Martin Frost, UK Sales Manager, Telsonic UK Ltd, discusses the principles and benefits of the Cut’n’Seal process, which has seen a growing number of manufacturers incorporating the technology.
Telsonic UK Ltd
The Cut’n’Seal process uses ultrasonic energy to cut or punch out a range of thermoplastic and synthetic materials whilst time sealing the edges. The process can also join the individual components to a secondary item. Capable of cutting and joining a range of substrates, the Cut’n’Seal ultrasonic process is a mature, well-established technology used in a number of applications in filtration, garment, medical, wound care and healthcare products.
There are many items manufactured from multiple layers wherein it is essential that the finished item has no frayed edges, loose threads or does not delaminate in use. In certain cases, and in addition to the aesthetics and integrity of the product, there are also instances wherein the ultra-smooth edge produced is an essential attribute for items which will come into close or constant contact with the skin.
The Cut’n’Seal process is capable of meeting all these requirements, which is why the technology is being adopted by manufacturers across multiple inductry sectors.
Examples of where the Cut’n’Seal process has proven to be indispensable include the high-volume manufacture of labels, wound care products, feminine hygiene products and filter pads used in respiratory support machines for patients suffering from sleep apnoea. In addition, the flexibility of the process means it can be incorporated into a wide range of manufacturing technologies.
Typical Reel/Reel Fed In-Line set-up
For high-volume products, the typical configuration would be a reel-fed indexing system wherein pre-laminated multi-layer material is passed between the sonotrode(s) and anvil(s). The individual pads, which have been both cut and sealed, are then pushed through the anvil by pneumatically operated plunger mechanisms and collected in tote boxes, ready for packaging. The skeletal waste of the original material is then fed onto a separate reel on the output side of the machine. This configuration, depending upon product design and reel width, allows for either single or multiple products to be produced in each cycle.
Changeover between product types or shapes is achieved by simply changing over the sonotrodes and anvils, and if required, adjusting the position and/or pitch of the tooling. Telsonic’s Cut’n’Seal technology is capable of achieving cut cycles of between 140/170ms representing a very small part of a machine’s overall process and index time.
Picked by robot
The Cut’n’Seal process is also easily integrated into systems where robots are being used. For example, the robot removes the cut and sealed pads from the anvils and loads them into intermediate trays prior to presentation into filter housings further upstream.
Another Cut’n’Seal configuration often employed is that of twin headed systems, but offset sonotrodes and anvils. This utilises wider web substrates where two smaller pads can be produced in a tandem cycle whilst optimising material usage. In a configuration such as this, the reel-fed material is typically between 100-150mm wide and between 100-150gsm in thickness. The typical throughput for a system such as this would be a total of 60 pads per minute, dependant upon material type and thickness.
The rapid rise in the demand for surgical type face masks, initiated by the COVID-19 pandemic, brought with it a significant increase in the the number of UK companies diverting their resources to manufacturing these products using automated systems. Telsonics’ ultrasonic technology with the Cut’n’Seal process is used to produce cut and formed mask types such as K95/N95 and FFP2/FFP3 variants.
Dual, offset sonotrodes and anvils
The quality, consistency and short cycle times of the Cut’n’Seal process, combined with the ability to easily configure and integrate the technology to suit individual applications, are just some of the key drivers behind the increasing uptake. In addition, developments in wound care technology with new materials, new feminine hygiene products, plus the demand for increased production of PPE have together opened up a wide range of new applications for this process, which also adds value by delivering a superior finished product.