ILPRA and Wattron Intelligent Sealing Technology Open House

ILPRA has partnered with Wattron to introduce a new generation of intelligent sealing technology designed to solve one of the most persistent challenges in cup and tray sealing: maintaining consistent seal quality when conditions change on the line.

This technology will be showcased at a two-day Open House event in Dresden, Germany, on 25 and 26 February. The event combines in-depth technical insight with live demonstrations on production lines, giving manufacturers the opportunity to see exactly how the system performs in real operating conditions.

Traditional sealing systems apply a fixed temperature and pressure across the sealing head. If there is product contamination on the pot rim, a slight variation in material, or an inconsistency in film placement, seal quality can quickly drop, leading to leaks, waste, and downtime.

The ILPRA and Wattron intelligent sealing system takes a different approach. The sealing head continuously monitors what is happening at each individual pot during the sealing process. If product contamination is detected on the rim, the system automatically adjusts sealing pressure in real time while the machine is still running. The goal is simple: keep the seal within specification without stopping the line.

This real-time response allows manufacturers to maintain seal integrity even when conditions are not perfect, which is often the reality in high-speed food production environments.

Consistent seal quality, even with contamination
The system can identify product residue on the pot rim and dynamically adapt sealing pressure. This reduces the risk of leaks and pack failures without relying on manual intervention or frequent line stops.

Inline quality control without additional equipment
Every single cup is checked during sealing. The system can detect missing lids, double lids, misaligned lids, and contamination without the need for separate inspection stations. This simplifies line layout and reduces maintenance overhead.

Optimised for sustainable packaging
The sealing heads are designed specifically for monomaterial packaging, such as polypropylene cups and lids. This supports compliance with the EU Packaging and Packaging Waste Regulation and helps manufacturers move towards fully recyclable packaging formats without compromising seal quality.

Reduced waste and higher efficiency
By reacting instantly to process variations, the system can significantly reduce rejected packs and material waste. Faster heat-up and cooling times also support higher overall equipment effectiveness and quicker start-ups.

Data-driven process control
Each seal generates data, giving manufacturers visibility of sealing performance at cup level. This supports traceability, continuous improvement, and easier validation for quality and compliance teams.

Day one will focus on the technology itself, explaining how intelligent, pixel-level temperature control and real-time pressure adjustment work in practice. This session is ideal for engineering, technical, and operations teams looking to understand how the system integrates into existing lines.

Day two will move onto live demonstrations, with the sealing heads running on ILPRA machines. Attendees will be able to see how the technology responds to real production scenarios, including contamination challenges, and ask detailed technical questions directly to the specialists involved in its development.

For manufacturers using fill seal lines, seal integrity is critical. Poor seals lead to product waste, rework, customer complaints, and lost shelf life. Intelligent sealing technology offers a practical way to protect output quality while supporting higher line speeds, reduced waste, and more sustainable packaging choices.

This development aligns closely with ILPRA’s approach to fill seal solutions: combining robust mechanical design with smart process control to deliver reliable, future-ready packaging lines.

If you would like to learn more about ILPRA’s fill seal machines and how intelligent sealing technology could benefit your production line, visit the fill seal page here.