A few weeks ago I mentioned in my blog "What do I do if I have leaking caps" how critical the alignment of the induction sealer is to insuring the consistency of seals. I frequently get asked, "What is the proper way to align my sealer?"
Here is how I go about setting a system up. First, make sure the bottles track down the center of the head. Adjust any guide rails as necessary and lock them into place. Adjust the unit and sealing head to make sure it is parallel to the conveyor. It doesn't matter if the sealer is level, so long as the head is level with respect to the conveyor. Then, set the gap between the top of the bottle and the sealing head to 1/8". Verify that the gap is consistent for the whole length of the head.
Of course, there are a few exceptions to the above setup. For a Universal head, perform the above steps. Then, pivot the head to the proper position for your closure, using the markings on the head as reference. For Deep tunnel heads, there are extra labels indicating the foil height on the sides of the head. Get the foil as close to the height of those markings as you are able instead of worrying about the 1/8" air gap. The rest is all the same.
For a more in-depth description of the above steps, check out "Positioning Your Sealing Head."
As an additional note, I recommend checking the alignment every shift change, every product change, and especially every package change. Most of the time there will be no need of adjustment. But should you find something out of line, you can potentially save lots of rework or discarded product. This is a great way to set yourself up for success!