Repeat Order, New Problem?How ADSURE Solved the Autobag 500 Bag Tearing Issues

📞The Call: "It’s happening again... but this time, they’re breaking."

It is a scenario every packaging manager dreads. We recently received urgent feedback from a valued client regarding a repeat order of our roll bags (Pre-opened Bags on a Roll).

The complaint was specific: the perforation lines were snapping prematurely, causing unexpected bag tearing that couldn't hold their 360g heavy-duty parts.

Here was the twist: This was the second continuous order. The first order—produced with the exact same specifications—had run perfectly. The client was frustrated, and rightly so. If the bag is the same, why is the result different?

At ADSURE, we don't just supply bags; we supply solutions. Our technical team immediately launched a "CSI-style" investigation to get to the root cause.

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Phase 1: The Internal Audit (Checking the "Inside")

Our first instinct is always to look inward. Did something change in our production? We rigorously reviewed the Internal Factors:

1. The Cut/Tie Ratio: We checked the blades. Had the ratio of the cut (the slit) to the tie (the holding point) shifted? Result: No change.

2. Material & Resin Blend: Did the formula fluctuate? Was the tensile strength compromised? Result: Consistent with the master sample.

3. Process Control: We reviewed the tension settings and cooling times during converting. Result: All within standard tolerance.

   
   

Technically, the bags were perfect. They were identical to the previous batch that worked flawlessly. So, if the "Inside" hasn't changed, we must look at the "Outside."

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Phase 2: The External Investigation (Investigating Causes of Autobag 500 Bag Tearing)

We asked the client for details on their equipment. When they confirmed they were using the Autobag 500 series, our team instantly shifted gears.

Notice how the bag "floats" without support the moment the 360g part drops. This split-second impact is what snapped the perforation.

We didn't just guess. Our engineers immediately went to the official Autobag website and downloaded the Autobag 500 Operator Manual. Armed with the manual and the video clips the client sent us, we called an emergency technical meeting.

In the conference room, we projected the client's video side-by-side with the machine's technical diagrams. We simulated the loading scenario step-by-step: Bag feeds down -> Air blows it open -> Heavy metal part drops.

That is when our engineers spotted it. The Load Shelf.（As you can see in ITEM 7)

The Autobag 500 system setup. Note the Load Shelf (Item 7) located beneath the bag opening. This component is critical for absorbing the shock of heavy items during the drop-loading process.

For those unfamiliar, the Load Shelf is the metal tray that sits directly under the bag being filled. Its job isn't just to hold the finished package; it is designed to be a shock absorber.

The Physics of the Drop

The client was loading a 360g metal part.

• Static Load: If you gently place 360g in the bag, the perforation holds easily.

• Shock Load: When that part is dropped from a chute into a hanging bag, gravity accelerates it. The momentary impact force is significantly higher than 360g.

By comparing the manual's guidelines with the client's video, we realized the Load Shelf was set too low. When the heavy part dropped, the bag was effectively "floating" in mid-air, forcing the delicate perforation line to absorb 100% of the impact shock. Snap!

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The Solution: A Simple Adjustment

We didn't need to remake the bags. We didn't need to change the resin formula.

We sent the client the exact page from the manual (shown below) with a simple instruction: "Please adjust the support shelf height to support the bag bottom."

Official adjustment guidelines from the Autobag Operator Manual. Step 1a explicitly states to "Adjust the support shelf... to proper supporting of bags loaded with product."

By raising the shelf as per the manual's instructions (Step 1a), the metal tray absorbs the impact of the heavy part—not the plastic perforation. The bag stays intact, the machine keeps running, and the "weak perforation" issue vanishes.

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The ADSURE Difference

This case highlights exactly how the ADSURE team operates.

It would have been easy to say, "The bags are within spec, it's not our fault." But that doesn't help our client. We believe that packaging is a system involving the Material, the Machine, and the Method.

We are optimistic troubleshooters. Whether the issue lies in the polymer chemistry or a mechanical setting on your factory floor, we are committed to finding the answer with you.

Need a packaging partner who looks at the big picture? Contact the ADSURE team today！