Heat Tunnel Stage in Bundle Shrink Wrapping Machines

Introduction

Bundle shrink wrapping is widely used in packaging lines to wrap multiple bottles, cans, or boxes into a single unit. The film-covered bundles pass through a heat tunnel where the film shrinks and forms a tight seal.

A packaging customer faced ongoing quality issues due to uncontrolled tunnel temperature, impacting bundle strength and appearance.

Challenges:

  • Incomplete Shrinking: Film left loose ends or gaps around the bundle

  • Film Tearing: Overheating weakened the film structure and caused tearing

  • Seal Failures: Irregular heating led to weak or open seals

  • High Waste & Downtime: Manual rework and film wastage increased

  • Inconsistent Output: Output quality varied across batches and shifts

Solution

  • Controller Used: 48×48 mm – Model TCS4T2AO

  • Installation: Placed in tunnel zones with sensors that give real-time feedback

  • Set Point: Adjusted according to bundle size and film thickness

  • Monitoring: Zone temperatures are shown in real time.

  • PID with Auto-Tuning: Consistent heat was guaranteed by adaptive control.

  • Interface for Operators: Simple changes and profile storage 

Benefit to Customer

  • Better Bundle Integrity: Film shrunk evenly with no loose ends

  • Reliable Seal Strength: Fewer open or failed packs

  • Lower Waste: Reduced film rejections and rework

  • Stable Performance: Consistent wrapping across shifts

  • Easy Operation: Simple user interface and maintenance

Conclusion

With GIC’s TCS4T2AO controller, the bundle shrink wrapping line achieved stronger, neater packs with minimal operator intervention. The customer saw improved production reliability, lower costs, and a better final product—making it a smart upgrade for their packaging line.