Shrinking (process) - BERNING precision technology for modern packaging solutions
Shrink technology combines product protection with efficient Packaging and is a decisive factor for the quality and competitiveness of modern industrial processes.
What do a dishwasher tablet, a PET Bottles and an electronic component have in common? They all benefit from precise shrink technology. In an industrial context, the term “Shrinking (process)” refers to a thermal process in which material is compressed in a controlled manner through the targeted application of heat. For manufacturing companies, the quality of shrink technology is crucial for product protection, packaging efficiency and ultimately for market acceptance.
Shrinking (process) in the industry - far more than just downsizing
At first glance, the process of Shrinking (process) seems simple: material is heated and contracts. In industrial applications, however, this technology encompasses an impressive variety of processes and areas of use. Shrink technology has developed into a key technology in the modern packaging industry. Different industries place specific demands on the process technology.
In the field of packaging technology, Shrinking (process) refers to the thermal compression of Films / Foils that wrap tightly around products and protect them. Films / Foils are first wrapped around the product and then compressed by applying controlled heat. This process not only guarantees protection against environmental influences, but also ensures an attractive product presentation.
Heat-shrink tubing is used in the electronics and cable industry to insulate and protect connections. Precise heating causes the tubing to contract and form a protective sheath around sensitive components. This technology is crucial for the longevity and reliability of electronic components and cable connections.
The various areas of application for shrink technology can be seen in the following overview:
| Industry | Application | Technology | Objective |
|---|---|---|---|
| Food industry | Product packaging | Film shrink-wrapping | Protection, shelf life, presentation |
| Beverage industry | Bottles multipacks | Shrink hoods | Bundling, transportation, marketing |
| Electronics industry | Cable insulation | Heat shrink tubing | Protection, insulation, labeling |
| Pharmaceuticals | Tamper-proof Packagings | Sleeves | Tamper evidence, compliance |
| Logistics | Pallet securing | Shrink hoods | Transport safety, weather protection |
What technologies are behind modern Shrinking (process)?
Industrial shrink technology is based on various heating processes that are selected depending on the application and material. Modern Shrink systems use different forms of energy to ensure precise and energy-efficient processes. Dry steam is a resource-saving alternative.
The dry steam shrink process uses superheated water vapor, which has a higher energy content due to the addition of heat. This technology offers decisive advantages for moisture-sensitive products. The even heat distribution of the dry steam enables a precise and homogeneous Shrink process, while the high heat capacity of the steam optimizes energy consumption.
Dry steam technology is characterized by the following properties:
- Even heat distribution for homogeneous shrink results
- Reduced energy costs thanks to efficient heat transfer
- Minimal environmental impact thanks to closed steam circuits
- Precise controllability of the process parameters
- Particularly suitable for sensitive surfaces and materials
How does dry vapor shrink technology work?
In dry steam Shrink systems, water is heated under pressure and converted into superheated steam. This steam is then directed onto the materials to be shrunk. The high heat capacity of the dry steam ensures rapid and even heating, while the change in saturation conditions ensures that the product remains dry. After the Shrink process, the steam is returned to the system, minimizing the consumption of resources.
Wet steam for special applications
In contrast to dry steam, wet steam still contains a certain amount of water droplets. This technology is particularly used for materials that are not affected by a certain amount of moisture during the Shrink processes. Wet steam enables intensive heat transfer and is therefore ideal for robust products with high shrinkage requirements.
Hot air - the classic method
Hot air Shrink tunnels work with heated air that is evenly distributed in the tunnel by fans. This technology is extremely versatile and suitable for numerous applications. Modern hot air Shrink systems have precise control systems that ensure exact temperature control and optimum air flow.
- Flexible adaptation to different product sizes and shapes
- Good controllability of the process parameters
- Easy integration into existing production lines
- Proven and reliable technology
- Economical operation with different production volumes.
Infrared - precise and energy-efficient
Infrared Shrink tunnels use electromagnetic radiation in the infrared range to heat materials in a targeted manner. This technology enables particularly precise and energy-efficient heat transfer directly to the materials to be shrunk. Infrared systems are therefore ideal for high-quality Packagings with defined shrink properties.
Infrared technology offers the following benefits:
- Precise control of the energy output for optimum shrinking results
- Fast heat-up times and short process cycles
- Reduced energy consumption through targeted energy transfer
- Ideal for sensitive products and premium Packagings.
- High process reliability due to constant heat distribution
Peripherals for Shrinking (process) systems - the environment plays a decisive role
The performance of modern Shrink systems is largely determined by their peripherals. In addition to the actual Shrink processes, numerous supplementary systems are required to ensure an efficient and high-quality process flow.
Preheating - the basis for optimum results
Preheating products or packaging materials is a crucial step in achieving uniform shrink results. Adapted preheating stations bring the material to a defined initial temperature. This increases process stability and enables energy savings.
Modern preheating systems work with:
- Infrared radiation for rapid heating close to the surface
- Convection heat for even temperature distribution
- Intelligent control systems for product-specific temperature profiles
- Energy recovery systems for the use of process heat
Drying - decisive for the final result
After the Shrink processes, controlled drying and cooling of the material is crucial for its quality. High-quality drying systems stabilize the shrunk materials and prevent unwanted deformation. Different drying technologies are used depending on the application.
Infrared drying uses targeted heat radiation to remove residual moisture, while cold air drying ensures rapid stabilization of the material structure. The optimum combination of both methods is individually tailored to the product and the production process.
Energy management and recovery
Intelligent energy management is a key aspect of modern Shrink systems. With the help of innovative heat recovery technologies, the process heat is kept in the system and reused. This leads to considerable energy savings and reduces operating costs and environmental impact.
