Troubleshooting Common Induction Sealing Issues: Leaks and Weak Seals

Even the best induction sealing process can encounter hiccups. If you are noticing leaking bottles or liners that fall out of caps, it's time to troubleshoot. Here are the most common culprits and how to fix them.

Problem 1: Weak or Partial Seals

Cause: insufficient energy or uneven pressure.
Solution:

• Check the coil height. It should be 2-3mm above the cap for optimal energy transfer.
• Ensure the conveyor speed is consistent. If it's too fast, the liner won't heat up enough.
• Verify cap torque. A loose cap means the liner isn't being pressed firmly against the bottle lip.

Problem 2: Burnt Liners or Odors

Cause: Overheating.
Solution: Reduce the power setting on your induction sealer. You might also be running the conveyor too slowly. Finding the "operating window"—the range between a weak seal and a burnt seal—is essential for setup.

Problem 3: High Caps (Cocked Caps)

If a cap is not screwed on straight, the air gap between the foil and the bottle lip will be uneven. The side with the gap won't seal provided. Ensure your capping machine is applying adequate and level torque before the bottles reach the induction sealer.

Conclusion

Regular maintenance and proper setup are key. A well-tuned automatic induction cap sealing machine runs reliably for years with minimal intervention.