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Gussets and multilayer seams

Heat Sealing Gusseted Bags and Thick Fold Transitions

Test the thickest fold and the transition to the flat section, not just two flat layers. A jaw sealer can be a candidate for a straight accessible mouth; a rotary sealer is only a candidate if the wheels maintain usable contact along the entire seam.

FABLE ·

FABLE HI long sealing arms for a supported straight seam
FABLE HI long sealing arms for a supported straight seam. Product photo by FABLE.

Map the layer count across the mouth

A side gusset, bottom fold or overlapping web can change the stack at one point of the seam. Mark the thin middle, thick fold and step between them on a sample. Record the actual layer structure in each zone rather than multiplying a single thickness and assuming the materials behave identically.

Shortlist by the seam and operator access

Try handheld jaws such as FDR on a shorter, flat accessible opening; compare HI for a long straight supported seam in compatible materials. For a large pack, check whether ROS-25 can follow the fold transition without losing contact. None of these geometry choices establishes that a specified layer stack can be sealed.

Look for a process window across all zones

A setting that bonds the thick section may damage a thinner one. Inspect cooled trial pieces at each zone and test seam integrity by the package’s acceptance criteria. If the zones cannot meet the criteria together, consult the packaging supplier about a different bag design or sealing system rather than repeatedly raising the setting.

  • • Test a representative filled bag, not a trimmed flat strip only
  • • Check seam ends, folds and any crossings
  • • Keep the trial results for the worst-performing zone

FABLE models to compare

FDR Series · Handheld Jaw Sealers · Specification sheet (PDF)

HI Series · Long-Length Hand Sealers · Specification sheet (PDF)

ROS-25 · Hand Rotary Sealer · Specification sheet (PDF)

Technical references

Machine dimensions and formats refer to FABLE specifications. These references describe testing principles, not certification of any FABLE machine or packaging process.

ASTM F2029 · Laboratory heat sealability

ASTM F88/F88M · Seal strength

Related sealing guides

Weak, Wrinkled or Burned Heat Seals: What to Check

Selecting a Long-Jaw Sealer for Wide Bags

How to Test a Bag Seal Before Ordering a Machine

Discuss your bag and application

Send the material, seam dimensions, expected quantity and destination power supply so we can review the shortlist with you.

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