Advanced energy management systems include:
- Heat exchanger for recovering process heat
- Intelligent control systems with demand-driven energy supply
- Insulation technologies to minimize heat loss
- Integrated energy monitoring systems
Cascaded heat utilization for different process stages
Special applications: Tab tunnels for dishwasher tabs
One particular area of application for shrink technology is the packaging of dishwasher tabs. Tabtunnels from BERNING are specially designed for the requirements of these products and take into account the special properties of the film materials and product shapes used.
The production and packaging of dishwasher tabs places specific demands on shrink technology:
- Precise temperature control to prevent product damage
- Uniform shrinkage for an attractive appearance and optimum protection
- High throughput rates for economical production
- Flexible adaptation to different tabs formats
BERNING has developed special expertise in this area and offers customized tab tunnels that are specially designed to meet the requirements of the detergent industry. The systems are characterized by high process stability, optimized energy efficiency and flexible format adaptation.
Shrinking (process) solutions for Sleeves - a combination of form and function
Another specialty in the BERNING Maschinenfabrik portfolio are Shrink tunnels for Shrink Sleeves. These special shrink labels completely enclose products and offer comprehensive product protection as well as a 360-degree decorative surface for marketing and product information.
Shrink technology for shrink sleeves requires special technical solutions:
- Precise temperature zones for controlled, differentiated Shrinking (process)
- Special air routing for even heat distribution
- Adapted process parameters for different film materials
- Flexibility for contour-shaped products
Integrated quality assurance for perfect optics
Technical details: What makes a good Shrinking (process) tunnel?
The quality of a Shrink tunnel is determined by numerous technical details that must be tailored to the respective application:
- Precise temperature control
Modern Shrink systems have several independent Heating zones that can be individually adjusted. This enables precise adjustment to different materials and product shapes. - Optimized air flow
The targeted flow of hot air or steam ensures even heat distribution and prevents local overheating or uneven shrinkage. - Robust Conveying technologies
Reliable conveyor systems ensure smooth product transport through the Shrink tunnel and contribute to process stability. - Intelligent control
Modern control systems with intuitive user interfaces make operation easier and enable precise process monitoring and documentation. - Modular design
The modular design enables flexible adaptation to different requirements and facilitates future extensions or modifications.
The path to the optimum Shrinking (process) unit
The development of a customized Shrink system follows a structured process that focuses on the customer’s specific requirements. BERNING is at your side from the initial needs analysis to commissioning and beyond.
Analysis of the requirements
First of all, all technical and economic requirements are recorded. Which products are to be Packagings? Which materials are to be used? What throughput rates are required? What quality requirements must be met?
Concept of the system
Based on this analysis, our engineers develop a customized concept. They select the appropriate shrink technologies, plan the material flow and define the necessary process parameters and quality assurance measures.
Design and production
Once the concept has been approved, the detailed design begins. Each element of the system is precisely designed and then produced in our in-house production facility. Thanks to the modular design, flexible adaptation to different requirements is possible.
Installation and commissioning
The finished components are assembled into Shrink systems and extensively tested. After successful commissioning, the customer receives detailed instructions and documentation.
Practical example: High-performance shrink tunnel for beverage multipacks
Initial situation
A leading beverage manufacturer was looking for an energy-efficient solution for packaging PET Bottles multipacks at a high throughput rate. The existing line was causing high energy costs and was not achieving the desired packaging quality
Solution
BERNING developed a customized Shrink tunnel with combined hot air and infrared technology. Innovative air guidance ensured optimum heat distribution, while an integrated energy recovery system significantly reduced energy consumption. Thanks to its modular design, the Shrink tunnel could be perfectly integrated into the existing production line.
Customer benefits:
- Reduced energy consumption by 35 % compared to the predecessor system
- Improved packaging quality with uniform shrink results
- Increased throughput from 12,000 to 18,000 units per hour
- Flexible adaptation to different bottle formats and pack sizes
- Reduced maintenance costs thanks to robust and accessible design
The future of Shrinking (process) technology
Shrink technology is constantly evolving. New materials, digitalization and increasing sustainability requirements are shaping the industry:
- Intelligent systems optimize Shrink processes in real time based on product properties and environmental conditions
- New film materials with improved shrink properties and reduced material usage
- Greater energy efficiency through innovative heating technologies and intelligent energy management
- Digital twins simulate and optimize Shrink processes as early as the planning phase
- Modular systems enable maximum flexibility and adaptability
Through continuous further development and close cooperation with customers and material manufacturers, BERNING remains at the forefront of these developments.
BERNING - Your partner for Shrinking (process) technology
BERNING Maschinenfabrik combines decades of experience with innovative technologies. Each Shrink system is individually designed and tailored to the customer’s specific requirements. The company develops and manufactures high-quality machines that are precisely tailored to the individual needs of its customers.
The portfolio includes:
- Shrink tunnel with various heating technologies (dry steam, wet steam, hot air and infrared)
- Special tab tunnels for dishwasher tabs
- Shrink solutions for Sleeves
- Peripheral systems for preheating, drying and cooling
- Energy management and recovery systems
- Integrated complete solutions for various industries
BERNING Maschinenfabrik sees itself as a partner for sophisticated shrink technology. The company supports its customers from the initial idea to the finished system and beyond. With a deep understanding of a wide range of Shrink processes and its many years of experience, BERNING creates solutions that impress with their quality, efficiency and reliability.
If you would like to find out more about the possibilities of modern Shrink systems, BERNING offers expert advice and customized solutions. For every Shrink process, for every requirement, for every customer.
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