Top 10 Reasons Why Ultrasonic Technology Creates a Better Elasticized Fabric

Posted on by Kristine

Personal care and hygiene products often use elastic strands secured in nonwoven materials to prevent leakage and improve fit. Many diaper manufacturers secure these elastics with adhesives; however, adhesives have several drawbacks.  Aurizon Ultrasonics is proving that there is a better way to produce elasticized fabric – ultrasonic technology!

The following ten reasons are just the beginning of the long list of benefits that ultrasonics offers:

10. UNAFFECTED BY BODY TEMPS – Warm temperatures do not affect the integrity of an ultrasonic bond.

9. STANDS UP TO OILS AND LOTIONS – Oils and lotions will never dissolve an ultrasonic bond.

8. CRUSH CONFORMABILITY – Fabric created by ultrasonic elastic entrapment has more drape, bend and crush conformability than products using adhesive.

7. PRODUCT DESIGN FLEXIBILITY – Enables customized aesthetics via bonding pattern and/or elastic strand positioning.

6. BREATHABILITY FACTOR – Eliminating adhesive makes the product more breathable, allowing excess body heat to escape, keeping the consumer cool and comfortable.

5. ODOR ELIMINATION – What doesn’t smell?  Ultrasonics, that’s what!

4. IMPROVED FIT – Use lighter weight fabrics so the final product is more flexible and has reduced visibility when wearing.

3. DECREASED FABRIC WEIGHT – Use lighter weight nonwoven materials because there is no need to worry about adhesive bleed-through.

2. SOFTER FEEL – Eliminating adhesives maximizes fabric softness and comfort for the consumer.

1. MAXIMUM ELASTIC PERFORMANCE – Aurizon’s ultrasonic entrapment technology provides extension and retraction curves close to non-attached elastic strands creating a fabric with near the pure elastic response for stress vs. strain.

Aurizon Ultrasonics manufactures rotary ultrasonic equipment used in various industries to bond, attach, emboss and laminate thermoplastic materials. Our rotary ultrasonic systems offer a number of features and benefits over hot melt adhesive applications and thermal bonding, such as material savings, energy savings, sustainability benefits and increased process speeds.

Aurizon is promoting ultrasonic technology at the Hygienix Conference in Austin, TX from November 7-8, 2017. We welcome you to stop by our tabletop display to learn more about the benefits of ultrasonic technology and how it can be incorporated into existing processes.

Read more about replacing heat or glue based processes with rotary ultrasonic technology in an industrial application.

The adhesive savings calculator estimates the savings incurred by no longer purchasing glue for your elastic entrapment process.  Feel free to contact us with questions.

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infographic - ultrasonic technology creates better elasticized nonwoven fabrics

 

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Material Solution Sales – New Manufacturer’s Representative for Aurizon Ultrasonics

MSS logo

Aurizon Ultrasonics, the leader in rotary ultrasonic solutions, announced today that Material Solution Sales (MSS) of Raleigh, North Carolina is their new manufacturer’s representative to manage rotary ultrasonic solutions in the states of Virginia, North Carolina and South Carolina.

MSS was formed in 2013 to provide manufacturers with products and services to increase productivity, reduce waste and reduce costs. For over 25 years, James “Les” Kimley has increased his technical engineering expertise by working as a sales engineer, regional manager and the owner of a small manufacturing company. Now, at MSS, he works with a customer’s existing process and recommends dispensing and assembly solutions from simple to full automation.

“Aurizon’s Manufacturer’s Representative training program enables us to provide access to ultrasonic technical specialists across the country,” said Mark Sjoberg, Aurizon Ultrasonics’ Director of Packaging and Specialty Converting markets, “We are excited that Les and MSS have joined our team of sales and marketing professionals.”

To learn more about Aurizon’s sales programs, contact Mark Sjoberg at 920.750.5090 or mark.sjoberg@aurizonultrasonics.com.

