Induction sealing non-standard containers can be difficult when traditional coil designs fail to deliver uniform energy distribution. Our team developed a custom induction sealing solution to reliably seal containers with elevated spouts, small sealing surfaces, and unconventional geometries—without compromising efficiency, safety, or seal integrity.
The Challenge: Induction Sealing Non-Standard Containers
The customer’s container design presented multiple sealing challenges:
- A spout positioned 30 mm above the foil seal
- A sealing surface smaller than the cap diameter
- Limited access to the foil area due to container geometry
Conventional induction sealing coils could not focus energy accurately enough, resulting in inconsistent heating and unreliable seals.
Custom Induction Sealing Solution
To overcome these challenges, we engineered a dual-sided tunnel coil specifically tailored to the container’s geometry.
Dual-Sided Tunnel Coil
- Directs magnetic energy precisely to the centre of the foil seal
- Compensates for elevated spouts and restricted sealing surfaces
- Ensures uniform heat distribution across the foil liner
Flat Coil Box for Versatility
- A standard flat coil box was also supplied
- Enables reliable induction sealing for flat-top containers
- Allows seamless sealing across multiple container formats on the same production line
Results: Consistent, Airtight, Tamper-Evident Seals
The custom coil configuration delivered 100% airtight and tamper-evident seals, even on containers previously considered difficult or impossible to seal using standard induction systems.
Key Benefits of Custom Induction Sealing
- Uniform sealing
Maintains consistent foil integrity on small, uneven, or irregular sealing surfaces - Versatility
Supports both elevated-spout containers and flat-top designs - Reliability
Reduces the risk of leakage, seal failure, and product contamination - Efficiency
Precise energy control enables faster, repeatable sealing with minimal waste
Why Custom Induction Sealing Matters
As packaging designs become more complex, standard induction sealing solutions are often no longer sufficient. Custom induction coil design allows manufacturers to:
- Seal innovative container designs with confidence
- Maintain product safety and shelf life
- Meet tamper-evident packaging regulations
- Reduce downtime, rejects, and sealing failures
By tailoring induction sealing technology to container geometry, manufacturers can achieve reliable, high-performance sealing—even on the most challenging containers.