What Is a Heat Sealer? Uses, Types, and Benefits for Industrial Packaging

October 23, 2025

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What Is a Heat Sealer? Uses, Types, and Benefits for Industrial Packaging

In the fast-paced world of industrial shipping and packaging, ensuring product safety, cleanliness, and presentation is paramount. One indispensable tool that plays a major role in achieving these goals is the heat sealer.

Whether you’re packaging food, electronics, medical supplies, or consumer goods, heat sealers provide a clean, secure, and tamper-evident seal that can dramatically improve the integrity and appearance of your packaging.

This article provides an in-depth look at what heat sealers are, what they’re used for, how they work, common industrial applications, and types of sealers,

If your operation involves shipping or packaging, we can help you determine whether investing in a heat sealer is the right move.

Let’s get started!

What Is a Heat Sealer?

A heat sealer is a device that uses heat and pressure to join two pieces of thermoplastic material together, typically by melting and fusing the materials at the seam. The result is a durable, airtight, and sometimes watertight seal that keeps contents secure during storage or transport.

Heat sealers are available in a variety of forms, from manual tabletop models for small operations to automated industrial sealers used in high-volume production lines, and many options in-between.

While they are most commonly used with plastic films like polyethylene (PE), polypropylene (PP), and polyvinyl chloride (PVC), certain models can also seal coated papers and foils.

The material just needs to be thermoplastic (have a heat-sealable layer) so it can melt and bond properly.

What Is a Heat Sealer Used For?

Heat sealers are used in a wide range of industries to protect and preserve products during storage and shipping. Here are some common applications:

1. Product Packaging
2. Tamper-Evidence
3. Sterility Maintenance
4. Moisture and Contaminant Protection
5. Void Fill and Protective Packaging

1. Product Packaging

In packaging environments, heat sealers are essential for sealing bags, pouches, or plastic wraps containing products such as:

Food items (snacks, frozen goods, dried fruits)
Pharmaceuticals and medical supplies
Electronic components
Industrial tools and hardware
Cosmetics and personal care products

2. Tamper-Evidence

Many manufacturers use heat sealers to create tamper-evident packaging, especially for consumable or sensitive products. If the seal is broken, it’s immediately obvious to the customer.

3. Sterility Maintenance

In sectors like healthcare and biotech, heat sealers are used to preserve sterility by sealing sterilized instruments and lab materials in protective pouches.

4. Moisture and Contaminant Protection

Sealing packages can protect contents from moisture, air, dust, and other environmental contaminants, which is vital for electronics, food, and industrial components.

5. Void Fill and Protective Packaging

Heat sealers can also help create air-filled bags for void fill or cushioning, preventing items from shifting or breaking inside larger boxes.

Now that we know what heat sealers are and what they are used for, let’s examine the different types of heat sealers.

Types of Heat Sealers

Not all heat sealers are created equally. Choosing the right type of heat sealer is critical for achieving strong, reliable seals and meeting production demands. Different sealers are designed for different packaging materials, product types, and production volumes.

Types of Heat Sealers Comparison Table

Here is a quick comparison of the some common types of heat sealers:

SEALER TYPE	MATERIAL COMPATIBILITY	VOLUME	TYPICAL USE / INDUSTRIES
Impulse Heat Sealers	PE, PP	Low to medium	Retail, food, general packaging
Constant Heat Sealers	Foil, Mylar, multi-layer	Medium	Pharma, military, specialty foods
Vacuum Sealers (Chamber and External)	Vacuum bags, films	Medium	Food processing, electronics
Band Sealers (Continuous Sealers)	Most flexible films	High	Industrial, pet food, agriculture
Portable and Handheld Sealers	PE, thin laminates	Low	Mobile teams, maintenance crews
Tray and Clamshell Sealers	Rigid trays, clamshells	Medium to high	Ready meals, retail packaging

Now we’ll take a deep dive into the most common types of industrial heat sealers, along with their features, best-use cases, and typical industries they serve:

1. Impulse Heat Sealers
2. Constant Heat Sealers
3. Vacuum Sealers (Chamber and External)
4. Band Sealers (Continuous Sealers)
5. Portable and Handheld Sealers
6. Tray and Clamshell Sealers

1. Impulse Heat Sealers

Impulse heat sealers generate heat only when the sealing arm is activated. A nichrome wire heats up briefly to melt the plastic and then immediately cools, forming the seal. They typically include a Teflon strip to prevent sticking and a silicone rubber base for even pressure.

They are often used with polyethylene (PE) bags and polypropylene (PP) bags, flat or gusseted, up to 6-10 mil thick. Ideal for light to medium-duty operations.

PROS	CONS
Energy efficient (no constant heat) Typically safer to operate Ideal for sealing in short runs or on-demand	Not suitable for thick or foil laminates Slower than continuous systems for high-volume needs

Common Applications: Food packaging (dry goods, bakery items), light electronics, retail and general purpose bagging

2. Constant Heat Sealers

Constant heat sealers maintain a steady temperature on the sealing element, often using brass or aluminum bars with Teflon coatings. They are capable of producing seals with decorative patterns (serrated, mesh, or flat).

Use these for foil, Mylar, cellophane bags, and other thicker or multi-layer laminated bags or pouches that require high-temperature, high-pressure sealing.