About Material Solution Sales
Material Solution Sales (MSS) is a customer focused sales organization specializing in assembly solutions for manufacturing companies. With over 25 years in manufacturing technical sales, their goal is to provide value to customers in technical expertise with both product and process improvements.  They have experience with a wide variety of industries including automotive, transportation, renewable energy, building related products, plastics joining, electronic and medical components.  MSS can provide a materials-based solution to the most challenging assembly requirements and work to automate the process to reduce waste and increase production output.

About Aurizon Ultrasonics
Aurizon Ultrasonics is a leading supplier of high power rotary ultrasonic systems to the packaging, hygiene and specialty converting industries with extensive experience designing, manufacturing, installing and supporting ultrasonic systems for bonding nonwovens, films and other materials.  Aurizon offers 20, 30 and 40 kHz systems capable of speeds up to 2000 fpm.  To learn more about Aurizon Ultrasonics, visit their website at www.aurizonultrasonics.com.

OPM Equipment Sales – Manufacturer’s Representative for Aurizon Ultrasonics

OPM Equipment Sales logo

September 14, 2017 – Kimberly, WI – Aurizon Ultrasonics, the leader in rotary ultrasonic solutions, announced today that OPM Equipment Sales, LLC of Cedar Hill, Texas is their new manufacturer’s representative for the states of Arkansas, Louisiana, Mississippi, New Mexico and Texas.

Paul Aruda is the owner of OPM which has been a manufacturer’s representative for plastic processing machinery since 2006. A 35 year veteran in the plastic industry, Paul has extensive experience in ultrasonic welding, cutting and sealing. For the past 11 years, OPM has built relationships with manufacturers and end users in Texas and the surrounding states.

“The addition of OPM is an important building block in allowing Aurizon to better serve the U.S. market, “said Mark Sjoberg, Aurizon Ultrasonics’ Director of Packaging and Specialty Converting markets, “We are happy to add Paul and OPM to our team of sales and marketing professionals.”

To learn more about Aurizon’s sales programs, contact Mark Sjoberg at 920.750.5090 or mark.sjoberg@aurizonultrasonics.com.

About OPM Equipment Sales
OPM Equipment Sales, LLC is a Manufacturer’s Representative representing leading technology manufacturers since 2006 in Arkansas, Mississippi, North Louisiana, Oklahoma and North Texas. They can be reached at 972-765-7998.

About Aurizon Ultrasonics
Aurizon Ultrasonics is a leading supplier of high power rotary ultrasonic systems to the packaging, hygiene and specialty converting industries with extensive experience designing, manufacturing, installing and supporting ultrasonic systems for bonding nonwovens, films and other materials. Aurizon offers 20, 30 and 40 kHz systems capable of speeds up to 2000 fpm. To learn more about Aurizon Ultrasonics, visit their website at www.aurizonultrasonics.com.

Latest Development: An Off-the-Shelf Solution for OEMs

Posted on by Kristine
Sonisolution RS Series is available in 20, 30 and 40 kHz frequencies.

Sonisolution RS Series is available in 20, 30 and 40 kHz frequencies.

Aurizon Ultrasonics, the leading supplier of high-power rotary ultrasonic systems for nonwoven processing applications, is introducing a new product, the Sonisolution™ RS Series, a series of rotary ultrasonic sonotrode assemblies. The units are available in 20 kHz, 30 kHz or 40 kHz with a selection of horn designs up to 75mm in width and power supplies ranging from 750W to 3600W depending on frequency. Subject to the application, the Sonisolution™ RS Series can operate at speeds of up to 800 meters per minute.

 

This new offering is being marketed to customers, primarily OEMs, with the experience, capability and skill necessary to integrate Aurizon’s patented rotary ultrasonic technology into their equipment while at a competitive cost. With the proper tooling, the assembly is suitable for applications including bonding, feature attachment, embossing, sheet lamination, cutting and adhesive-free elastic panel construction.

Aurizon Ultrasonics will continue to offer complete and customized rotary ultrasonic solutions to customers with disposable hygiene manufacturing, flexible packaging sealing and specialty converting applications.  You may contact us with questions via the contact form or +1 920-750-5080.

