinema can make a significant difference in how customers receive a product.
How This Issue Can Affect Product Appearance And Sales
Poor clarity and gloss can obscure the product inside, making it difficult for consumers to gauge its quality. The outcome might appear dull or uninviting on the shelf, reducing sales and potentially harming your brand’s image. Poor film quality can be a deal-breaker in consumer-focused markets where first impressions count.
Effective Solutions
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If you’re facing challenges with film clarity and gloss, here are some solutions to consider:
Quality Issue #5: Inadequate Durability
Importance Of Durability In Shrink Films
Durability in shrink films is a non-negotiable quality. The film needs to be flexible enough to shrink and fit your product and sturdy enough to protect it during handling, shipping, and shelf life. Having spent years observing various manufacturing settings, I can attest to the critical nature of film durability, especially in sectors like food, electronics, and pharmaceuticals, where even a minor compromise can lead to significant repercussions.
How Lack Of Durability Can Compromise Product Safety
A less durable film is susceptible to tears, punctures, or cracks, which could expose the product to external elements like moisture, dust, and contaminants. Consequently, you risk product spoilage, damage, or even legal issues related to compromised consumer safety. We’ve all heard the horror stories; don’t let your brand be the following cautionary tale.
Recommended Solutions
To address durability issues, consider these strategies:
3 Tips to Ensure Quality Shrink Film
1. Purchasing From Reliable Suppliers
One of the most straightforward ways to ensure you’re working with quality shrink film is to buy from reputable suppliers. Doing so dramatically decreases the likelihood of encountering any of the issues above. Based on years of interaction with various suppliers, I can vouch for the importance of checking certifications, reviews, and testing small batches before making a large-scale purchase. A reputable supplier is a cornerstone of quality control in any manufacturing setting.
2. Regular Quality Checks
Frequent quality checks at different stages of your manufacturing process are vital. It’s not just about checking the final product but also about verifying the quality of the shrink film before it even touches your product. I’ve seen operations turned around simply by implementing rigorous quality checks, which help in the early identification of problems and allow you to take corrective actions before they escalate.
3. Investing In High-Quality Materials And Machinery
Sometimes, the urge to cut costs can lead to poor decisions, like opting for cheaper materials or older machinery. However, I’ve noticed that investments in quality always yield long-term benefits. For example, high-quality shrink films and modern, well-maintained machines ensure consistency, durability, and fewer defects in the end product.
Manufacturers can mitigate the risks of poor-quality shrink film by focusing on these three areas. With the right supplier, regular quality checks, and an investment in top-notch materials and machinery, you’re well on your way to a smooth and efficient manufacturing process. Trust me, the initial investment will pay off manifold, not only in terms of product quality but also in brand reputation and consumer trust.
Conclusion
To sum it up, we’ve delved into the critical quality issues concerning shrink film, ranging from inadequate shrinkage and poor seal strength to uneven film thickness, lack of clarity, and insufficient durability. We also covered effective ways to circumvent these issues, such as sourcing from reliable suppliers, conducting regular quality checks, and investing in high-quality materials and machinery.
Addressing these quality issues isn’t just about avoiding production hiccups; it’s about building a brand that stands for quality and reliability. In my years of working closely with manufacturing processes, I’ve found that a commitment to quality isn’t just good practice—it. It’s essential for long-term success. A keen eye for detail and a proactive approach can save time and resources while helping to uphold your reputation in a competitive market.
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When it comes to shrink wrapping your soap, you have options. In this article we discuss the different types of shrink wrap films, so you can make the best choice for your product packaging.
Which shrink wrap is right?Wrapping your soap protects it from the environment, excess handling and your clients, while increasing customer confidence in the integrity of your product. There are several different types of plastics used to make shrink wrap film, and each comes in different weights, with and without perforations. So when it comes to selecting the best for your individual application, the answer depends on a number of factors.
If you don’t want, or don’t care if, the scent of the soap comes through the film, 75 gauge PVC is the best-looking film to use. It is also the easiest to work with. PVC is crinkly, with a beautiful glossy finish. It makes your packages sparkle, which is why PVC is the first choice for gift applications such as Spa Kits, gift sets and gift baskets, as well as single items such as soap or candles. It’s often a good choice for products placed in retail outlets other than your own, as it looks great, and typically, will not allow the scent through quickly, if at all.
