By Brandon Hoser, Business Development and Marketing, Toss Machine Components, Inc.

Form-fill-seal (FFS) equipment is used across the packaging industry to form a package from film, fill it with product, and seal it for protection, transport, and display. Consistent heat sealing is one of the most important factors in overall package quality because poor seals can lead to product loss, wasted material, downtime, and reduced throughput. As packaging operations work with a wider range of films, including recyclable and other newer materials, precision temperature control and well‑engineered sealing systems have become increasingly important for achieving repeatable, high‑quality seals.

What is FFS Equipment?

Form-fill-seal equipment is automated packaging machinery that forms film into the required package shape, fills the package with product, and then seals it to preserve the contents. Two common machine orientations are vertical form-fill-seal (VFFS) and horizontal form-fill-seal (HFFS).

VFFS machines are typically well suited for flowable granular, loose, or liquid products and offer the benefit of a smaller footprint, although their taller design can create ceiling-space constraints and they may be more limited by gravity-fed product flow. HFFS machines generally require more floor space, but they can support more complex package shapes, often run at higher speeds, and are better suited for single-item packaging or less flowable products. For both machine types, seal quality remains a critical performance factor.

Critical heat-seal components of form-fill-seal machines 

Used widely in food, medical, industrial, and consumer packaging, automated FFS machines rely on plastic films to create packages that protect, preserve, and present a wide range of products. These packages must be formed, filled, and sealed precisely, often at high speeds, while also standing up to transport, handling, and end-use requirements. Whether the application involves sterile medical products, electronics, or food packaging, seal quality has a direct impact on package performance.

To meet these requirements, the sealing system plays a crucial role. Precision temperature control systems provide the response and accuracy needed to seal a wide variety of polymeric films used in contemporary packaging while helping reduce scrap, downtime, and unnecessary operating costs.

New advances help solve common challenges faced by packaging engineers

Temperature control, material selection, and machine calibration all affect seal integrity. Material selection determines the required sealing parameters, including time, temperature, and pressure, and those parameters cannot be achieved consistently without proper calibration.

The two most common heat-sealing approaches used in FFS equipment are constant heat sealing and impulse heat sealing. Constant heat technologies, often called hot bar sealers, use heated tooling that is maintained at a constant temperature, also known as direct-contact thermal sealing. They use one or more heated bars, irons, or dies which contact the material to heat the interface and form a bond. They work best with films engineered for constant heat sealing. These are typically films that do not require much of a cooling cycle, for example, laminated foil. For that reason, constant heat is generally not the best choice for many high-speed polyethylene film applications, as well as some newer biodegradable films entering the market which require significant cooling parameters.

In impulse heat sealing systems, one or more heating elements are placed between a resilient silicone rubber backing and a release layer. The heating elements are not continuously heated; instead, heat is generated only when a seal needs to be made. When film is conveyed into place, the sealing bars actuate and electric current is applied to the heating elements to quickly heat and achieve the temperature parameter. Impulse sealing reaches the required temperature much faster than constant‑heat sealing equipment while also cooling off much quicker. This enables speedy equipment start up times for manufacturing and typically expeditious equipment cool down times for maintenance when needed. 

Several impulse heat-sealing approaches are available. Basic systems may provide limited or no temperature feedback, which can allow temperatures to drift and increase the risk of inconsistent seals or seal failure. Advances in heat-sealing technology have significantly changed the landscape of FFS packaging over the past decade. 

Several engineered impulse heat‑sealing innovations provided by TOSS Machine Components, Inc. enable equipment to achieve faster seals while maintaining consistent results, forming an integrated, engineered sealing system rather than a collection of individual components. For example, TOSS PIREG® temperature controllers provide management of the sealing process with the instantaneous feedback required to maintain the desired sealing temperature within milliseconds and regulate the selected temperature and sealing time with repeated precision. The result is higher productivity, fewer rejects, superior seals, and reduced cost.

