Ultrasonic Sealing Processes in Packaging − Continuous Processing − Plunge Processing − Form, Fill, & Seal − Application Solutions Packaging Market Trends

Ultrasonic Sealing in Packaging: Theory & Principles, Equipment & Solutions Presentation Outline

• Packaging trends • Ultrasonic Technology Overview • Polymer Welding Characteristics • The Ultrasonic advantage • Package types • Ultrasonic Sealing Processes in Packaging − Continuous processing − Plunge processing − Form, Fill, & Seal − Application solutions Packaging market trends

• Sustainability • Recycling/reusing materials • Reduction in Energy used in production (Carbon footprint) • Supply chain transparency • Sourcing • Safety/traceability • End-of life cycle • New Barrier/coating technologies • Paper/board- easily recyclable when combined with new barrier technologies • Lightweight packaging • Reduced costs • Environmental sustainability • “Frustration-free” packaging • Build customer loyalty by offering easy to open packs that can be opened and resealed quickly Ultrasonic Technology Overview Ultrasonic Theory

Electrical Energy Mechanical Vibrations

2000 X

20 kHz Power Supply 50/60 Hz

Converter Booster Horn Hysteresis Heating

 Mechanical oscillations about an equilibrium point create molecular stress and heat Ultrasonic System Converter Output Amplitude

30 µm : 15 kHz

20 µm : 20 kHz

15 µm : 30 kHz

8 µm : 40 kHz Horn Amplitude

 Amplitude: the peak-to-peak displacement of the face of the horn while ultrasonics are applied

Amplitude

Nodal area Stack Amplitude

Converter X Silver Booster X High gain horn = 120 20 microns Gain = 2 Gain = 3 microns

Converter X Gold Booster X Unity gain horn = 30 20 microns Gain = 1.5 Gain = 1 microns Amplitude Reference Guide • Most films used in packaging have a semi-crystalline component in the structure.  They typically require more amplitude for welding than amorphous materials. 20kHz 30kHz 40kHz Nylon 70 – 120m 56 – 96m 42 - 72m PET 80 – 120m 64 - 96m 48 - 72m PE 90 - 120m 72 - 96m 54 - 72m PP 90 - 120m 72 - 96m 54 - 72m Ultrasonic Theory

Energy = Power X Time

Force X Velocity

Force can be varied Factors of by changing: velocity are:

Pressure Downspeed Frequency AmplitudeAmplitude Balun technology • Patented Multi Converter technology • Ultrasonic horn driven by two or more converters • The converters are being driven in parallel and in phase, thereby providing a horn transmitting greater power than the same horn driven by a single converter. • Higher power per linear inch = Faster cycle rates • Available in 20, 30, & 40-kHz • Reduced size and mass • Balanced RF load distribution • Superior amplitude uniformity Balun technology – Ultrasonic Stacks

20kHz – 19” long

30kHz – 9” long

40kHz – 6” long Polymer welding characteristics Polymer Welding Characteristics

• Melt Characteristics (Tg, Tm) • Stiffness (high Modulus of Elasticity) • Polymer structure: Amorphous Semi-Crystalline Specific Heat vs. Temperature

Amorphous materials: • Gradual softening & melting

Semi-crystalline materials: • Narrow melting peak indicates sudden melting and rapid solidification.

• Height of peak indicates the amount of energy required to melt. Weldability of Films

• Thermoplastics material can be cast, extruded or blown into a film, generally under 0.010” thick.

• Factors Influencing Weldability: − Film thickness − Density − Thermoplastic type Weldability of Laminate / Coated Materials

• Coated materials: − Films can covered with a layer of thermoplastic, such as polyethylene, BOPP/EOPP, EVOH, nylon. − Base material need not be thermoplastic, such as coated cardboard or paper.

• Factors Influencing Weldability: − Coating material and thickness − Substrate − Sealing layer thickness Joint Design • Rigid Plastics: – Energy director designed into parts themselves

• Textiles and Films – Energy directing patterns on the face of the horn, anvil, rotary drum or stitching wheel. The Ultrasonic Advantage The Ultrasonic Advantage Performance:  Seals thru contaminants - reduce leakers The Ultrasonic Advantage

Energy:  Low energy consumption compared to thermal process  Energy only applied during process cycle  No warm up required

Sustainability:  Up to 75% reduction in carbon footprint over thermal systems  Narrow seal area requires less material  Process compatible with PLA and other bio-plastics The Ultrasonic Advantage

Performance:  No residual heating of package contents  Reduced tool clean up = less downtime  High cycle rates ( > 110 bags per minute)  Increased Process control The Ultrasonic Advantage- Material Savings

• Based on film cost of $0.25/ft • Package length of 10” • Cycle time: 100 ft per/ min Sonic seal • Seal area: heat .250” • Seal area: sonic .080“ (2mm) • Utilization:16 hrs/day 250 Heat seal days / yr. • Efficiency: 80% • Savings of 544,000 ft/yr Material savings : $ 136,000 / year The Ultrasonic Advantage- Increased Process Control Parameter Adjustment

Increase: • Pressure/Downspeed • Energy • Amplitude

Under-welded?

Inspect Process Initial Setup Part Validation

Over-welded?

Decrease: • Pressure • Energy • Amplitude − Amplitude Profile? Additional Control Options Primary Control • Acts as primary control of weld cycle Primary Weld Mode • Can select one Weld Mode Optional Control Capabilities • Terminates ultrasonics once a certain condition is met Secondary Control (e.g. Weld Time Limit is exceeded) Mode −Hold Time is initiated to complete weld cycle • Aborts the weld cycle immediately Cycle Aborts 1. Missing Part: 2. Ground Detect

• After weld cycle is complete, triggers alarm indicating parameter is out-of-range Suspect and Reject • Suspect Limit: If weld result may be acceptable, part Limits should be subjected to further evaluation • Reject Limit: Indicates an unacceptable part Types of packages Types of Flexible Packages

Flat Bottom / Stand Pillow Bags Stick Packs Up Pouches Types of Rigid Packages

Coffee/ Yogurt Cup Tea pods Types of Rigid Packages Gable top coated- Clamshells paperboard cartons Ultrasonic sealing processes Ultrasonic Sealing Processes in Packaging

• Continuous mode − Clamshell sealer − Radial actuator

• Plunge mode − Standard bench top welder (clamshell, stand up pouches, yogurt cups) − Tube sealer (stand up pouches) − Vertical or horizontal form & seal (various bag types) Continuous Processing – Clamshell Sealing

• Easily welds various size packages, including tamper evident • Speeds up to 110 ft/min Continuous Processing- 30-kHz Radial Actuator

• RMX-30 Radial Actuator Plunge processing - Clamshell Sealing Plunge processing- Pouch Sealer Plunge processing- Tube / Pouch Sealer Date code in the seal area Vertical Form, Fill and Seal System Vertical Fill Form Sealing

Branson USA Lab machine- continuous motion; designed for the snack food market; vertical & horizontal ultrasonic seals VFFS - Ultrasonic End Sealing VFFS – Ultrasonic vertical sealing Machine Formats

Single Lane:  Has a single lane tube form to shape the pouch at each cycle  Suitable for many different sized pouches  Most common configuration

Multi-Lane: Has multiple lanes of tube to form multiple pouches at each cycle Commonly known as “stick-pack” machines. Used for small packets such as sugar, salt, and condiment packets Application Solution- Rigid container (clamshell) sealing

Product/Application Name: Clamshell Market Segment: Packaging Material: PET Requirements: Structural seal Joint Design: None Technology: Ultrasonic