Heat Seal Bar Recoating Service

Heat seal bar recoating service from AEGIS Advanced. Ship the bar to our Elkton, Maryland workshop and get it back coated. PTFE, PFA, and FEP fluoropolymer systems for sealing jaws, packaging line bars, and impulse sealers.

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When a heat seal bar needs recoating

• Seals are weak or inconsistent down the bar length
• Film is sticking to the bar (release has failed)
• Visible burns, scratches, or chipping in the coating
• Coating has discolored from heat cycling
• Original PTFE wrap has shifted or torn
• You are switching to a film that needs a different release surface

What we recoat

• Bar sealers (continuous, hot knife, side seal, L bar). PFA at 1 to 2 mil is standard.
• Impulse sealer jaws and ribbon bars. PTFE impregnated glass tape replaced, or full liquid PTFE applied when the OEM allows.
• Vertical form fill seal jaws (VFFS). PFA topcoat for chemical resistance plus release.
• Tray sealer jaws. Custom PFA system, food grade.
• Pouch sealers and medical packaging jaws. PFA or FEP, FDA compliant systems.

Masking heater channels before recoat

How the recoat process works

1. Inspection and quote. Send us the bar (or drawings and photos) along with the current coating spec and target sealing temperature. We quote within 48 hours. Custom quote per bar. We do not publish pricing.
2. Strip. Existing fluoropolymer removed mechanically and thermally without damaging heater elements or thermocouples.
3. Surface preparation. Grit blast to the right anchor profile. Mask all heater and sensor channels.
4. Prime. PTFE primer applied and partially cured.
5. Topcoat. PFA, FEP, or PTFE applied in controlled passes to target film build.
6. Cure. Programmed cure verified with surface thermocouples. We do not exceed the bar substrate temperature limit.
7. Inspection. Film thickness measured at minimum 8 points along the bar. Continuity tested.
8. Ship back. Workshop bars ship within 5 to 10 business days from receipt.

Recoat or replace?

A new heat seal bar can cost more than ten times the recoat. If the heater elements, thermocouples, and bar substrate are still good, recoating gets you back to original sealing performance for a fraction of replacement cost. Our quote includes an inspection note on substrate health so you can make the call.

Why AEGIS

• Workshop coating dedicated to fluoropolymer systems, not powder coat or paint.
• Custom system per bar. We do not force fit one coating onto every job.
• A Spectrum Advanced company. Fluoron heritage in fluoropolymer application since the 1970s.
• Located in Elkton, Maryland. Fast turnaround for packaging plants in the eastern US.

See also our parent topic page on heat seal bar PTFE coating.

Frequently asked questions

How long does a heat seal bar recoat take?

Typically 5 to 10 business days from receipt. Rush turnaround is available, quoted case by case.

Do I have to remove the heaters and thermocouples before shipping?

Usually no. We mask sensitive components in our process. Send us photos before shipping if you are unsure.

Can you match my original OEM coating spec?

Yes if you can share the spec or the original coating material. If not, we sample the existing coating and build a matching system.

Is the recoated bar food grade or FDA compliant?

We use FDA compliant PFA and FEP systems by default. Specify when you request a quote.

Get a quote

Every heat seal bar recoat is custom quoted. Send the bar specs, photos of the current condition, your sealing temperature, and what film you are sealing. We respond within 48 hours.