Client Industry: Leading Toy Manufacturer (XXX Company).
Product: Luxury toy box; 15W × 35L × 15H (cm)
When the client came to us, they were preparing to start a high-end toy brand, but their existing packaging process could not keep pace. Its box height alone was already beyond the capabilities of most conventional L-sealers. And on top of that, the product required that extreme tamper-proof integrity and clean, moisture-free presentation.
Their three biggest roadblocks:
- Oversized Product Height: The normal L-sealers tap out at approximately 10 cm. These boxes needed 15 cm consistently.
- No-Compromise Tamper Protection: Packaging was required to resist any kind of malicious tampering
- Contamination Control: Dust and moisture barriers must be completely perfect.
They did not just require a machine, but a customized engineering shrink wrap solution.
High-Precision Shrink Wrapping Solution by Tengyi
We examined the product dimensions and the client’s quality requirements, and our engineering team recommended the TY-5545CZ L-bar sealer, a solution designed to exceed the 10 cm sealing height limitation while maintaining cycle speed and operational stability
1. The Star of the System: Tengyi 5545CZ Customized Vertical Servo L-Bar Sealer
Key Advantage: Overcoming the 10 cm Barrier
- A raised frame structure
- Accuracy of vertical movement with a servo system
- A sealing stroke that can work easily at 15 cm height
The result: it handled the oversized toy box cleanly and repeatedly without compromising fast speed of 5545CZ.
Standard 5545CZ Performance Metrics
– Speed: 40–50 pcs/min
– Power: 2.5 kW
2. The Partner: Tengyi TY-5030 ConstantTemp LowerFlow Heat Tunnel
In order to make the film shrink uniformly around the taller product, we paired the sealer with a strong heat tunnel.
Key Features:
- Omron temperature control to maintain the same temperature.
- Efficient, targeted shrink with 1500W lower airflow technology.
- A generously-sized tunnel opening (L1600 × W500 × H300 mm); enough space to fit 15 cm-tall boxes.
- Total Power: 15 kW
Solution Optimization (Technical Specs)
- Film Used: 15μm cross-linked POF shrink film, 60 cm width
- Process Setting: Heat tunnel set at 135°C
- Achieved Speed: 30–40 pcs/min, keeping the film shrink clean and tight.
Implementation & Final Results
The system removed the height restriction, temperature stabilization, and provided the tamper-resistant quality that the client required.
Performance Comparison
| Metric | Before (Traditional Process) | After (Tengyi Solution) | Result |
| Packaging Speed | 3–5 pcs/min | 30–40 pcs/min | 700% increase |
| Height Capacity | – | Seamless at 15 cm | Size limitation eliminated |
| Temperature / Components | Unstable, hot-air-gun based | Constant at 135°C with Omron + Schneider | Major reliability boost |
| Core Objective | Partially met; slow and inconsistent | Fully achieved | Tamper-free, dust-free, contamination-free |
Client Feedback
“The servo L-sealer by Tengyi was a game-changer for us. We had all the tamper-proof we wanted, and the fact that we could run 30-40 pieces per minute (on a product of this size) was a welcoming surprise. This configuration has been a significant element in our quality control process.” – Mr. Liu, Production Operations Manager from Zhongshan Excellence Toys Co Ltd
Conclusion
When your products are not within normal equipment ranges, or you just require additional control over seal quality and film performance, the Tengyi 5545CZ customised vertical servo L-Bar sealer is specifically designed to do just that. When used together with the TY-5030 heat tunnel, you get:
- High-precision packaging
- Even film performance
- Reduced operating cost in the long run
- Secure protection for fragile or valuable items
The case discussed above is an ideal example of how our team goes beyond the typical machine specifications to provide specialized, production-ready solutions.
Ready for a Customized Packaging Solution?
Whether you’re dealing with oversized items or want to optimize your POF film usage, our engineers can build the right system for your product.
Contact us for a free evaluation, custom solution, and accurate quotation.
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