Shrink wrap machines are critical for efficient packaging in industries like food, bakery, cosmetics, wood, and pharmaceuticals. Even the most advanced automated shrink wrap machine can encounter issues that disrupt production and affect product quality. Here are the five most common failures in shrink packaging systems and practical solutions to keep your line running smoothly.
What Causes Burn Holes in Shrink Film and How Can You Prevent Them?
Burn holes are a frequent problem in shrink packaging. They appear as small, cloudy holes in the film after it passes through the heat tunnel. The primary cause is excessive heat applied to the shrink film.
How to fix it:
Lower the temperature of the shrink tunnel.
Increase the speed of the conveyor belt so products spend less time under heat.
Add more vent holes in the shrink film to allow trapped air to escape.
Why Are Seals Weak or Off-Center and What’s the Solution?
A weak or off-center seal can compromise package integrity, causing products to fall out or look unprofessional. This often results from incorrect sealing bar temperature, uneven pressure, or improper conveyor height.
How to fix it:
Adjust the sealing bar temperature to match the film type.
Ensure the sealing bar applies even pressure across the film.
Set the conveyor or sealing table to the correct height for your product.
What Leads to Wrinkles Like Crow’s Feet and Dog Ears on Packages?
Crow’s feet (wrinkles radiating from corners) and dog ears (bunched film at corners) are common cosmetic issues. They usually happen when there’s too much film around the product or the heat tunnel settings are incorrect.
How to fix it:
Use a smaller size shrink film roll to minimize excess material.
Increase the tunnel temperature slightly or decrease the conveyor speed to allow more time for shrinking.
Adjust the air speed inside the tunnel for even heat distribution.
How Do You Stop Products from Getting Crushed or Deformed?
Sometimes, the shrinking force is too strong, causing delicate products or packaging to become crushed or misshapen. This is usually due to high tunnel temperatures, slow conveyor speed, or using film that’s too small or too tight.
How to fix it:
Lower the shrink tunnel temperature.
Increase the conveyor speed so products move through faster.
Choose a shrink film size that’s slightly larger and with lower shrink tension for fragile items.
What Causes Zipper-Like Holes or Filaments at the Sealing Line?
Zippering—zipper-like holes along the film—or thin filaments at the seal, are often caused by issues with the venting device or sealing bar temperature.
How to fix it:
Check and adjust the venting device to prevent tearing the film.
Increase the number of vent holes if needed.
Raise the sealing bar temperature if filaments appear, and ensure the sealing bar is level and applies consistent pressure.
Why Kallfass Automatic Shrink Wrap Machines?
Complete Packaging Solutions & Systems Inc. / Kallfass USA specializes in high-end automatic shrink wrap machines engineered for performance, durability, and precision. Their automated shrink wrap machines, shrink packaging machines, and auto wrapping machines offer 98.5%+ uptime, easy film switching, and no programming required in the field. With advanced features like motion control and energy regeneration, these systems eliminate common failures and save on materials—making them the preferred automatic wrapping machine suppliers for businesses that value quality and reliability.
Ready to solve your shrink packaging challenges? Contact Complete Packaging Solutions & Systems Inc. / Kallfass USA for the most dependable shrink wrap machines and complete packaging solutions.
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