TOSS PIREG controllers help maintain highly consistent heat‑seal band temperature throughout the sealing cycle. Their fast response and precise control are ideal for sealing a wide variety of polymeric films. The PIREGcontroller measures the temperature 60 times a second, adjusting the power to the heat-seal band to ensure the band stays at the correct temperature throughout the sealing cycle as cold films absorb heat. The controller prevents temperature overshoot, can seal films requiring a cooling phase, and reduces the time required to reach sealing temperature. The controls also offer robust diagnostics and data logging capabilities to help users identify and troubleshoot issues more quickly.

Another advance is the TOSS Alloy-20® heat-seal band, which can be sourced in a wide variety of widths and profiles to produce the desired heat seal result. Examples include wide or narrow seals, intermittent seals, multi-line seals, as well as seal and cut bands which trim excess film while providing a hermetic seal in one process eliminating the need for a separate knife component. When paired with PIREG controllers and the TOSS system, ultra fast heat up times to 300°C can be achieved in 400 milliseconds (ms) enabling faster cycle times and consistent temperature through the seal cycle because energy can be replaced quicker than cold film can draw from the seal band.

Key considerations for seal quality and machine uptime

To achieve consistent results, engineers and operators should focus on a few core factors:

• Maintaining sealing jaws and heat‑seal bands properly and ensuring consistent, uniform pressure on the heat‑seal band
• Understanding the film being sealed and what is inside the package
• Determining whether seal‑and‑cut capability is needed
• Defining the required seal length and width before selecting a band design

How do process controls support seal quality?

With a clear understanding of material and equipment requirements, the next step is to focus on process parameters and control systems. To achieve consistently high‑quality seals, it is essential to maintain adequate dwell time and to select sealing technology that matches the specific film in use. In addition, controllers equipped with diagnostics and data logging can help operators identify and resolve issues faster, reducing downtime and supporting more efficient production.

Customer success story

To illustrate how engineered impulse sealing systems can improve results in demanding applications, consider the experience of a leading international VFFS machine manufacturer that needed to produce uniform, dependable seals, particularly when sealing directly above liquids. This process often increased susceptibility to contamination, leaks, and compromised seal integrity.

“As a manufacturer of VFFS machines for liquid packaging, achieving a consistent and reliable seal is a significant challenge, especially when sealing directly over liquid. TOSS technology has proven to be a key component in our solutions, allowing us to maintain perfect, repeatable seals even in demanding applications. Their quality and precision have helped us raise our sealing performance to the highest standards,” stated the customer.

By incorporating TOSS technology into their VFFS machinery, the manufacturer improved seal consistency, reduced product loss, and increased operational efficiency, helping it maintain high standards for packaging quality and reliability.

New trends shaping the future of heat sealing in flexible packaging

Achieving consistent seal quality in form-fill-seal operations is both a technical and operational imperative. As packaging materials diversify and sustainability demands grow, the integration of advanced technologies, such as precision temperature controllers and innovative heat-seal bands, has become essential for ensuring seal integrity, maximizing machine uptime, and reducing waste. By aligning material selection and process control, manufacturers can overcome the challenges of sealing a wide variety of polymeric films, including the latest recyclable substrates.

As the industry pushes for faster production, broader film compatibility, and more sustainable packaging materials, advanced temperature control and engineered heat‑seal systems will play an increasingly important role. For packaging engineers and OEMs alike, the ability to deliver repeatable, high-quality seals across changing materials will remain a key competitive advantage.

VANCOUVER, Wash. — Aug 2, 2026 — System integration firm ABM Equipment has published a new industry guide comparing nearly every X-ray OEM on the market. The guide is designed to help processors land on the most practical equipment by comparing factors that determine performance, usability, and cost—upfront and long-term.

As more buyers begin to require x-ray and manufacturers seek better detection with fewer false rejects, selecting the right X-ray inspection partner has grown in importance. The new guide offers an overview of the industry's leading suppliers by assessing the technologies, capabilities, and service that define them.