GTM Associates – Manufacturer’s Representative for Aurizon Ultrasonics

Posted on by Kristine

July 18, 2017

Kimberly, WI – Aurizon Ultrasonics, the leader in rotary ultrasonic solutions, announced today that GTM Associates, located in Colorado Springs, is their new manufacturer’s representative to manage rotary ultrasonic solutions in Colorado, Utah and Wyoming.

Ben and Kathleen Guasto formed GTM Associates, Inc. in 1983, establishing a successful career in field sales and support engineering for a variety of leading manufacturers of custom mechanical components, sub-assemblies, devices, machines and processes. Ben Guasto can be reached at 719.338.8796 or you may visit their website at www.gtmsales.com.

“This is an important step toward our goal to expand our offerings across the globe, “said Mark Sjoberg, Aurizon Ultrasonics’ Director of Packaging and Specialty Converting markets, “We are thrilled to add Ben Guasto and GTM Associates to our team of sales and marketing professionals.”

To learn more about Aurizon’s sales programs, contact Mark Sjoberg at 920.750.5090, mark.sjoberg@aurizonultrasonics.com.

About GTM Associates

GTM personnel and their manufacturers are active in the design and supply of prototypes to high volumes of components, assemblies, devices and automation solutions for the major markets of medical devices and disposables, aerospace, automotive and peripherals, computer peripherals, emerging green/energy markets, consumer device and material technologies, especially automation and high production volumes, and various industrial applications.

Ben Guasto interned with industry leaders, attained a BSEE degree and was a lab development engineer with Allen-Bradley Company in Milwaukee, WI.  He eventually attained an MSEM (a Master’s in Engineering Management from Milwaukee School of Engineering-MSOE).  His experience includes electro-mechanical new product engineering projects, production engineering and marketing application engineering in direct support of field sales engineers and customers.

About Aurizon Ultrasonics

Aurizon Ultrasonics is a leading supplier of high power rotary ultrasonic systems to the packaging, hygiene and specialty converting industries with extensive experience designing, manufacturing, installing and supporting ultrasonic systems for bonding nonwovens, films and other materials.  Aurizon offers 20, 30 and 40 kHz systems capable of bonding at speeds up to 2000 fpm.  To learn more about Aurizon Ultrasonics, visit their website at www.aurizonultrasonics.com.

Aurizon Ultrasonics and Dukane Reseller Partnership

Posted on by Kristine

Aurizon Ultrasonics announces a new partnership that expands their business in Europe.

(Kimberly, WI, USA – April 28, 2017)

Aurizon Ultrasonics has recognized Dukane as an official Authorized System Reseller (ASR) of their products.  Dukane will be providing Aurizon’s rotary ultrasonic technology to the Czech Republic and European Region.  Effective immediately, this partnership allows Dukane to broaden their offerings to include solutions that involve Aurizon’s patented rotary ultrasonic sealing technology.

The ASR program requires that the reseller’s key technical sales and service personnel pass a course designed to impart specific technical knowledge of the equipment as well as how to identify the best applications for the equipment.  Aurizon also offers an Authorized System Integrator (ASI) program for manufacturers that would like to incorporate Aurizon’s rotary ultrasonic bonders into their machinery.

Mark Sjoberg, Aurizon’s Director of Packaging and Specialty Converting markets stated, “Dukane and Aurizon have had a mutually beneficial relationship for some time.  This new partnership makes a lot of sense for both companies as it expands both Dukane’s product offering in Europe and the Aurizon global footprint.  We are very happy to officially welcome Dukane IAS, s.r.o. to the Aurizon sales team.”

Dukane’s Manager of the EMEA (Europe, Middle East and Africa) Region, Brian Yamato, stated, “Dukane Europe is very pleased to join the Aurizon global team.  Aurizon’s product line fills an important gap in our product offering allowing Dukane to deliver automation-ready solutions, application engineering and local service across Europe.”

To learn more about Aurizon’s ASR or ASI programs, contact Mark Sjoberg at 920.750.5090, mark.sjoberg@aurizonultrasonics.com or visit Aurizon’s website at www.aurizonultrasonics.com.

