How to Replace Heat Sealer Tape

Step 1: Turn Off and Cool the Machine

Switch off the heat sealer and allow the sealing jaw to cool to room temperature. Never attempt to replace tape on a hot jaw — you risk burns, and the silicone adhesive on the new tape will activate unevenly on a hot surface, creating bubbles and weak spots.

On impulse sealers, the jaw cools within a few minutes. On constant-heat sealers (band sealers, some tray sealers), allow 15–30 minutes for the jaw to cool below 50°C.

Step 2: Remove the Old Tape

Peel the old tape from one corner, pulling slowly at a low angle (almost flat against the jaw). Pulling straight up at 90° can leave more adhesive residue behind.

Tip: If the old tape is stubbornly bonded and tears during removal, warm the jaw slightly (to around 60–80°C) to soften the adhesive, then try again. Do not use metal scrapers on the jaw surface — they can scratch the metal and create grooves that trap film residue.

Step 3: Clean the Jaw Surface

This is the most important step and the one most often skipped. Adhesive residue, burnt film, and contaminants left on the jaw surface will cause the new tape to bond unevenly, leading to premature lifting and shorter tape life.

Apply isopropyl alcohol generously to a lint-free cloth and wipe the entire jaw surface until no residue remains. For stubborn adhesive, use a citrus-based adhesive remover (such as De-Solv-it or Orange Power), then follow up with IPA to remove any oily residue from the citrus cleaner.

The jaw surface should be completely clean, dry, and free of any sticky residue before applying new tape.

Step 4: Measure and Cut the New Tape

Measure the jaw length and cut the PTFE tape to size, adding 10–15 mm extra on each end for trimming. If the tape needs to be narrower than the roll width, measure the jaw width and cut a strip to match.

Tip: If you regularly replace tape, consider ordering custom-cut tape from GORTEF pre-cut to your exact jaw width. This eliminates measuring and cutting on the factory floor and ensures consistent tape placement every time.

Step 5: Apply the New Tape

Peel back approximately 30–50 mm of the release liner from one end. Align the exposed adhesive edge with one end of the jaw and press firmly into place.

Gradually peel the liner while pressing the tape onto the jaw surface, working from one end to the other. Use a flat roller, squeegee, or the flat of your hand to press firmly and push out any air bubbles as you go.

Key rules for application:

• Apply firm, even pressure — light pressure traps air bubbles that cause hot spots
• Do not stretch the tape — stretching thins the PTFE coating and causes premature wear
• Keep the tape aligned — if it drifts off-centre, peel back and reposition rather than leaving a crooked application
• Overlap strips by at least 5 mm if using multiple strips on a wide surface

Step 6: Trim the Edges

Once the tape is fully applied, trim any overhang with a sharp blade. Ensure all edges are firmly pressed down — lifted edges catch on packaging film and peel back during operation. Run a fingernail or roller along all edges to seal them.

Step 7: Heat Cure (Recommended)

Close the heat sealer at normal operating temperature and hold for 30–60 seconds. This heat cure activates the silicone adhesive for maximum bond strength and ensures the tape conforms fully to the jaw surface. After curing, inspect the tape for any bubbles or lifted edges and press them down if needed.

Impulse Sealers

Tape covers the heating element pad on both upper and lower jaws. When replacing, do both jaws at the same time — if one jaw is worn, the other is usually close behind. Use 3 or 5 thou tape (TCG003AD or TCG005AD). For machines with exposed nichrome wire, consider zone tapes which have a non-adhesive centre strip over the wire area for cleaner seals.

L-Bar Sealers

The L-shaped sealing wire requires tape cut to follow the L-profile. Cut two strips (one for each arm of the L) and overlap at the corner by 5–10 mm. Zone tape (TZT005AD) is strongly recommended for L-bar sealers to prevent seal marks from the adhesive layer.

Flow Wrappers

Cross-seal jaws and fin-seal bars on flow wrappers run at high cycle rates (60–200+ cycles per minute). Use 3 thou (TCG003AD) for maximum heat transfer. Replace more frequently than lower-cycle machines — typically every 1–2 weeks. The jaw is usually accessible by removing a guard or opening a service panel.

Tray Sealers (MAP)

The sealing plate on a tray sealer is larger than most jaw surfaces. You may need to apply tape in overlapping strips. Use 5 or 10 thou (TCG005AD or TCG010AD) for the longer service life needed on these lower-cycle machines. Ensure the tape covers the full sealing area including any gasket contact zones.