Starting with a table averaging company scores given by end-users and distributors, the guide then explains the metrics—what they are, why they matter, and how to understand the market by them. It then gives a blurb overview of material information for each supplier, where it factors in remarks from survey respondents, competitors, and allies. It then provides two tables, one mapping out the available specs and features offered by each supplier, and the other mapping nearly every machine on the market by inspection area width at the belt.

Rather than relying on brands’ web presences, the guide then evaluates companies using criteria that impact user experience. Topics covered include contaminant detector resolution, algorithm performance, software capabilities, application versatility, machine construction, serviceability, customization options, and long-term support.

Readers will also find comparisons of performance metrics, including:

• Detection performance across common contaminants
• Inspection speed and throughputs
• Image processing and artificial intelligence features
• Cleanability and hygienic options
• Software functionality, reporting, traceability, and data integration
• Total cost of ownership, including maintenance and service considerations
• Industry experience and application expertise
• Customer support, installation, training, and aftermarket service
• Best-fit providers for boutique applications

The guide is intended for food processors, quality assurance professionals, operations managers, engineering teams, and executives responsible for evaluating inspection technology for new production lines or equipment upgrades.

ABM Equipment has been a provider of engineering solutions—specializing in handling and processing of dry ingredients and inspection and packaging of all products— for over 50 years. ABM offers comprehensive services including equipment selection, sales, system integration, parts, maintenance, and customizations for food applications and those using the same equipment (pharmaceutical, chemical, and nutraceutical).
The complete guide can be seen here at ABMEquipment.com.

How biological modeling transforms time and temperature exposure into instant food safety signals

By; Jeff Desrosiers, President at Vitsab®

Modern food distribution systems depend on a delicate balance of time and temperature. From seafood shipments and ready-to-eat meals to airline catering and home delivery boxes, perishable products travel through a series of environments where temperatures fluctuate constantly. At any given time, a pallet may move from refrigerated storage to a loading dock, onto an aircraft, into a truck, and finally onto a consumer’s doorstep, while each step introduces variables that influence microbial growth and product quality.

Historically, monitoring these conditions relied on thermometers, data loggers, and manual temperature checks. While these tools provide valuable data, they often create an interpretation challenge at the moment a decision must be made about the safety of the product. A temperature graph may show a complex series of spikes and recoveries, leaving operators or consumers uncertain about whether the product remains safe to consume.

Time-temperature indicators offer a different approach. Rather than capturing isolated measurements, these systems track how temperature and time interact cumulatively across the product’s journey. When designed for ease of use, they translate biological risk into a visual signal that can be understood instantly. But the simplicity of the visual signal masks an intricate scientific foundation; behind every color change lies a carefully engineered biological process designed to mirror the real conditions that influence spoilage and microbial growth.

The Biological Engine Behind a Color-Changing Indicator

At the heart of advanced time-temperature indicators is a biochemical reaction embedded within the label. The indicator contains two separate components housed in small compartments. One contains an enzyme, a naturally occurring biological catalyst that drives chemical reactions. The other contains a substrate, a compound that reacts with the enzyme once the system is activated. When the label is activated, the enzyme and substrate begin interacting through a controlled reaction. As this interaction progresses, it gradually alters the pH environment within the indicator. That subtle chemical shift is what eventually produces the visible color change.

The reaction behaves much like a highly calibrated pH test strip. Under warmer conditions, the reaction proceeds faster. Under colder conditions, it slows dramatically. Because the reaction cannot reverse once it has occurred, every temperature exposure leaves a permanent record in the indicator. This mechanism allows the label to accumulate the effects of temperature fluctuations throughout the product’s journey. A brief warm exposure might advance the reaction slightly, while prolonged warmth accelerates it significantly. If the product returns to refrigeration, the reaction slows but never reverses, preserving a cumulative history of handling conditions. The result is a biological system that evolves in response to the same environmental conditions that affect real food products.

