Ultrasonics Expand Packaging Potential for Sustainable, Bio-Based Plastic Materials (part 2 of 2)

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2020/11/24 Ultrasonics Expand Packaging Potential for Sustainable, Bio-Based Plastic Materials (part 2 of 2)

Ultrasonics Expand Packaging Potential for Sustainable, Bio-Based Plastic Materials

Source from: https://www.flexpackmag.com/articles/90734-ultrasonics-expand-packaging-potential-for-sustainable-bio-based-plastic-materials

Because they are equipped with multiple bonding/sealing modes, fully programmable controls and data-gathering capabilities, ultrasonic welders offer package makers the promise of more precise and repeatable bonding and sealing within the narrower processing “windows” of bio-based resins. They replace the simple thermal sealing tools and controls of the past with the capability to:

Bond bio-based materials using weld-by-energy, peak power or weld-by-time modes that offer control over all parameters of the bonding process.

Fine-tune the amplitude — the frictional heating potential generated by ultrasonic tooling — using sensitive, digital controls.

Collect performance data for every weld that is made, comparing actual welder performance with specified parameters.

As weld data is collected, package developers can set high/low limits on selected parameters or trigger alarms that flag individual weld cycles or packages that fall outside of process limits. Because these signals are latchable, they can be used to automatically data-log and eliminate bad packages from processing. These ultrasonic welding capabilities can not only help packagers accelerate the development and implementation of new packages built with bio-based plastic materials but also provide them with the means to assure and manage package quality and integrity as new designs are tested and rolled out to market.

Beyond its applicability to building and sealing packages made with bio-based plastic materials, ultrasonic welding technology contributes to plastic package sustainability in other ways:

Reduced package and product waste. There are a range of products — various foods and beverages, powders, leafy produce, oils, cereals or feeds — that, when packaged, can leave residue on the sealing surfaces. When conventional heat seals are used, this residue can become encapsulated within the seal, resulting in product contamination or package leaks and failures. Ultrasonic welding eliminates this potential problem because before the high-frequency vibratory motion of ultrasonic welding heats the sealing surfaces, it first vibrates and displaces potential contaminants — solids, fluids or moisture — out of the seal interface. The result is less package and product waste due to contamination, failure or rejects.

Reduced package material consumption. Because of its precision, ultrasonic welding can provide strong seams and welds using significantly less width of material than typical heated-tool seals. Narrower sealing bands reduce the amount of plastic material needed, whether conventional or bio-based, to complete each package.

Reduced process energy consumption. Because conduction heat-sealing systems must be continually powered and maintained at a specific operating temperature, they consume relatively high amounts of energy compared to ultrasonic welding systems of identical production capacity. Ultrasonic welders consume electricity only in short bursts, typically under one second, when they are in operation. This results in substantial process energy savings, conservatively estimated at 25% to 75%.

Worldwide, manufacturers and packagers are responding to the challenges of sustainability by adopting bio-based plastic materials and ultrasonic welding technology to implement a growing range of innovative products made with bio-based plastic materials. These include compostable coffee pods, stand-up pouches and bags, sustainable VFFS (vertical form-fill-seal) snack food packages, and e-commerce packages that utilize high percentages of recyclable or compostable content.

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