Why Manufacturers Are Making the Switch

Pressure-sensitive liners and induction seals are two widely used methods for sealing bottles and containers. Both help protect product integrity, but they operate differently, offering varying levels of security and performance. In recent years, manufacturers have been phasing out pressure-sensitive liners in favour of induction sealing. Here’s what’s driving the shift.

What are Pressure-Sensitive Liners?

Pressure-sensitive liners feature an adhesive backing that sticks to the rim of the container when the cap is tightened. This forms a seal through the combination of pressure and adhesive. They are easy to apply and are commonly used in food, pharmaceuticals, and personal care, as they don’t require any special equipment beyond standard capping machinery.

Benefits of Pressure-Sensitive Liners

Cost-effective solution for short-term sealing
Easy to apply – no additional machinery is required
Offers basic tamper evidence.

Limitations of Pressure-Sensitive Liners

Less secure – can be removed and reapplied without showing visible evidence of tampering
Shorter shelf life – adhesive can degrade over time, resulting in seal failure
Not suitable for liquid products – prone to leaks due to weaker barrier properties
Sensitive to heat and humidity, which can compromise the adhesive
Increasing concern over polystyrene content, which poses recycling challenges

What Are Induction Seals?

Also known as induction wads, these liners create a hermetic seal on containers using electromagnetic induction. The liner is placed inside the cap, which is then screwed onto the container. As the capped container passes under an induction sealing machine, an electromagnetic field heats the foil layer of the liner. This heat causes the foil to bond securely to the rim of the container, forming a tight, tamper-evident seal that helps protect the product from contamination and leakage.

Benefits of Induction Seals

Stronger tamper evidence – seal cannot be reapplied once broken
Airtight and moisture resistant, extending product shelf life
Leak prevention
Stronger barrier protection, safeguarding against contamination and spoilage
Durable in the face of heat and humidity.

Limitations of Induction Seals

Requires an induction sealing machine – though this investment is quickly offset by the benefits.
Slightly more complex application process compared to pressure-sensitive liners.

Why are Manufacturers Moving Away from Pressure-Sensitive Liners?

There are many reasons manufacturers are transitioning from pressure-sensitive liners to induction seals.

Improved Product Integrity and Shelf Life
Pressure sensitive liners lose their adhesive effectiveness over time, which can result in seal failures. Induction seals, on the other hand, provide a stronger, longer-lasting seal, ensuring the product remains fresh and protected throughout its shelf life.
Stronger Tamper Evidence and Consumer Trust
Induction seals provide clear irreversible tamper evidence, reducing the risk of product tampering and giving customers confidence in the brand.
Superior Protection Against Leaks and Contamination
For liquid-based products, pressure-sensitive liners often fail to prevent leaks, leading to spills, wasted product, and potential contamination. Induction seals form a more secure barrier, significantly reducing the chances of leaks.
Compliance with Industry Regulations
Many industries, especially pharmaceuticals and food, have stringent packaging regulations that prioritise tamper evident and leak proof seals. Induction sealing meets these regulatory requirements better than pressure-sensitive liners.
Sustainability Considerations
Induction seals can be made with eco-friendly, recyclable materials, aligning with sustainability goals. Additionally, because they provide a better seal, they help reduce product waste from leaks or spoilage.

Conclusion

While pressure-sensitive liners still have their place in certain applications, they are frequently being replaced by induction seals because of supply chain issues, sealing performance, and evolving legislation. For manufacturers looking to enhance product safety, extend shelf life, and meet industry standards, induction sealing is increasingly becoming the preferred choice.

See Packserv's Induction Sealing

Make: Pillar Technologies

Sealing Machines

C-Series Hand-Held Induction Sealer
Code: INS-IF1-C
Make: Pillar Technologies

Sealing Machines

iFoiler Automatic Induction Sealing Machine
Code: INS-IF2.25-U
Make: Pillar Technologies

Sealing Machines

Benchtop Induction Sealer
Code: INS-UF1-H-SA

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