One of the greatest challenges in cold chain monitoring is variability. Temperature abuse rarely occurs as a single catastrophic failure. More often, it appears as a series of brief fluctuations throughout transportation and storage. A shipment might remain properly chilled during air transport, warm briefly during unloading on a tarmac, cool again inside refrigerated storage, and experience intermittent exposure during delivery. Traditional threshold-based indicators often struggle with this complexity. Some systems respond to a single temperature spike, even if the exposure was brief and biologically insignificant.

Biological time-temperature indicators address this challenge by accumulating exposure gradually rather than reacting to a single event. Because the enzyme-driven reaction progresses continuously, the label effectively mirrors the cumulative thermal history of the product, and by following the true dynamics of microbial growth, these indicators provide a far more meaningful representation of product condition than isolated temperature readings.

Calibrating Indicators to Real Microbial Risk

Designing a reliable time-temperature indicator requires more than simply creating a reaction that changes color over time. The reaction must be calibrated to reflect the actual biological risks associated with a specific product. Different foods spoil in different ways and at different speeds. A seafood shipment, for example, may present different microbial concerns than leafy greens or prepared meals. Each product category has distinct organisms of concern, critical temperature thresholds, and shelf life expectations.

Developing an indicator formulation therefore begins with data. Researchers collect microbial growth information at multiple controlled temperatures, often using incubators or water baths to simulate real storage conditions. These experiments help establish how quickly spoilage organisms grow under various temperature scenarios. Once these data points are established, scientists can begin adjusting the indicator formulation. Different enzymes, substrates, and concentrations can be combined to fine tune the speed and behavior of the reaction. Through repeated testing, researchers align the reaction curve with the biological curve of microbial growth.

Transit conditions also influence calibration. A product shipped across oceans will experience a very different temperature profile than a meal delivered locally within a few hours. Packaging methods—such as gel packs, dry ice, or mechanical refrigeration—must also be considered when designing the indicator. Because food safety is inherently conservative, additional safety margins are typically incorporated into the model. By building these buffers into the formulation, the indicator ensures that warnings occur before microbial risk becomes unacceptable. Through this process, a simple label becomes a highly tailored monitoring tool designed around the biology of the product it protects.

From Scientific Modeling to Real World Cold Chain Visibility

Developing reliable monitoring tools requires collaboration across multiple scientific and regulatory communities. Food safety regulators establish protective guidelines but often depend on academic research and industry data to refine those standards. Universities and research laboratories conduct microbial studies that reveal how pathogens behave under different environmental conditions. Bridging these domains requires organizations capable of translating complex scientific findings into practical tools for the food industry. Those dedicated to food safety should be focused on research and development in this area and should work closely with regulators, academic researchers, and industry partners to refine monitoring technologies.

Vitsab is one example of an R&D company operating at this intersection. Working with scientists, regulators, and industry stakeholders, the organization has focused on developing cumulative visual monitoring technologies designed to align with real biological risk. Its Freshtag® indicators apply enzyme-based reactions and calibrated formulations to translate complex temperature exposure histories into a clear stoplight signal that operators, quality managers, and consumers can interpret instantly.

This collaborative model allows new formulations to evolve alongside advances in microbial science. As researchers better understand pathogen behavior and shelf life dynamics, those insights can be incorporated into future indicator designs. The result is a monitoring approach that improves both safety and sustainability. By accurately distinguishing between safe and compromised products, cumulative indicators help prevent unnecessary disposal while still identifying situations where intervention is required.

As global food systems continue to expand and delivery models become more decentralized, the demand for clear, trustworthy cold chain signals will only grow. Technologies that combine rigorous scientific modeling with intuitive visual communication may play an increasingly important role in ensuring that perishable foods remain both safe and responsibly managed throughout their journey.

By Sylvain Charlebois — July 20, 2026

Food safety isn’t just about finding the source of an outbreak anymore. It’s about helping Canadians understand the evidence

Every summer, Canadians are reminded that fresh produce, while essential to a healthy diet, can also pose food safety risks. This year’s Cyclospora outbreak in the United States has already sickened at least 1,644 people, making it one of the largest in recent memory.