The weight of the PVC film makes a difference. We often hear complaints about “hard, rough edges” from soapers who are using the pre-made PVC shrink bags which are typically made from 100 gauge PVC. The recommended thickness for PVC used to wrap small items (such as a bar of soap) is 75 gauge. Anything over that is way too thick and will result in those sharp edges.
PVC Wrap is great for display!For moisture sensitive items such as bath bombs, fizzies and MP soap, the same properties of PVC that keep the scent from escaping will also protect the moisture (or rain!) from getting in. That makes PVC film an excellent choice for these items as well.
Tip: Sometimes if you perfectly seal a bar of soap, it will trap some air in the package and puff up like a little pillow as you shrink it down. To resolve this minor issue, squeeze the bar as you handle it normally for shrinking. The air will find a way out and it doesn’t take any extra time.
If you want the glossy look-and-feel of PVC for your soaps and candles but still want the scent to come through the film, think about Perforated PVC. This is the same 75 gauge film, but made with tiny pinholes that will allow the scent to come through. Keep in mind when considering Perforated PVC for moisture sensitive items that there are actual holes in the film that will let in humidity and water.
If you DO want the scent to come through, polyolefins can be a better choice. It is an FDA-approved-for-food-contact film that is breathable, freezable, microwaveable and allows the scent through the film, whether perforated or not.
Polyolefins are soft shrink films with a feel similar to that of your standard Ziploc-type sandwich bag. There are two processes by which polyolefin is manufactured, the latest of which is a method called cross-linking. Cross-linked polyolefin yields a stronger and more puncture-resistant film than shrink packaging produced by the old method. It’s more expensive than standard films and is usually sold under the “premium” designation. (This is the only type of polyolefin we sell at National Shrinkwrap.)
Within the confines of a shop or if you ship mail-order, 60 gauge polyolefins is the film of choice. It is thinner, easier to cut and seal, and quicker to shrink than any of the other films. Keep in mind, though, that it’s also easier to blow a hole through 60 gauge film if you get a little careless with your heat gun.
However, if you are often moving your product (for example to and from fairs, festivals, or farmer’s markets) the stronger, thicker, 75 gauge film will make for stronger packages that will stand up better to the repeated handling during packing and unpacking and setting up your racks or displays. The heavier weight film also offers a bit more protection from customers’ handling of your products.
In the same vein, you might want to wrap Multi-Bar packs, gift sets or soap/dish combinations. These would also benefit from the added strength and durability of 75 gauge polyolefin.
Just to give you some perspective on the film, Apple uses 60 gauge film wrapping iPad boxes. Polyolefin film in 60 gauge is available in standard, perforated and Soft Shrink varieties.
60 or 70 Gauge Polyolefin Rolls?At National Shrinkwrap, we originally perforated many of our film selections for the benefit of our customers making goat’s milk and dairy based soap which need to “breathe” (to avoid rancidity from any dairy components).
Another reason many of our soapers, even those not using milk in their recipe, prefer the perforated films is that the perforations make it easier any air trapped in your package to escape.
Finally, the perforations allow the scent through quickly on wrapping. However, given a day or so, the scent of the soap will still come through the non-perforated polyolefin films just as well.
As with perforated PVC, we don’t recommend perforated polyolefin for MP soap, bath bombs, fizzies or other moisture-sensitive products. In humid or rainy environments perforated film allows moisture in more easily; and in an arid environment it may allow for too much moisture evaporation over time. That said, at National Shrinkwrap we do have many customers who us the perforated polyolefin for MP soaps and are happy with it, especially those that do not typically sell in outside environments.
It's a tall decision, can you shrink of the right one?Soft shrink polyolefin is a special formulation that requires less heat to shrink down, a big plus for wrapping butters and other heat sensitive items. It also exerts less force during the shrinking process, allowing it to conform to intricate shapes better than other films. If your decorative bars feature delicate designs like the petals on a soap rose, or if you make shaped soaps, like pie slices, cupcakes or frosted items, you might want to opt for this variant of polyolefin film.
If you’ve “gone green,” Biolefin™ is a biodegradable film that will take 90% less time to degrade in the environment and will decompose into biomass in a span of 3-5 years in a landfill situation.
Biolefin serves the same purposes as standard film, and is available with or without perforations. As with all polyolefins, it allows the scent of your soaps through whether perforated or not. NOTE: Biolefin is only available in 60 gauge.
So, in a nutshell, here are your film options, in order of popularity, amongst our legions of soapmaking customers.
Contact us to discuss your requirements of Beverage Shrink Film. Our experienced sales team can help you identify the options that best suit your needs.