About Aurizon
Aurizon Ultrasonics has extensive experience designing, manufacturing, installing and supporting ultrasonic systems for bonding nonwovens, films and other materials. Their Soniseal ™ series of rotary systems, designed specifically for flow wrapper, VFFS and HFFS machinery, offer maximum seal consistency and control. These systems can achieve both continuous motion and intermittent motion sealing for maximum process flexibility.

About Dukane
Dukane designs, manufactures and supplies advanced technology plastic welding solutions used in manufacturing operations throughout the major industrial regions of the world. In addition they develop and apply their high power ultrasonic technology to other industrial applications such as cutting tacky and abrasive materials, welding of metal components, sieving, and fluid processing. The company is headquartered in St. Charles, IL but has operations in Europe, Japan, Ireland, France, India, and China and factory trained sales and service representatives in the major industrial regions around the world.

Aurizon Ultrasonics: Latest Developments Presented at Interpack – Hall 12, Booth 12/CO3-12

Posted on by Kristine

Aurizon Ultrasonics designs and manufactures high-power rotary ultrasonic systems that are optimally designed for vertical and horizontal package sealing as well as other packaging-related applications. Our patented technology and process experience allow us to provide solutions that increase productivity, reduce costs, are more sustainable or enable new capabilities for our customers.

Our spirit of innovation and dedication to technology development motivates us as we continue to develop custom and off-the-shelf solutions.  A few of our latest developments are designed specifically for the packaging and special converting industries.

The Soniseal™ 40 UL series of rotary systems offer maximum seal consistency and control in a high speed yet reasonable cost package designed specifically for flow wrapper, VFFS, and HFFS machinery. Included in these new offerings are the ability to achieve both continuous motion and intermittent motion sealing for maximum process flexibility.

The Soniseal™ Wash-Down Series is now available, a 40 Khz rotary ultrasonic bonder that is designed specifically for food manufacturing and packaging applications in which lower maintenance, reduced energy costs and sanitary design are priorities.

Aurizon is also offering a stand-alone rotary ultrasonic horn assembly as a flexible and versatile component to any suitable application. It is available in 20 kHz, 30 kHz or 40 kHz frequencies and can be mounted in any direction.

Let us know if we can put our technology and capabilities to work for you – and see if we have solutions to your packaging challenges!  Visit us at Interpack in Dusseldorf to learn more.

Aurizon Ultrasonics: A More Sustainable Option? – Decide for Yourself at INDEX 17 Stand #1568

Posted on by Kristine

(March 9, 2017 – Kimberly, WI, USA)  Aurizon Ultrasonics designs and manufactures high-power rotary ultrasonic systems for a variety of nonwoven processing applications including bonding, attaching and elastic entrapment. In addition, we have engineered solutions for feature attachment, embossing, acquisition layer attachment and back sheet lamination. Our patented technology provides a solid foundation for delivering solutions that increase productivity, reduce costs or enable new capabilities for your organization. Our ultrasonic sealing systems will also reduce energy consumption through more efficient sealing methods.

At INDEX 17, Aurizon will be showcasing our adhesive-free elastic entrapment system.  The elastic entrapment system is comprised of a high power rotary ultrasonic bonder that creates bond points in nonwoven materials adjacent to a reduced diameter, elongated elastic strand.  When the elastic strand is relaxed, the strand expands and is captured between the bond points. The process is robust to temperature, time and end-user solvents because the elastic is entrapped in the thermoplastic substrate, not attached with a susceptible binder material.  Our elastic entrapment method eliminates the need for adhesives, lowering your costs and making products more environmentally friendly and more easily recycled.

Aurizon’s ultrasonic entrapment technology provides extension and retraction curves close to nonattached elastic strands, maximizing performance of the elastic and improving product comfort.  The tension of the entrapped elastic is lower at elongation versus any other means of attachment.  Eliminating the stiffening effect of the adhesive also produces a softer and more breathable fabric with improved drape, bend and crush conformability.  In addition, this method allows for a wide range of aesthetic customizations since gathers are produced by the bonding pattern and strand feed positioning.

