Induction Sealing Ensures Corrosive Chemicals Arrive Leak Free
New liner technology and Enercon induction sealing eliminate leaks, improve safety, and deliver peace of mind for chemical packaging.
Buckman’s Inc. supplies products like Sodium Hypochlorite Solutions and Hydrochloric Acid which are versatile and powerful disinfectants and bleaching agents used for water treatment, pool sanitation, and cleaning applications. While highly effective, these chemical formulations can be as much as three times stronger than typical household bleach. And, extended storage time and transit considerations make packaging integrity essential.
Today, Buckman relies on Enercon Super Seal™ induction cap sealers to ensure leak prevention and safe transit to customers. However, their journey with induction sealers nearly two decades ago did not start out that well.
Customer Demand Leads to Revisiting Induction Sealing
Twenty years ago, Buckman’s attempted to seal their products, but “it was a disaster,” recalls Jeff Coyle, Director of Operations. The issue wasn’t the sealer itself; it was the liner technology available at the time. The liner materials were not compatible with the long-term storage requirements of the products. Over time, the chemicals and their fumes would degrade the induction seal liners. As a result, Buckman’s abandoned induction sealing and relied on conventional closures.
Without induction seals, another challenge emerged. During their transit through distribution channels, the products’ caps would loosen, creating the potential for leaks.
Anticipating future customer demand for sealed containers, Buckman’s proactively revisited induction sealing. Working closely with Enercon representative Charlie Caruso, the team began evaluating new liner materials that had become available over the years. Improvements in polymer technology offered the possibility of withstanding the highly corrosive chemicals that had previously affected seals.
Testing for the Long Haul
Finding the right solution required patience. And both Caruso and Enercon were up for the challenge. Using an Enercon Super Seal™ Jr., they sourced liners from multiple different suppliers. Small batches of test containers were sealed and then subjected to long-term evaluation. Some bottles were stored upright. Others were placed on their sides or upside down. The containers remained in storage for months, some approaching a full year, to simulate real-world conditions.
The extensive testing eventually identified a liner capable of resisting chemical degradation.
“After a series of months, almost a year, we found a supplier that could manufacture a liner that would not disintegrate,” said Caruso. For the Sodium Hypochlorite Solution, a vented liner is used to allow off gassing of the product, while the Hydrochloric Acid products use a more conventional liner designed for chemical resistance.
With confidence in the liner performance, Buckman’s returned to induction sealing and the results have exceeded expectations.
Cap Sealers Save Money & Improve Packaging Quality
Since adopting the new liner technology and reinstituting induction sealing, Buckman’s has experienced no seal-related failures. “We haven’t had a single issue,” said Coyle.
The benefits of the new sealers extend well beyond sealing performance. “The quality of the finished product is more professional,” said Coyle. “And there are fewer issues with credits because of leaks.”
For Buckman’s, preventing leaks carries substantial financial implications. According to Caruso, if customers discover several leaking containers in a shipment, they may reject the entire truckload rather than inspect every package individually. A single rejected shipment can create significant costs through product loss, returns, replacement shipments, and customer dissatisfaction.
“It’s hard to quantify exactly what that means for the business,” said Caruso. “But if that happens a couple of times a year, the savings from the new Super Seals and induction sealing process are enormous.”
There are also safety benefits. Leaking containers of corrosive chemicals create hazards for employees, carriers, distributors, and customers alike. Perhaps most valuable of all is the confidence that comes with knowing shipments will arrive as intended.
Partnership Matters
Buckman’s story demonstrates that sealing challenges are not always equipment challenges. Sometimes the right combination of equipment, liner technology, testing, and expertise is required to achieve success.
When asked about his experience working with Enercon, Coyle was quick to acknowledge the support he received. “Everyone has been great. I deal mostly with Enercon’s local rep, Charlie Caruso, and he’s been great.” That partnership proved critical to finding a solution that addressed Buckman’s unique packaging challenges.
Today, Buckman’s delivers a more professional package, reduces the risk of leaks and product returns, improves safety, and provides customers with the secure seal they requested.
The company continues to focus on what has always driven its business: “We strive for customer service and excellence. You can’t go wrong pleasing the customer.”
