Stabilise the group before it reaches the film
Unstable products need a controlled arrival pattern, limited transfer gaps, correctly positioned guides and a repeatable method of forming the complete bundle. Depending on the product, that method may include a side-feed pusher, pack clamp, tray, pad or operator-controlled presentation.
Film should not be expected to correct a group that is already leaning, spreading or missing products. Observe the exact point where collation changes and address the mechanical or timing cause before adjusting seal or tunnel settings.
Find the first loss of control
- Run the products without film and observe arrival gaps and contact points.
- Mark where the first item rotates, tips, separates or climbs another product.
- Check transfer openings, conveyor speed differences, guide positions and pushing direction.
- Add only the support needed to maintain the intended group.
- Repeat the trial through film, tunnel, cooling and downstream handling.
Choose support by failure mode
| Observed risk | Possible control to assess | What still needs proving |
|---|---|---|
| Products spread before sealing | Side guides, controlled back pressure or positive pusher. | No damage, scuffing or incomplete group at the film. |
| Tall or narrow products tip | Tray, pad, clamp, reduced transfer gap or different feed direction. | Stability through tunnel conveyor and cooling discharge. |
| Products rotate or change orientation | Profiled guides, lanes, timing control or pack support. | Repeatable orientation at the seal and accepted presentation. |
| Bundle collapses after the tunnel | Film/support review, cooling and discharge control. | Handling strength after the pack has stabilised. |
| Mixed products load unevenly | Kitting, dedicated positions, tray or alternative secondary pack. | Balanced bundle without local film damage. |
Make the collation trial representative
Use production-weight products, normal surface condition and the real bundle count. Empty bottles, dry test items or hand-held groups can behave differently from filled production packs. Include start-up, a missing item, a short stop and restart so the controls and recovery method are visible.
- Video the group before, during and after transfer.
- Record every manual correction needed.
- Check guides for scuffing or concentrated pressure.
- Inspect the cooled bundle after the intended lifting method.