The Aurizon Ultrasonics team has been committed to the research, development, and commercialization of ultrasonic process solutions for industrial applications for the last 30 years. We work through a structured process that starts with understanding your challenge, continues through designing and integrating the required equipment, and culminates with the delivery and installation of the system. You can depend on our knowledge and expertise to formulate the best approach to deliver precise, measurable results.

Let us know if we can put our technology and capabilities to work for you – and see if we have solutions to your process challenges! Visit us at INDEX 17 in Geneva, stand #1568 to learn more.  For a sneak preview, visit us at www.noglueneeded.com and use our calculator to estimate how much you can save by eliminating adhesives in your manufacturing process.

High Speed Crushing of Zippers Using Rotary Ultrasonic Technology

Posted on by Kristine

At the PMMI Innovation Stage at Pack Expo 2016 in Chicago, Aurizon Ultrasonics and Zip-Pak collaborated on a presentation to demonstrate why rotary ultrasonics is the most fitting solution for the zipper crushing process.  They discussed benefits of the technology including a higher process rate, shorter seal times and increased quality of the zipper crushing process.

 

Using a rotary ultrasonic process to perform zipper crushing provides a zone on a zipper web that has been reduced in thickness. This thinning or “crushing” allows a faster cross seal of the product downstream in the process. If the zipper is full thickness at the cross seal process, it takes longer for the cross sealer (typically a heat seal) to make a complete and hermetic seal. Crushing or thinning this zone allows that seal to be made in a much shorter time, thus increasing the process rate capability.

Aurizon Ultrasonics’ zipper crushing equipment is comprised of a rotary ultrasonic horn acting on a lobed anvil with two high spots. The anvil is servo driven and camming software is utilized to locate the crush zone in the appropriate place on the product. This control process allows the customer to make grade or size changes electronically without having to change equipment.

The initial reason for applying rotary ultrasonics to the zipper crushing process was to find a solution that increased line speeds in a continuous process. Using a heat crush or stationary blade system would require that the web be stopped, which was functional but not ideal.  In continuous flow wrap applications, using rotary ultrasonics increased speeds by nearly 50% – from 125 to 185 bags per minute.

Other advantages of the rotary ultrasonic solution include the following:

Rotary horn to anvil contact is acceptable

  • Contact often leads to converter or horn failure in a stationary system.

Rotary horn systems accommodate varying thicknesses

  • Stationary systems can be challenged by sealing over back seals or gussets.

Rotary horn fly-wheel effect

  • Only a portion of the working surface is loaded at any given moment.
  • The freely vibrating portion of the horn minimizes amplitude sag during peak loading.

Film-type flexibility

  • Potential to eliminate “heat seal” layer
  • Materials self-heat, which means that films that melt at high temperatures are sealable

Rolling contact helps remove residual product from the seal zone

  • Both styles of ultrasonics are effective at sealing through residual product.
  • Rotary ultrasonics helps clear some materials instead of capturing them in the seal.

Adjustable cross direction width capability

  • Traversing rotary horn can be programmed to package size
  • A single rotary horn can be used for seals that are longer than the typical size

For more information, see Aurizon’s previous posts regarding Replacing Heat or Glue-based Processes with Rotary Ultrasonic Technology in an Industrial Application and Comparing Rotary Ultrasonic and Stationary or Blade Technologies or contact us here.

Which Bonding or Sealing Solution is Right for Your Process?

Technical advances in the hygiene, packaging and converting industries have led to a variety of options for the bonding, sealing and welding of nonwoven textiles, plastic packaging film and other materials. Understanding the benefits and drawbacks of each technology can help you make the right choice for your application. This article compares rotary and stationary ultrasonic with hot melt adhesive, thermal and compression welding solutions.

Each application has its own characteristics to consider when comparing these technologies.  This could include ease of deployment, composition of materials being bonded, consumer preferences for the end product, production cost, process control and sustainability.  Additionally, some applications must also consider FDA / USDA requirements, storage and heat tolerances of package contents, consumer preferences for re-opening a sealed package and cleanliness of the production area.

