Comparing Rotary Ultrasonic to Stationary or Blade Technologies

Ultrasonic technology is offering new potential across various industries including cutting, bonding, sealing, embossing, elastic entrapment and countless other custom applications. Manufacturers are employing ultrasonic technology to bond various types of materials together without using adhesives or heat sealing. Ultrasonic processes are particularly effective on nonwoven laminates and other plastic films. Making the switch to ultrasonic technology can provide increased productivity and sustainability, reduced operating costs and enable new capabilities in your industrial applications.

Once you have made the decision to apply this technology to your application, you will need to choose between a rotary ultrasonic system and a stationary or blade ultrasonic system. There are some applications that will have an obvious solution, but most of the time, you will have to consider both avenues to understand which route will be most beneficial.


Rotary Ultrasonic and Stationary or Blade Sealing System Comparison

Rotary ultrasonic technology can offer a number of valuable advantages to your industrial processes.


The following are some variables to consider when looking at your options for taking advantage of this leading technology.


What kind of process are you running?

Rotary systems work well in both intermittent and continuous processes while the blade systems are more suitable for intermittent systems. Rotary horns also provide higher continuous power delivery and more uniform horn amplitude.  More power means faster, more consistent sealing and more uniformity delivers higher, more consistent and efficient seal performance.


Are you having mechanical problems with your current process?

Sometimes with stationary or blade systems, there is danger of component failure due to metal contact. The rotational action in rotary systems deflects the force response rather than sending a shock wave directly back into the converter, causing less vibration and greatly reducing the risk of failure. Not only does this feature allow for faster process speeds and greater consistency than stationary systems can offer, it also means less downtime, higher productivity and lower repair cost.


What kind of material are you working with?

One of the key advantages of the rotary horn is the ability to achieve very high amplitudes and operate in contact with other surfaces (patterned steel anvils) without catastrophic failure of the horn or converter—as mentioned above.  This characteristic is especially valuable for the processing of extremely thin materials since the horn and anvil is able to operate in contact mode and generate the forces required for high speed bonding of lightweight materials.


Do you have varying thicknesses in the seal zone?

All types of ultrasonic technology can offer improved process speeds, the ability to seal through residual product and the ability to bond through varying thicknesses and layers.  However, the rolling contact from a rotary horn enables better sealing over varying material thicknesses like seams and gussets because of the inertia possessed by the system.  This can directly lead to less product failures, less waste and more effective seals.


How wide is your cross-directional bond or seal?

width of cross directional bond in a rotary ultrasonic system

The orange line shows the potential width of the cross directional bond in a blade system as compared to a rotary system.

Another thought-provoking comparison of these technologies is that of potential cross-directional bond width. In a stationary or blade system, the seal width is limited by the width of the horn blade, but in a rotary system, the horn can travel across the web and is only limited by the design of the process configuration.


Would you like to test your materials?

Rotary ultrasonic technology has been custom engineered, developed and implemented on hundreds of bonding, sealing and converting applications.  Aurizon Ultrasonics works with customers around the world to deliver rotary ultrasonic solutions that address your particular process.  Our patented technology provides a solid foundation for delivering cutting-edge products and processes. We will strive to gain a thorough understanding of your needs and consider key parameters such as horn metallurgy, acoustic design, component fabrication and system engineering.

Contact us with your ideas or challenges and we will determine if we can develop a customized solution to meet your requirements.

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