Yet despite its scale, investigators have not conclusively identified the source. The U.S. Food and Drug Administration’s traceback investigation has focused on shredded iceberg lettuce supplied by a Mexican grower, but an initial laboratory finding was later withdrawn. That alone illustrates why public health officials must communicate uncertainty carefully as investigations unfold.

Canada’s food regulators have appropriately resisted calls to suspend produce imports because there is simply no scientific evidence pointing to a particular commodity or country of origin. From a regulatory standpoint, that is the right decision. From a communications standpoint, however, we have an opportunity to do much better.

Food safety agencies have become remarkably sophisticated at tracing pathogens through increasingly complex supply chains. But when it comes to communicating uncertainty, many are still relying on a model designed for another era. Press releases and media interviews remain the primary tools for informing the public, even though most Canadians now consume information through search engines, social media and increasingly through artificial intelligence. The way people seek answers has changed dramatically. The way governments communicate risk has barely evolved.

Cyclospora presents a particularly difficult communication challenge because consumers have very little control over their own exposure. Unlike bacterial outbreaks involving foods that can be cooked, this parasite is commonly associated with fresh produce that is eaten raw. Washing leafy greens or herbs offers only limited protection, and by the time illnesses are reported, the contaminated products have usually disappeared from store shelves. Add an incubation period that often exceeds a week, and consumers are left trying to remember meals they barely recall eating.

Public health officials therefore face a difficult balancing act. Warn too aggressively and consumers may avoid fresh produce altogether, unnecessarily harming growers, distributors and retailers. Say too little, and the public may conclude that authorities are withholding information.

One of the biggest shortcomings of current risk communication is its lack of precision. When headlines mention “leafy greens,” most consumers do not distinguish between romaine lettuce, spinach, kale, arugula or mixed salads. They simply avoid the entire category. Behavioural economists have long recognized this as a spillover effect: one product’s problem becomes everyone else’s problem. The result is collateral economic damage extending far beyond the actual source of contamination, often affecting producers who had absolutely nothing to do with the outbreak. This is precisely why communication matters as much as epidemiology.

Artificial intelligence offers an opportunity to fundamentally rethink how food safety information reaches consumers. Imagine asking your AI assistant whether spinach is implicated in the current outbreak and receiving a clear, evidence-based response explaining that no such link exists, while also describing what investigators do know and what remains uncertain.

If a specific imported herb were eventually identified, consumers could receive targeted guidance immediately instead of vague warnings that leave them guessing. Rather than relying on generalized announcements that inevitably fuel confusion, regulators could provide personalized, real-time answers based on verified data, reducing unnecessary panic while improving public confidence.

The Canadian Food Inspection Agency has earned an international reputation for scientific excellence. Its inspectors, laboratories and traceability systems are among the best in the world. The next frontier is not simply improving detection; it is modernizing communication. Instead of issuing static recalls and occasional updates, regulators should develop dynamic, AI-ready information platforms capable of distinguishing between products that are confirmed sources of illness, products that remain under investigation and products for which there is no evidence of concern.

Just as importantly, agencies should become more comfortable communicating uncertainty. The FDA’s recent withdrawal of an initial laboratory finding while continuing its traceback investigation illustrates exactly why that matters. Scientific investigations evolve as new evidence emerges. Communicating those changes openly builds far more confidence than pretending certainty where none exists. Telling Canadians, “We don’t yet know, but here’s what we’re doing,” is far more credible than offering broad reassurances that can quickly unravel as new evidence emerges.

Food safety has always depended on science. Increasingly, it will also depend on trust.

In an era where artificial intelligence is rapidly becoming the public’s first source of information, regulators must ensure that trustworthy, evidence-based guidance reaches consumers before speculation and misinformation do. The future of food safety will not be defined solely by faster laboratory testing or more sophisticated traceback investigations. It will also be defined by our ability to communicate risk with the same precision as the science itself.