Key points of comparison shown in the table and addressed in more detail below include technical capability, quality of the bond, start up time and production speed, product damage, cost, process control, end user concerns and sustainability.

Ultrasonics

Technical Capability – Capability is impacted by composition of the materials being bonded. Ultrasonics is only applicable to certain plastics and nonwoven blends.

Quality of Bond – Excellent; providing all parameters are correct.

Start Up Time – Very short

Production Speed – Increases production line efficiency; can increase your process uptime while lowering your process waste, robust to process and web upsets such as substrate splices, elastic splices, machine stop/start events.

Product Damage – Minimal, no adhesive bleed-through, no heat damage

Cost – Ultrasonic technology carries a higher initial cost than the others, but makes up for it with savings on costly adhesive materials, complex adhesive delivery systems, labor and materials (it allows you to utilize lower cost nonwoven materials or film substrates).

Process Control – Enables customized aesthetics, Can utilize lighter weight elastic materials without compromising performance, and eliminates adhesive creep

End User Concerns – Improves product comfort and performance; maximizes elastic performance; maximizes fabric softness; eliminates the stiffening effect of adhesive; size, shape of gathers customizable

Sustainability – Lower energy cost than thermal solutions; cleaner technology than hot melt adhesive solutions.

 

Adhesives

Technical Capability – Adhesive processes offer the most substrate flexibility.

Quality of Bond – Usually very good; although there are some instances when the adhesive breaks down due to oils or temperature of the surrounding area.

Start Up Time – Process delay associated with system heat-up/cool-down cycles

Production Speed – Excellent speed capability

Product Damage – Negative product effects—stiffness, tackiness, bleed-through, blocking

Cost – Higher system energy costs; high cost of raw materials usage, storage, handling, and transportation

Process Control – Process delay to clean adhesives from process equipment due to overspray, bleed-through, etc.; spray limitations / challenges with high-speed, intermittent processes; waste issues because the lines are full of adhesive between startup and shut down events; safety concerns because of high temperature raw materials, applicators, hoses, pumps, and melters.

End User Concerns – Adhesives can cause stiffness and discomfort.

Sustainability – Adhesives are the least sustainable option listed mostly due to difficulties recycling complex chemicals.

 

Thermal Bonding

Technical Capability – Capability is impacted by material properties but often requires a sealant layer

Quality of Bond – Usually very good; although there are some instances when it causes degradation of material outside bond zone

Start Up Time – Process delay associated with system heat-up/cool-down cycles

Production Speed – External application of heat can reduce speed capability

Product Damage – Potential product damage due to over-exposure to heat

Cost – Higher system energy costs

Process Control – Safety considerations due to high temperature equipment

End User Concerns – Degradation of material, speed capabilities

Sustainability– More sustainable option than hot melt adhesive option due to the fact that there are no raw materials added to the process.

 

Compression / Pressure Welding

Technical Capability – Capability impacted by material properties

Quality of Bond – Dependent on speed of process

Start Up Time – Starts immediately, but getting up to speed can take time

Production Speed – Best when operating at high speed

Product Damage – Similar to ultrasonics, no heat damage, but could have adhesive bleed through when adhesive is added to the process

Cost – lowest per code; often requires grade specific parts

Process Control – Can be a high-wear process; Waste and variability due to speed-dependent attachment strengths—at times an added adhesive system is used to overcome these limitations

End User Concerns – Grade change flexibility

Sustainability – High, unless adhesives are required to enhance low speed capabilities.

Aurizon Ultrasonics manufactures rotary ultrasonic equipment used in various industries to bond, attach, emboss and laminate thermoplastic materials. Our rotary ultrasonic systems offer a number of features and benefits over hot melt adhesive applications and thermal bonding, such as material savings, energy savings, sustainability benefits and increased process speeds.

Read more about replacing heat or glue based processes with rotary ultrasonic technology in an industrial application.

Feel free to contact us with questions.

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