How to Choose the Right Heat Sealer

Heat sealers are used for mending two sides of film together to form an air tight seal. The sealer uses heat to melt and mend materials forming a seal. A variety of materials can be used with heat sealers. In this guide we are going to discuss what to know before making a purchase and how different heat sealers work with a variety of material thicknesses.

Common Materials

Heat sealers are used for everything. Look down any frozen food aisle and many products are sealed with a heat sealer. There are many different materials and material blends that can be sealed with a heat sealer. Understanding the material being used will help determine the type of sealer needed.

Most flexible materials are measured in mils. Materials ranging from 1-3 mils thick are considered standard to light thickness. Materials 4-8 mils thick are medium to heavy thicknesses. Thicker materials require more heat and thicker seals to properly mend the material together. Understanding the largest and thickest materials being sealed will help determine what type of sealer is right.

Types of Heat Sealers

Heat sealers are available in round wire and flat wire. The round wire sealers have thinner seal seams and are often used for thinner materials under a 2 mil thickness. Flat wire sealers are made for thicker films up to 8 mils thick. View details of each type below to help determine which type is best for your application.

Round Wire Sealers

Round wire sealer offers two primary benefits over flat wire sealers. Round wire sealers cut excess film after the seals have been made. They also have thinner seal seams and look better aesthetically. The thin seals from a round wire sealer are often used for shrink wrapping. The smaller seal seams provide a perfect look after heat has been applied to the film.

There are drawbacks to round wire sealers as well. The thinner seal seams limit the strength of the seal. For thicker materials and larger products, the thinner seal seams produced by round wire sealers may not suffice. Round wire sealers can also struggle to make complete seals with thicker films in excess of 4 mils.

Flat Wire Sealers

Flat wire sealers come in a large selection of widths and can be used with thicker materials for heavier products. Flat wire sealers make a full seal and leave excess film on the bag. The excess film can be used for hanger holes and custom printed headers with hanger holes. Flat wire seals can also be embossed adding additional seal strength. Embossing adds a texture to the seal seam increasing overall strength.

Disadvantages of flat wire sealers are the large and noticeable seal seams. Flat wire sealers are not designed to cut excess film after the seal is made. If excess film removal is necessary a cutter option with the flat wire sealer will be required.


Knowing the product dimensions and material being sealed will help determine which heat sealer to buy. There are several forms and designs of heat sealers available on the market. A great starting point in choosing the right one is understanding the difference in round and flat wire sealers. If you need any further assistance in choosing the right heat sealer call our sales team at 1-800-441-5090.

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