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What does Aurizon Ultrasonics do?

Don’t feel bad, we get this one a lot! It is a rather complicated technology. To put it briefly, Aurizon designs and manufactures machines that use ultrasonic vibrations to bond thermoplastic materials. These ultrasonic bonders are used in several different applications in the hygiene, packaging and specialty converting industries.

How does ultrasonic technology work?

Ultrasonic technology generates molecular friction within compressed material, resulting in the temperature within the material rising, flowing together and creating a bond, a cut, embossing, or crushing, etc.

What is ultrasonic processing?

You will see the term “ultrasonic processing” thrown around a lot on our website. When we use this term at Aurizon, we are talking about the process of converting high frequency acoustic vibrations into mechanical pressure waves used to change or convert thermoplastic materials.

What does the term sonotrode mean?

In ultrasonic processing, a sonotrode can also be called a ‘horn’ and it is a tool used to apply vibrational energy to the materials being converted. Aurizon Ultrasonics designs and manufactures custom rotary sonotrodes with 20 kHz, 30 kHz and 40 kHz frequencies in-house.

Due to more than 30 years of research and development, Aurizon’s expertise is apparent in the metallurgy and acoustic design of the rotary sonotrode. We continually add to our knowledge of sonotrode design and its life cycle by collaborating with the customers that regularly send them back to us for resurfacing.

What differentiates Aurizon from other ultrasonic companies?

The Aurizon team has conceived and developed our high-powered rotary ultrasonic technology over the course of 30 years and is vastly experienced with process development, process integration, training, service and support of ultrasonic systems in commercial production environments. Customization expertise is the cornerstone of our business model. We are committed to listening to you and working with you to find a viable alternative that addresses your particular challenges.

Feel free to contact us to discuss your application, materials and how we can help assess the capability of our technology in relation to your requirements.

Why rotary ultrasonics?

One of the key advantages of the rotary sonotrode 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. This characteristic is especially valuable when processing extremely thin materials since the components can operate in contact mode and generate the forces required for high-speed bonding of lightweight materials.

In addition, 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. An added benefit of the rotary sonotrode is that of potential cross-directional bond width. In a stationary ultrasonic system, the weld capability is limited by the width of the blade, but in a rotary system, the acoustical device can travel across the web and is only limited by the process design.

Which materials can be ultrasonically processed?

Materials, such as thermoplastics, that can be reheated and repeatedly melted are prime candidates. Yet each material has different properties and weight, which may necessitate some experimentation before determining the susceptibility to bonding. For that reason, an obvious first step is to answer the question of feasibility for your application. Aurizon Ultrasonics has pilot facilities set up to provide initial testing that can help you determine if rotary ultrasonic technology can add value to your application.

How can I get my materials tested?

Contact us and we will do the rest! The right technology solution starts with being able to validate equipment capability and viability for a given application. To assist with this process, our pilot facilities are set up to provide initial proof-of-principle testing that helps determine whether our technology can add value in your application.

What advantages does ultrasonic technology have over competing technologies?

Competing technologies include adhesives, thermal bonding, and compression pressure welding, among others. If ultrasonic technology is a good fit for your process, it will provide multiple positive returns such as material and energy savings, increased process speeds and improved product aesthetics.

For packaging applications, ultrasonic technology can offer a reduction in materials due to narrower seals and smaller fin sizes, the ability to seal through residual product, higher processing speeds, improved seal consistency as well as a safer working environment due to the elimination of heat in the process.

In hygiene applications, ultrasonics enables the use of lighter weight materials (which are often lower cost), improved fabric performance and comfort, elimination of adhesive and adhesive delivery systems.

All applications report that their experience includes reduced machine maintenance which includes less down time and higher productivity. In addition, those who have replaced heat sealing processes experience reduced energy consumption with low wattage ultrasonic processes. This can result in a substantial savings in production costs and reduction of utility costs.

Why are ultrasonics considered more sustainable?

Ultrasonic technology can reduce energy consumption by increasing operational efficiency while decreasing energy use. It eliminates the need for adhesives which, in turn, removes the need for transporting and storing them. In addition, since there is no adhesive added to the process, products sealed ultrasonically are more easily recycled.

How long has Aurizon’s rotary ultrasonic technology been around?

The Aurizon team has offered highly efficient, proven and reliable rotary ultrasonic bonding processes to large players in the hygiene converting industry for more than 30 years and has been operating under the name Aurizon Ultrasonics for the last 8 years.

What are some good applications for rotary ultrasonic technology?

Aurizon Ultrasonics’ rotary ultrasonic equipment is used in the hygiene industry to bond, attach, emboss and laminate thermoplastic materials. We also have engineered solutions for feature attachment, elastic entrapment, core bonding, acquisition layers and back sheets. We are continually testing and developing new uses for the technology.

In the flexible packaging industry, Aurizon’s rotary ultrasonic equipment is used for a broad range of sealing and process solutions. The Soniseal™ Series of systems currently includes the Soniseal™ 40 and Soniseal™ 40 UL, both of which are optimally designed for vertical and horizontal package sealing. The Soniseal™ 40 comes in a single drive or a dual drive package and is ideal for many packaging applications including zipper attaching and zipper crushing. The Soniseal™ 40 UL bonder offers maximum seal consistency and control in a high-speed, lower cost package and is designed specifically for flow wrapper, VFFS and HFFS machinery.

What other industries are a good fit for Aurizon’s ultrasonic technology?

You tell us! We know there are more uses for our technology than we can think of. If you have an idea and would like to discuss it with one of our technical experts, please don’t hesitate to contact us.

What is the ROI of an ultrasonic bonder?

Good question! Both the initial investment amount and the ROI will vary according to circumstances, but experience shows that most customers see a sizable return within 6-18 months.

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