Operator assistance systems can help to reduce disturbance-related machine downtime in food production and packaging processes, especially when combined with machine learning algorithms. These assistance systems analyze the available sensor signals of the process control over time to help operators identify the causes of disturbances. Training such systems requires sufficient test data, which often are hardly available. Thus, this paper presents a study to investigate how test data for teaching machine learning algorithms can be generated by numerical simulation. The potential of using virtual commissioning (VC) software for simulating disturbances of discrete processes is examined, considering the example of a friction and collision-afflicted sub-process from an intermitting wrapping machine for confectionary. In this study the software industrialPhysics (iP) is analyzed regarding accuracy of static and dynamic friction and restitution. The values are verified by setting up virtual substitute tests and comparing the results with analytically determined values. Subsequently, prerecorded disturbances are classified, and seven selected elements are simulated in VC software, recording visual effects and switching the characteristics of sensors. The verification shows that VC software is generally adequate for the assigned task. Restrictions occur regarding the computing power required of the built-in physics engine and the resulting reduction of the machine to be simulated.

Easy opening of heat sealable tray and topfilm food packaging concepts is often realized by using a peelable seal layer. Peel strength needs to be strong enough to prevent the package from opening during and after storage, transportation and handling at different environmental temperatures. It also needs to be weak enough to be convenient for an ageing population. When designing packaging concepts, a balance needs to be found assuring food quality, safety and convenience. This study presents a method to evaluate and optimize peel performance of a packaging concept with polyethylene seal layer undergoing cool processing at −18°C and 4°C. A design of experiment approach is used as a basis. With a limited amount of tests, models are fitted and experimentally validated to obtain an optimal peel strength of 0.5 N mm⁻¹ at an environmental temperature of 23°C. When measured during thermal treatment at −18°C and 4°C, the peel strength increased but no effect was seen once the seals are tested at 23°C after treatment. Bending of the bottomweb during the peel test slightly decreased peel strength while bending stiffness increased at low temperatures, suggesting a minor impact of bending of the bottomweb related to environmental temperature on the observed peel performance. Increased peel strengths during cool processing were clearly related to a change in seal failure mechanism. Besides cohesive peeling, partial delamination occurred in these stronger seals.

Functional papers with a minimum weight proportion of barrier and heat‐seal coating are one alternative to difficult‐to‐recycle plastic‐based multilayer composite films. Due to the low amount of thermoplastic polymer coating compared to the base paper material, the meltable material alone is not sufficient to close the channel leak at the transition between cross and fin seals when producing pouch packaging. Therefore, this paper focuses on the influence of the thermomechanical material properties of the seal coating, the paper layer structure and process parameters of the heat‐sealing process to reduce the channel leak at the layer transition area. Regarding the technologically based measures, the focus of the study is on the application of a deformable layer on the sealing jaws and the localization of sealing pressure by profiled sealing jaws. It is shown that the amount of thermoplastic material flowing into the channel leak highly depends on the thickness of seal coating and the melting behaviour of the applied coating. For the selection of suitable heat‐sealing parameters, sealing pressure on the paper material and temperature of the jaws must be considered. By applying a deformable material layer on one side of the sealing jaws, the closure of the channel leak at layer transition area is significantly reduced. Finally, with the use of certain deformable materials, a complete closing of the channel leak at the layer transition area is achieved on a laboratory scale.