Induction sealer helps Catania-Spagna go green

Catania-Spagna packages and processes cooking oils ranging from vegetable to fine olive oil, servicing the retail, restaurant, bulk and export food industry. It operates four packaging lines to keep up with demand, two of which rely on induction sealing technology.

Induction sealing technology comprises two main components: the power supply and the sealing head. When energised by the power supply, the head produces an electromagnetic current, called an eddy current. The capped bottles enter the electromagnetic current and the foil of the inner seal generates electrical resistance, heating the foil. The hot foil in turn melts the polymer coating on the inner seal. The heat, coupled with the pressure of the cap, causes the inner seal to bond to the lip of the container. The result is a hermetic seal.

Induction sealing technology isn’t new to these seasoned packaging veterans. They’ve used induction sealing for over 20 years to keep their products’ seal integrity intact. Catania-Spagna started using Enercon equipment in the 90s when installing its water-cooled induction sealing systems. After over a decade of use it was time to upgrade.

There has been a rapid shift from the use of water-cooled induction sealing systems to air-cooled systems across the packaging industry. Enercon’s breakthrough in sealing head design allows for higher sealing efficiencies and the elimination of the water recirculator. Air-cooled power supplies are able to achieve speeds that were once only in the realm of water-cooled systems and require a lot less maintenance.

“Our 2008-2009 initiative was to go green; one of the first places we started was by replacing our Enercon water-cooled induction sealers with air-cooled systems,” said Steve Sampson, Vice President of Operations.

Catania-Spagna replaced five of its water-cooled induction sealers with Enercon’s Super Seal air-cooled systems. The induction sealers support their ‘gallon line’ and ‘jug-in-a-box line’, sealing high-density polypropylene containers ranging from three litres to two and a half gallons. They use a universal sealing head, which gives Catania-Spagna the flexibility to run containers with cap sizes ranging from 20-120 mm without having to switch sealing heads.

In addition to the energy saving obtained by the elimination of the water recirculator with the latest air-cooled design, the systems have been proven to reduce downtime, maintenance and the amount of defective product. Catania-Spagna has saved thousands of dollars a year by upgrading its equipment.

”The water recirculator had to be flushed on a regular basis. We also struggled with rust and corrosion from the water recirculator. Now, the downtime is practically non-existent,” says Sampson.

Catania-Spagna’s green incentive didn’t stop there. It also installed two new energy-efficient air compressors, variable-frequency drive pumps and motors which optimise the energy output to the amount of energy actually needed, a new lighting system triggered by sensors and started an in-house recycling program which saves on trash disposal. With these simple green changes, Catania-Spagna is not only able to conserve energy but it also saves a lot of green. Sampson reported upwards of $100,000 a year is saved on energy costs.

With a hundred years of packaging experience under its belt, Catania-Spagna knows how important progress is in the packaging industry. It continues to apply innovative packaging solutions, allowing it to keep an edge by delivering its customers the same quality product at a competitive price.