PROS	CONS
Strong uniform seals, even on complex materials Can seal through contamination or dust in the seal area Ideal for industrial-grade packaging	Higher risk of burns because heating elements are always on Consumes more energy than impulse sealers

Common Applications: Pharmaceutical blister packs, military and aerospace packaging, high-barrier vacuum or retort pouches

3. Vacuum Sealers (Chamber and External)

Vacuum sealers remove air from the bag before sealing it, helping to preserve freshness, extend shelf life, prevent oxidation, and create a more compact package. They come in chamber and external (no-chamber) styles:

Chamber vacuum sealers place the entire bag inside a chamber for deep vacuum pulls.
External vacuum sealers pull air from bags via a nozzle or suction port.

These require a vacuum seal bag and are typically utilized in food processing for perishable food products, in healthcare for medical kits and sterile supplies, and for electronics and other moisture-sensitive items.

PROS	CONS
Extends product shelf life and freshness Provides a tight, professional appearance Helps with shipping efficiency by reducing volume	Slower cycle times for chamber models Vacuum-specific bags required May not be necessary for non-perishable or bulk shipping

Common Applications: Meat, seafood, and cheese packaging, laboratory and biotech storage, PCB and circuit board shipping

4. Band Sealers (Continuous Sealers)

Band sealers use a continuous moving belt system that feeds bags through heated sealing jaws and then cools them before discharge. They can operate vertically or horizontally, and some include embossers or printers. They are excellent for high-volume operations.

Choose a band sealer for high-volume sealing lines using stand-up pouches, flat bags, or resealable products made of most flexible films, including poly and foil.

PROS	CONS
Very high throughput at up to 40+ bags per minute Consistent and repeatable seal quality Can be integrated into conveyor lines	Larger footprint Higher upfront cost May require training for optimal setup and use

Common Applications: Coffee and tea packaging, pet food and lawn care products, industrial parts or fasteners

5. Portable and Handheld Sealers

These compact sealers are used in light-duty applications or fieldwork where portability is key. These are usually battery or manually powered.

Use these for low-volume or field sealing, oversized or irregularly shaped items, or for temporary or emergency packaging setups.

PROS	CONS
Lightweight and easy to transport Useful in tight spaces or remote locations Minimal setup required	Not suitable for high-volume operations Seal consistency can vary with manual pressure

Common Applications: Field service kits, on-site repair and parts shipping, mobile healthcare units

6. Tray and Clamshell Sealers

Tray sealers use heat to apply film or foil over pre-formed trays, while clamshell sealers fuse hinged plastic packaging closed.

These are great for medium to high volume situations and particularly useful for sealing prepared food trays, consumer goods in retail packaging, and medical or sterile kits.

PROS	CONS
Ideal for presentation-ready packaging Excellent for tamper-evident seals Seals containers of various sizes and shapes	Specialized to tray/clamshell formats only Often requires matched packaging formats (trays, film rolls)

Common Applications: Meal prep and frozen meals, blister packaging for small electronics or hardware, over-the-counter medical products

When to Upgrade to an Industrial Heat Sealer

If you’re currently using a basic sealer and experiencing any of the following issues, it might be time to upgrade:

Increased production demands beyond the capacity of your current model
Inconsistent or failed seals
Frequent downtime due to overheating or mechanical wear
Need for automation or integration into a production line
Need for sealing thicker or multi-layered materials

Investing in a higher-end industrial heat sealer can significantly boost output and reduce labor costs, especially in shipping and fulfillment centers.

Benefits of Using a Heat Sealer in Industrial Settings

Heat sealers offer many advantages that go beyond just sealing a bag. Here’s why they’re so valuable in industrial settings:

1. Enhanced Product Protection: Heat-sealed packaging provides an effective barrier against contaminants, moisture, and air, potentially reducing spoilage or damage during transit.

2. Improved Shelf Life: For perishable or sensitive products, sealing can drastically extend shelf life by preventing oxidation or microbial exposure.

3. Professional Packaging Appearance: A clean, even seal can enhance the visual appeal of your packaging, which is especially important for retail and branded goods.

4. Tamper Evidence and Security: A heat seal shows visible signs if tampered with, helping protect consumers and build brand trust.

5. Versatile Material Compatibility: From poly bags to multi-layer foil pouches and just about anything in-between, heat sealers can be adapted for a wide range of packaging formats.

6. Cost Efficiency: In-house sealing may eliminate the need for third-party packaging services and can reduce shipping damage, potentially saving money long-term.

7. Customizability: Some sealers allow for custom seal widths, embossed date codes, or branding stamps, making it easy to personalize your packaging.

Final Thoughts

In the realm of industrial shipping and packaging, a heat sealer is more than just a convenience—it’s a crucial tool for ensuring product integrity, operational efficiency, and customer satisfaction. Whether you’re working in food production, logistics, healthcare, or electronics, a reliable heat sealing process helps you maintain quality and safety standards while meeting high-volume demands.

By choosing the right type of sealer, training your staff properly, and maintaining the equipment regularly, you can maximize your investment and keep your packaging operation running smoothly.

Need help choosing the right heat sealer for your business? Reach out to Imperial Dade with details about your packaging materials and daily output, and we’ll help you find the perfect fit.