Shrink packaging systems are critical for delivering clean, tamper-evident, and protective seals across a wide range of product types. But like any automation process, shrink equipment can develop performance issues over time. Left unaddressed, these problems can lead to reduced throughput, wasted materials, and compromised packaging quality.
Understanding the most common issues—and how to fix them—can help you keep your line running smoothly and efficiently.
1. Inconsistent Seals or Seal Failure
One of the most frequent issues in shrink packaging is poor or inconsistent sealing. This can result in loose film, open ends, or product exposure. The most common culprits are worn sealing wires, incorrect temperature settings, or contaminated sealing surfaces.
Solution:
Inspect and replace worn or corroded sealing components regularly. Make sure your temperature settings align with the film manufacturer’s specifications, and clean the sealing surface to remove any buildup of melted film or debris. Sealing consistency often improves with regular preventative maintenance and operator training.
2. Uneven or Incomplete Shrinkage
When film doesn’t shrink evenly around the product, it may bunch, sag, or leave wrinkles that impact appearance and product stability. This issue often stems from incorrect tunnel temperatures, air flow imbalance, or incompatible film selection.
Solution:
Verify that your heat tunnel is reaching the target temperature and maintaining even heat distribution. Adjust air flow direction and volume to ensure full film contact. Also confirm the shrink film’s compatibility with your product size and tunnel setup. Some materials shrink more aggressively or require tighter control of heat exposure.
3. Film Tearing or Breakage
Frequent film breakage disrupts productivity and wastes materials. Tearing often occurs when film tension is too high, the feed system is misaligned, or the film itself is too thin for the product size or weight.
Solution:
Check film roll alignment and ensure feed rollers apply consistent, moderate tension. Evaluate whether the chosen film gauge is appropriate for the application. Thinner films may reduce costs but can fail under stress if not properly supported by the equipment or product shape.
4. Product Misalignment or Jams
Misaligned products can cause jams in the sealer or heat tunnel, leading to downtime and potential equipment damage. This problem usually originates from inconsistent infeed spacing or worn conveyor components.
Solution:
Inspect conveyor belts, guides, and infeed mechanisms for wear or misalignment. Ensure that spacing between products remains consistent and that guides keep items centered before they reach the sealing area. Installing photo eyes or alignment sensors can also help maintain proper flow.
5. Excessive Tunnel Heat or Burnt Film
Overheating film can lead to holes, burn marks, or warped packaging—especially on delicate items.
Solution:
Reduce tunnel temperature incrementally and observe results. Ensure proper product spacing so heat can dissipate evenly. Consider upgrading to programmable tunnel controls for precise temperature zoning.
Proactive Maintenance Reduces Downtime
Many shrink packaging problems stem from small oversights that escalate over time. A proactive maintenance plan—including routine inspections, operator training, and proper material selection—helps minimize issues before they affect production.
When in doubt, consulting with a shrink packaging specialist can help identify root causes and optimize your system for long-term reliability and performance.
