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.

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Aurizon Ultrasonics and Dukane Reseller Partnership

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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, [email protected] or visit Aurizon’s website at

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 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.


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.



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.

Aurizon Introduces Soniseal™ 40 UL Series at Pack Expo International in Chicago

Posted on by Kristine


At Pack Expo 2016, Aurizon will be introducing our Soniseal™ 40 UL series of rotary ultrasonic bonders. These systems offer maximum seal consistency and control in a high speed package and are designed specifically for flow wrapper, VFFS and HFFS machinery. In addition to an increased capacity for sealing through residual product due to the rotary action of the sonotrode, the 40 UL has the ability to achieve both continuous motion and intermittent motion sealing for maximum process flexibility.

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 provides a solid foundation for delivering novel solutions to industrial challenges, and our spirit of innovation and dedication to technology development motivates us as we develop custom solutions.

Aurizon Ultrasonics at Hygienix 2016

Posted on by Kristine


This week, Aurizon is introducing our Adhesive Savings Calculator at Hygienix 2016 in Orlando, FL. We welcome you to stop by our tabletop display to learn more about the benefits of rotary ultrasonic bonders, including:

  • Faster operating speeds
  • Reduced energy costs
  • Increased productivity
  • Lower maintenance costs
  • Improved safety

For more information, see Introducing the Adhesive Savings Calculator.


Introducing Our New Adhesive Savings Calculator

Posted on by Kristine


Personal care and hygiene products often use elastic strands secured in nonwovens to prevent leakage or improve fit. Many manufacturers secure these elastics with adhesives; however, adhesives have several drawbacks.  Adhesive is expensive, the delivery systems are costly to maintain, overspray and strike-through cause machine delay and reduce elastic performance.  In addition to all of the above, adhesives are not environmentally friendly.

Aurizon Ultrasonics’ Adhesive Free Elastic Entrapment solution does not require adhesive to secure the elastic strands; thus when you add this system to your process, the cost of the adhesive product is immediately eliminated.  In order to estimate an accurate amount of savings over a period of time, Aurizon technical specialists have created the Adhesive Savings Calculator.

The calculator estimates “adhesive cost” savings.  However, the amount saved from eliminating adhesives is only a fraction of the total savings that can be acquired when changing processes.  Other benefits gained as a result of switching to ultrasonic technology includes increased operational efficiency, material cost savings and improved product comfort and performance.

Increased Operational Efficiency – By eliminating the cost of operating and maintaining the glue applicator equipment, labor and utility costs will decrease.  Adhesive application processes require a significant amount of maintenance, expensive spare parts and labor to maintain.  Adhesive overspray and strikethrough require the converting line to be stopped regularly for cleaning.  Each delay event results in lost production time and creates a waste stream shutting down and starting up.

Material Cost Savings – Ultrasonic technology provides the option of purchasing less expensive, lighter weight nonwoven materials and elastics because there is no need to worry about adhesive bleed-through or loss of elastic performance due to the stiffening effect of adhesive.

Improved Product Comfort and Performance – Not only does eliminating glue maximize fabric softness; Aurizon’s ultrasonic entrapment technology provides extension and retraction curves close to non-attached elastic strands, maximizing performance of the elastic.

The adhesive savings calculator estimates the savings incurred by no longer purchasing glue for your elastic entrapment process.  Below is a list of parameters you need to know to calculate your savings.

Adhesive Application Rate  – This is the rate at which your adhesive is applied to the elastic; measured in milligrams of adhesive per meter of elastic.

Product Length – This is the length of the portion of your product that has elastic applied (in millimeters).

Number of Strands – The number of strands in the adhesive panel.

Number of Panels – The number of elastic panels per product.

Production Rate – The number of products produced per minute.

At this point the calculator will provide your total glue consumption per hour in kilograms.  Once you insert the number of hours of production per day, you will have your total glue consumption per day.

Cost of Glue – The cost of glue in USD (US Dollar) per kilogram.  If you need to convert your currency, Google has a simple calculator here.

Cost of Entrapment System – This cost can vary greatly.  Please contact us to help you accurately define the cost of an elastic entrapment system for your application.

Days – The number of days in which to determine ROI, typically 365.

We think that removing glue from your elastic process not only results in significant savings when making hygiene products, but also helps you to produce a softer product with an improved fit.  If you have any questions about using the calculator or would like to speak to us further about the Adhesive Free Elastic Entrapment solution, please contact Dan Sorensen at [email protected] or (+1) 920-750-5087.

For additional information, read our post about the benefits of Replacing Heat or Glue-Based Processes with Rotary Ultrasonic Technology in an Industrial Application.

Horn Resurfacing Frequency

This chart is based on real life industrual processing examples. Horns are separated by frequency by their vertical position.

This chart shows how many weeks horns can last before they need to be refurbished.

The technical experts at Aurizon Ultrasonics have invested many years and millions of dollars in rotary ultrasonic research and development—including advanced acoustic tool (sonotrode) modeling, fabrication and analysis. In our rotary bonders, the sonotrode (horn) delivers the ultrasonic motion radially around the disc circumference to the material being processed.

Examples of several of Aurizon's horns.

Aurizon has a tremendous variety of horns; a select few shown above.

Some of that research and development has paid off in the understanding of what can be done from a design standpoint to extend the life of the horn. We have designed the pattern placement on many of our anvils so that they evenly distribute wear across the width of the horn. We also offer bonders with independent drives that optimize the speed relationship between the horn and anvil, which can maximize the duty cycle of the horn.

How long will a horn last?
Horn life is based on the application and the materials being bonded, which can vary greatly. It is important to know what to expect in regards to the service life of the horn in a bonder so that you can determine its return on investment and create a maintenance schedule that minimizes production delay.

How will I know when the horn needs resurfacing?
Substantial wear does not always affect the performance of the horn. A horn that looks abused can still function, so rather than err on the side of resurfacing too soon, you should make sure that it actually needs to be done before going forward. Our experienced team can help you define your evaluation protocol so that you can determine when a horn needs to be resurfaced. In addition, we will work with you to develop a maintenance plan to take care of this valuable asset.

What factors influence horn wear?
The three main factors that impact horn life are metallurgy, material type and the environment in which the horn is operating.

  • Metallurgy—Aurizon has its titanium source material manufactured to a specific proprietary recipe. Over the years, we have developed a manufacturing process that minimizes variability in our horns. Likewise, depending on your application, we may suggest a steel horn, which has a very long lifespan in certain situations.
  • Material type–The materials being processed unquestionably affect the life of the horn. Not surprisingly, heavy and/or bulky materials positively influence horn life by creating a buffer between the horn and anvil that minimizes wear; resulting in longer horn life. Meanwhile, thinner material does not allow the same protection and may have the opposite effect on the life of the horn.
  • Operating environment—The environment in which the horn is operating can range from benign to very aggressive based on application needs, directly influencing wear life of the horn.

What is Aurizon’s process for resurfacing a horn?
Most horns can be resurfaced several times. Aurizon can provide this service for you or, if you would prefer, our technical specialists can train your people to develop the in-house capability to refurbish your horn.

Contact us here or send an email to [email protected]

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