Welcome to the P3 Solutions™ Blog by Greener Corporation, featuring a comprehensive approach to cutting, sealing, and forming on horizontal and vertical form fill seal packaging machines. Please subscribe or check back often for updates on integrating Parts, Process, and People to improve package quality, increase productivity and reduce costs.

Optimizing Knife and Anvil Set-Up on Horizontal Wrappers

Set-up procedures for knives and anvils can vary according to the make and model of the packaging machine, knife adjustment style, and other factors. There are, however, some general principles that make these adjustments more effective and efficient, reducing downtime and parts costs.

Diagonal Zig Zag Knife for Horizontal Wrapper_Greener Corporation
  Optimize Knife Design

  • Knives ground on a diagonal, or bias–whether they have a zig zag or a straight cutting edge–require less pressure to cut so they are easier to set up and typically last longer.
  • Zig zag knives with smaller (more) teeth are also easier to set up and provide longer life.

  Set Up the Crimpers First

  Make Sure the Crimpers, Including the Slots, are Clean Before Installing Knives and Anvils

  • Material or product build-up can make parallel adjustment of the knives and anvils difficult or impossible, and may cause intermittent cutting issues during production.

  Always Change the Anvil When Changing a Knife

  • Anvil for horizontal wrapper with double impressionA knife may not cut cleanly across previously made impressions in a used anvil, and the excess pressure required to cut can cause premature knife failure. 


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HEAT: Improving Seal Quality and Consistency

For heat seal applications, each packaging film structure has a Seal Initiation Temperature (SIT), at which the sealant layer is heated enough to flow into and seal off gaps in the end seal and provide a minimally acceptable seal, and a Maximum Temperature, beyond which the film distorts, fractures, or has inadequate hot tack (seal strength and integrity while the seal is still warm). The temperature range between the minimum and maximum is the film’s Operating Window.

For a number of reasons, regulating heat is not as straightforward as simply adjusting the temperature setting within the operating window for the film you are running.

 The sealing face of crimpers and sealing jaws is often hotter in the middle than at the ends, where heat dissipates more quickly. These inconsistencies are readily apparent in the thermal profile shown below:

Stainless Steel Crimper Thermal Profile

Stainless Steel Crimper Thermal Profile

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Case Studies of Collaborative Projects

Following is the first in a series of case studies that demonstrate the many ways Greener Corporation has collaborated on packaging projects and helped to facilitate positive results. In addition to providing quality replacement parts for cutting, sealing, and forming, we offer a well-rounded, solutions-oriented approach that considers the processes and people that are essential for project success—engineering, installations, training, establishing SOPs, film trials, and other supportive functions. Read more

Case Study: Packaging Material Cost Reduction

Project Goals

The corporate engineering department at a large, international company commenced a project to reduce material costs for a variety of products that are individually packaged on horizontal flow wrappers. Greener Corporation was invited to participate in a series of meetings that defined the project’s initial goals:material cost reduction_Greener Corporation

  • To reduce the cut-off length for each package by reducing the overall seal width, thus allowing the product envelope to remain unchanged.
  • To achieve material savings without degrading seal integrity or productivity levels.
  • To achieve a project payback period of twelve months or less.

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Clearance and Pressure on Horizontal Wrappers: What’s the Difference?

Greener’s latest “Tech Bites” video explains how proper clearance and pressure adjustments optimize horizontal flow wrapper performance.

Clearance and pressure settings on horizontal flow wrappers are critical for achieving quality packages, minimizing downtime, and controlling costs. We’ve noticed that the differences between clearance and pressure, and the proper occasions to adjust each of them, are not always clear to those making these adjustments. Greener’s latest “Tech Bites” video and blog post differentiate the function and adjustment of clearance and pressure. Read more

Keeping Your Packaging on Track

Side to Side Misalignment

Side to Side Misalignment

Even experienced users of forming sets can, over time, become conditioned to accept the hidden costs and preventable constraints of their packaging equipment. As with all waste, however, careful diagnosis of the root causes will lead to implementation of effective solutions.

One such root cause is forming tube misalignment. This can occur if the forming set has been accidentally mishandled and damaged or if the forming set has not been properly designed and fabricated in the first place. Read more

Greener Corporation Open House

Students working to establish and enhance careers in manufacturing recently visited Greener Corporation and gained perspective on some practical applications for their new skills. They learned that in addition to manufacturing knowledge, a commitment to excellence at all levels and to complete customer satisfaction will guide their success.  Read more

White Papers: From Problem Solving to Proactive Improvement

Greener Corporation has published a series of white papers devised to help optimize package quality and productivity on horizontal and vertical form fill seal packaging lines. In addition to helping you solve problems, these technical articles provide foundational information you can use to implement proactive improvements—an approach that helps deter problems from occurring in the first place.

End Seal Leaks at the Fin Seal Fold

End Seal Leaks at the Fin Seal Fold

Serration Pattern Design

Serration Pattern Design

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Our 50th Anniversary!

Joseph Wojtech's Machine Shop, 1912

Joseph Wojtech’s Machine Shop, 1912

When Ted Wojtech Sr. founded his company over 50 years ago he followed the business model of his father and his grandfather, who had opened a machine shop in 1912. Through the years Ted Sr. and his business partner, Noel Brown, instilled the foundational principles and beliefs of Greener Corporation. The result has been a consistent focus on customer relationships and an unending quest to provide the finest quality parts and services. Nowadays these efforts are guided by the next generation of Wojtechs—owners Ted and Matt. Read more