Packaging technology. Ultrasonic systems for sealing, welding, cutting and punching

Packaging technology Ultrasonic systems for sealing, welding, cutting and punching Packaging by ultrasound Individual packaging solutions for optim...
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Packaging technology Ultrasonic systems for sealing, welding, cutting and punching

Packaging by ultrasound

Individual packaging solutions for optimised processes

Our systems and solutions for sealing,

Environmentally friendly process

welding, cutting and punching different

and low energy consumption

types of packaging are based on highly

Compared with thermal processes, the

developed ultrasonic technology.

energy consumed in ultrasonic welding is low. Energy is not supplied continu-

A special technology

ously but only when welding takes place.

with special features The extremely gentle process makes ultrasonic

technol-

ogy ideal for packing heat-sensitive products. The contents

The cost of maintaining and cleaning the

“Environmentally friendly technology for efficient process design.”

are not heated because the tools are cold. Because the welds are completely gas and Combined sealing and punching

liquid tight, it is possible with ultrasound

duly adapted ultrasonic systems (IP68 possible) reduced,

is

even

because

the ultrasonic tools are

self-cleaning

and are not contaminated by residues of packaging material or package contents.

to seal packaging in one step and at the

Appealing weld geometries

same time punch it out. Even product that

for demanding packaging tasks

adheres in the sealed area does not affect

When developing the ultrasonic tools and

the weld quality, which means far fewer

anvils, we adapt the weld geometries in-

rejects.

dividually to the packaging requirements and properties of the packed products. Ultrasound makes it possible to produce seals with peel or solid, firmly bonded positive welds.

Anvil for simultaneous sealing and punching

Film samples with various weld designs

Optimised packaging materials

Only a small film overlap is needed in

for versatile applications

the sealing area for the preferred narrow

In order to achieve optimum fusion joints,

welds. Moreover, during ultrasonic sealing

the

have

and welding, no additives whatsoever are

thermoplastic sealing layers. Ultrasound

used, thus making type-specific disposal

is therefore also suitable for cartons or

possible.

packaging

materials

must

papers, as well as packaging materials of more complex structure. In order better

Detailed view of the fused joint of a sealing seam

More efficient processes

to match the packaging materials to ultra-

with results that can be validated

sound technology, they are continuously

Processing and tooling times are very short

optimised in consultation with packaging

for our ultrasonic systems. This sharply

material manufacturers.

increases the productivity of packaging

Less packaging and no additives By use of ultrasound,

“Ultrasound – versatile possibilities.“

machines.

Continu-

ous monitoring of the welding parameters guarantees process

packaging companies save packaging ma-

control and reliability. They can be trans-

terials, because both laminates and mono-

mitted to external EDP systems via one

films can be reliably and tightly worked.

interface. Modular systems and individual solutions The versatility of ultrasonic technology

Sealing through areas in contact with the product

Advantages ■■ Consistent weld quality ■■ Visually appealing seam design ■■ Tight weld seams, even in areas which are in contact with liquids, fats, powders or fibres

makes countless applications possible.

■■ Cold tools

Using modular systems and individual

■■ No machine heating up times

solutions, we satisfy the demands of our customers and their packaging tasks –

■■ Contents are not heated or destroyed when the machine stops

from standard formats to special formats.

■■ Very short process times

Depending on application, we also incor-

■■ Very good process control and reliability by monitoring welding parameters

porate applications for zips or valves.

■■ Environmentally friendly and energy saving

Tubular bags

Sealing system for outstanding seam quality

Our new ultrasonic sealing system for ver-

joints to be formed. In a very short time,

tical (VFFS) and horizontal (HFFS) tubular

excellent quality seal seams are produced.

bag machines is an innovation in packaging technology. It delivers absolutely tight

Fewer production faults

seal seams and is extremely material and

for packaging companies

energy efficient.

Production faults are drastically reduced with the use of ultrasound, because the

Gentle process with short sealing times The cold tools press the tubular bag together for sealing. The ultrasonic oscil-

contents themselves are not heated. Also,

“Tight sealing even when film is in contact with content.”

the contents to be found in the seal area are separated by

the

effect

ultrasonic during

the

lations of the sonotrodes then cause the

sealing process. The quality of the seam

molecular chains in the sealing area to

produced and the barrier layers of the bag

break open with formation of heat and new

film are not affected.

Ultrasonic sealing system for tubular bags

Advantages ■■ Consistent sealing results of outstanding quality ■■ No distortion of the seals (hot-tack) ■■ Expandable seam widths as a result of modular sonotrode systems ■■ Reduced film consumption ■■ Narrow sealing seams (down to < 1 mm possible) ■■ Tight sealing of very thin films, even when they are in contact with contents ■■ No destruction of barrier layers ■■ Far fewer production faults ■■ Reduced maintenance costs ■■ Can be used in vertical (VFFS) and horizontal (HFFS) tubular bag machines

Blisters, trays, pots and cups

Combined sealing and punching of a quality that can be validated

Sonotrode table with flat welding area

Sealing a tray in contact with product

Format-dependent blister pack with sonotrode

With the patented, modular sonotrode

This results in great flexibility of packaging

Packaging that is dependent on format

table, blister packs, trays, pots or cups

design.

For format-dependent packaging solutions

can be sealed and punched in one step. This dispenses with subsequent punching machines and the packaging

“The sonotrode table – the modular system for individual packaging tasks.”

process is shorter. Packaging that is not dependent on format Because the sonotrodes, which emit the ultrasound, are arranged in one level welding area, the sonotrode table can be used irrespective of format. It is sufficient simply to change the anvil plate or the receiving tool to change the packaging format.

