Common Packaging Problems — and How the Right Machine Can Solve Them

Packaging plays a vital role in protecting products, enhancing presentation and ensuring smooth distribution. However, even the best operations can run into frustrating packaging issues — from poor seals to wasted film and inconsistent shrink results. At Sontex (Machinery) Ltd, we’ve spent decades helping businesses identify and eliminate these problems through better machinery, maintenance and setup. Here are some of the most common packaging challenges — and how the right machine can solve them.

1. Weak or Incomplete Seals

Problem: If your seal is breaking, uneven or incomplete, it’s often a sign that your sealer isn’t reaching the correct temperature or the sealing time isn’t properly calibrated. Solution: Modern L-sealers and side sealers from Sontex provide precise temperature control and consistent sealing pressure. This ensures every pack has a strong, professional finish — critical for presentation and product integrity. Regular cleaning of the sealing bar and using the correct film type also help maintain reliability.

2. Uneven Shrink or “Dog Ears”

Problem: After shrinking, you may notice wrinkles or corners that don’t tighten properly — known as “dog ears”. This usually happens when the shrink film isn’t evenly heated, or the product isn’t centred correctly. Solution: Our chamber shrink wrapping machines and tunnel systems distribute heat evenly around the product, producing a smooth, tight finish every time. Adjusting the tunnel temperature and conveyor speed can eliminate irregular shrink patterns for a perfectly wrapped pack.

3. Excess Film Waste

Problem: Using too much film not only increases costs but also reduces sustainability. It’s often caused by poor machine setup, incorrect film width, or an outdated sealer with limited control. Solution: Modern automatic shrink wrapping machines feature precise film feed control, ensuring only the required amount of film is used per product. By investing in newer technology, you can cut film waste by up to 25% while achieving consistent, professional results.

4. Slow Packaging Speeds

Problem: As demand grows, manual or older semi-automatic machines can struggle to keep up — creating bottlenecks in your packaging line. Solution: Upgrading to an automatic side sealer or sleeve wrapper can dramatically boost throughput. These systems work continuously, automatically adjusting to product size and sealing each pack quickly and accurately. Combined with an integrated conveyor or pallet wrapper, you can significantly reduce downtime.

5. Frequent Machine Downtime

Problem: Equipment breakdowns or frequent stoppages can be costly. They’re often due to lack of maintenance or worn parts. Solution: At Sontex, we not only supply new machines but also provide Service & Spares across the UK. Regular servicing and genuine replacement parts keep your machines performing reliably, reducing unexpected downtime and repair costs.

6. Poor Presentation or Film Clarity

Problem: Cloudy or wrinkled film can make even the best product look unprofessional. Solution: Using high-quality polyolefin shrink film with the correct sealing and shrink temperatures can improve clarity and overall finish. Sontex can recommend the ideal combination of film and machine settings for your specific product range. Professional Packaging, Every Time The key to solving most packaging problems lies in choosing the right machine, film and aftercare support. With the right setup, you can achieve consistent quality, faster output and reduced costs — all while improving your environmental footprint. 👉 Explore our full range of Shrink Wrapping Machines or contact Sontex (Machinery) Ltd today for expert advice on upgrading your packaging line.