1. Pre-Run Setup
☐ Install all tooling:
Gusset punches, cross seals, longitudinal seals
Zipper seals, tear notches, handles/hang holes
☐ Mount roll centered on shaft
☐ Use set-up roll if available
☐ Set initial parameters:
Temps & dwell from last job (preferred)
If unknown:
☐ Heats: 350°F
☐ Rubbers: 190°F
☐ Dwell: 325 ms
☐ Leave heaters OFF initially
☐ Set machine speed: Use Wait Time to achieve set-up speed, reduce wait time to achieve run speeds
☐ 30–40 CPM
☐ Accel: 1.5–2.0
☐ Disable start loss inhibit (if needed)
2. Web Path & Gusset Setup
☐ Thread web → center after gusset form (±4 mm)
☐ Set gusset folding:
☐ Idlers centered before/after spreader
☐ ~1 mm gap
☐ Spreader tips flush with plow
☐ Set tensions:
☐ Narrow web: 3–4 bar
☐ Wide web: ~6 bar
☐ Adjust nip rollers:
☐ Avoid zipper & gusset fold areas
⚠️ Critical: Poor gusset alignment = high risk of seal failure
3. Zipper Setup
☐ Square zipper guide to machine
☐ Align heat seal tooling (centered over guide gap)
☐ Set zipper position from pouch bottom
☐ Verify tracking
☐ Set zipper gaps:
☐ Heat & chill: 1–2 mm (MANDATORY)
☐ Confirm alignment:
☐ Infeed & outfeed
☐ Upper & lower tooling
⚠️ Misaligned zipper = seal failures + cosmetic defects
4. Film Tracking & Controls
☐ Run film through machine
☐ Verify straight tracking
☐ Adjust nips to steer web
☐ Set EPC (edge guide)
☐ Set heat/chill gaps (before heat ON):
☐ Max 2 mm
☐ Set mark sensor (if printed):
☐ Align to eyespot
☐ Register to knife edge
5. Seal & Tool Registration
☐ Turn heats ON
☐ Set gusset punch:
☐ 0.125″ from bottom edge
☐ Align longitudinal seals to print
☐ Verify all 4 points (K-seals if applicable)
☐ Register:
☐ Cross seals – adjust temps as needed
☐ Punches / handles / notches
☐ Install and set:
☐ Splice detector
☐ Zipper crush tooling (if required)
Best Practice: Use minimum pressure required to achieve seal/cut
6. Cutting & Trimming
☐ Set trim blades:
☐ Blade in anvil groove
☐ Set knife:
☐ Minimum back pressure
☐ Minimum down pressure
⚠️ Excess pressure = wear + poor cut quality
7. First Article Validation
☐ Enable start loss inhibit
☐ Run 2 stacks of 25 pouches at speed
☐ Perform quality checks:
☐ Seal integrity (especially gusset)
☐ Zipper alignment & seal
☐ Cut quality (no fuzzing/sticking)
☐ Registration to print
☐ Submit for approval
If you find this helpful and want to support the site – download a copy in the site store. Print it out, use it for training, its a useful reference for new operators.
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