Advantages ■■ Modular system ■■ Free formatting

with ultrasound, we not only adjust the receiving tools to the packed goods but also the sonotrodes themselves.

Depending on application, sealing and punching tasks are also combined in this case.

■■ Combined sealing and punching

Advantages

■■ Clean, non-sharp punched edges

■■ Format-dependent, customised and application-specific tools

■■ Rapid tool change ■■ Long tool life ■■ Sealing and punching quality that can be validated

■■ Considerable experience in tool design ■■ Own tool manufacture

Bags

Tight sealing with ultrasound

Our ultrasonic systems are used, amongst

the contents. Mechanical pre-pressing by

other things, to seal prefabricated, flat-

the cold sealing tools and the subsequent

ended bags and flat bags. However, vari-

ultrasound effect force the contents out of

ous special formats are not only sealed but

also

punched

or cut to size with ultrasound. Zips or valves can also be

“Sealing without changing the taste of the contents.”

incorporated at the same time. Tight seams and maximum flavour The main advantage of ultrasound compared with other technologies is that the bags can be sealed absolutely tightly even Flat-ended bag sealed by ultrasound

when the sealing area is in contact with

the sealing area. The flavour of the product is not changed.

Advantages ■■ Tight seams even in sealing areas in contact with product ■■ The taste of the contents is not affected ■■ Application-adapted systems

Cartons

Tight seals for coated cartons Cartons which are coated with a weldable

product to its best advantage whilst the

surface are suitable for working with ultra-

welded on carton serves to provide prod-

sound.

uct information.

Secure closures

Use of high-quality materials

In drinks cartons this coating is usu-

In order to comply with the special produc-

ally made from PE. The closures, which

tion requirements of food packaging, our

are likewise made from PE, are tightly welded to the sealing layer of the carton by ultrasound.

“Ultrasonic system to satisfy strict requirements.”

Drink cartons with welded on closures

to blister trays. The layer on the carton must be adapted to the material of the blister. The transparent blisters, which are usually deep-drawn from PET, show the

complies

system with

the

IP68 safety standard. For the welding tools we use stainless steel or titanium.

Cartons as information carriers A further application of cartons is welding

ultrasonic

Advantages ■■ Welding coated cartons ■■ Welding components of stainless steel or titanium

Cutting with ultrasound

High precision with low material wear

Whether in large industrial bakeries, in

Long tool life with low wear

confectionery manufacture or cheese-

Because of the ultrasonic vibrations, cut-

making – our ultrasonic cutting technology

ting sonotrodes work with a lower initial

is versatile in application.

pressure than conventional cutters. At the same time, sonotrode wear is less and the

Individual cutting geometries

cutting quality is considerably better. In ad-

for the perfect cuts

dition, the use of ultrasonic cutting systems

Bakery products con-

has a positive effect

taining cream or sugary layers, as well as other dough or

“Precision cuts and perfect edges.”

Cutting cakes made up of different layers of dough

on the maintenance and down times of the equipment.

fat-containing foods, can be cut or trimmed in a controlled way by ultrasound to produce a quality that is visually appealing. The cutting geometries of the tools for longitudinal or cross cuts

Advantages ■■ Pleasing cut and form stability

are individually tailored to product require-

■■ Product-specific cutting geometries

ments.

■■ Cutting sonotrodes with little product adhesion and self-cleaning action

Permanently clean cutting tools As a result of ultrasonic vibrations, only slight product residues remain adhered to the sonotrode, so that to a certain extent, it demonstrates a self-cleaning action.

Cutting raw pretzels following brushing with the water-soda solution

■■ Reduction in maintenance and down times ■■ Products cut almost irrespective of consistency

Cutting pretzels after baking

Your partner for packaging solutions with ultrasound

As your partner for packaging solutions

With our many years of experience and

with ultrasound, we will accompany

our special know-how in the field of ultra-

you from product development

sonic technology, we are also able to solve

through to product launch. Experience in solving packaging problems

difficult welding problems. Individually adapted and specially designed ultrasonic systems For the various requirements and cus-

Inspection of the sealing seam in the test laboratory

In our technical

tomer requests, we individually adapt our

isfy customer requirements by continuous

application labo-

innovative ultrasonic systems or produce

quality and environmental management in

ratories we look

special one-off designs. We develop and

our company, according to the tried and

“Advice and design from product development to product launch.” into your packaging

problems

and conduct experi-

tested standards DIN EN ISO 9001 and DIN EN ISO 14001.

manufacture our systems to be fitted both into new installations and into existing ones.

ments, trial runs and development projects on

Tested quality

your behalf. In finding the

All our ultrasonic packaging systems are

optimum solution we apply the

perfectly matched to one another and

latest analytical and test methods.

comply with the safety class, IP68. We sat-

Company headquarters in Karlsbad, Germany

Linked with success. SONOTRONIC Nagel GmbH Headquarters Becker-Goering-Str. 17-25 76307 Karlsbad Germany Phone: +49 72 48 91 66-0 Fax: +49 72 48 91 66-144 [email protected] www.sonotronic.de SONOTRONIC, Inc. Branch USA 28025 Oakland Oaks Court Wixom, MI 48393, USA Phone: +1 248 987 5970 Fax: +1 248 987 5964 [email protected] www.sonotronic.com

Industries ■■ Automobile industry ■■ Plastics industries ■■ Packaging industry ■■ Food industry ■■ Textile industry ■■ Environmental sector Products ■■ Ultrasonic components ■■ Ultrasonic systems ■■ Standard machines ■■ Special machines Technologies ■■ Ultrasound ■■ Hot plate ■■ Infra red

Revision 08/2014 © SONOTRONIC Nagel GmbH ▪ Subject to alterations! Printed in Germany on paper bleached without chlorine.

Development partner and system supplier