Why does package waste
suddenly increase?
Why does package waste increase on thermoforming and tray sealing machines? Common causes related to cutting tools, punches, sealing and vacuum, plus a checklist.
A rise in waste on thermoforming and tray sealing lines usually comes not from one big breakdown but from small parts that wear down gradually. We have summarized the most common causes we see in the field and the order of checks.
If cutting quality deteriorates
Burrs or fraying on the film edge, or a cut that doesn't separate cleanly, show that the cutting tool is dulling. When star knives, circular knives and cross-cut knives wear, operators often try to compensate by increasing pressure or air pressure; this puts unnecessary load on the die and pneumatic parts.
Hanging hole and punch problems
Micro-tears at the edges of air punches and euro punches, whitening around the hole or holes that don't come out clean are signs that the punch and die are worn. When the clearance between punch and die grows, cutting quality drops quickly.
Sealing and closing faults
Irregular sealing quality can come from a worn heater surface, hardened sealing gaskets or an unstable sealing temperature. If wrinkles and channels form on the seal line, check the gaskets and heater surface first.
Vacuum and gas line
A vacuum level that drops late or a gas mixture that doesn't settle can come from causes such as pump oil, filters, hose connections and nozzle blockage. Cleaning and checking the gas nozzles should be part of periodic maintenance.
Quick check order
- Visually inspect the cutting line and the knife edges.
- Check punch and die wear.
- Inspect the gaskets and heater surfaces.
- Check the vacuum pump and filters.
- Clean and check the gas nozzles.
Frequently asked questions
What should I check first when the waste rate rises?
First visually check the cutting quality and the sealing line; the problem is most often in the knife, punch or gasket.
Why is running with a dull knife harmful?
The pressure needed for cutting increases; this puts extra load on the die and pneumatic parts and lowers package quality.
For parts or service needs: WhatsApp / phone +90 549 734 34 02, altay@evopak.com.tr or our spare parts catalog.
