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Welding and sealing systems: product lines reviewed.




Builds dielectric welding equipment and supplies electronic sealing dies, tooling, and equipment for welding supported and unsupported PVC films, urethane, and coated fabrics. The latter include heat-sealing dies, articulating seal-and-cut dies, 360-degree tube sealers, pushbutton automatic trays, Colpit and Kiefel dies, capping fixtures, and vacuum-form and applique dies. Typical applications are medical supplies, protective clothing, packaging, looseleaf binders, automotive interiors, furniture, luggage, life-support equipment, inflatables, and sales promotion.


Manufactures electronic heat-sealing dies and fixtures for the medical, advertising specialty, looseleaf binder, and handbag trades.


Offers hot-air welding equipment for use in fabrication, along with noncorrosive welding rods; and also a full line of sheet rod tubes, both thermoplastics and thermoset.


Offers the ST40, a 40-kHz ultrasonic tube sealer. System adapts to most filling machines, is said to seal over 80 tubes/min, and includes a date-coding and trimming station.




Manufactures equipment for heat-sealing plastic materials to each other or to coated paperboard. Machinery ranges from basic semi-automatic versions to fully automated equipment. Two sealing methods are used: 1) applying heat and pressure to the back of the lidding material or paperboard and 2) applying heat and pressure to the face of the plastic material. Typical applications are conventional blister packages and lidded trays. Also available is a complete line of thermoforming equipment and automatic loaders to be used with company's heat-sealing equipment.


A wide range of 20-kHz ultrasonic systems with 150 to 3200-watt power handle most thermoplastic assembly requirements, including welding, staking, swaging, spot welding, inserting, and degating. Each unit contains an electronic programmer that automatically controls power output, ultrasonic exposure, and pneumatic sequences. Dynamic triggering reportedly ensures that optimum conditions are reached before weld cycle begins. A system protection monitor is designed to safeguard components and ensure optimum results. New microprocessor-controlled systems enabling constant-time or constant-energy welding and precise weld control are available in 20 kHz. An ultrasonic trim knife and hand-held units are also available.

Company also offers a line of modular 40-kHz equipment with the same features as 20-kHz equipment. The higher frequency results in lower amplitude and more gentle vibration that can be beneficial for certain applications involving small, delicate parts. Component systems are available for automated production lines.

The Series 900M microprocessor-based power unit/controller for ultrasonic welding features multiple operational modes: conventional time welding, time welding with energy limits, energy welding with time limits, time/ energy compensation welding, continuous and multiple-distance welding. The units are used with new 20- and 40-kHz actuators. Integrated units are also available. Company offers software packages for external control of welders and statistical process control.

A vibration welder is available for large or irregularly shaped parts and resins that cannot be ultrasonically welded. Custom systems are also available.


Ultrasonic welders for low- to medium-power plastics applications are offered. A 100-w, 40-kHz, or 50-kHz "Gentle Touch" system is designed for small, delicate parts. A 125-w, 40-kHz "Model Shop 40" is available for plastic model building, as is a 450-watt system that can accommodate medium-sized assembly applications. A 900-watt system is also available for larger units. An ultrasonic analyzer for testing systems and horns is also available. Company also manufactures horns and automatic assembly systems.


Manufactures RF sealing equipment from 0.9 to 60 kw. The appropriate generator is combined with the Callanan press best suited to the customer's application; a turnkey system is then furnished complete with production tooling. The company builds equipment for fabricating medical disposables, for clamshell and blister packaging, and for welding seams and letters for back-lit signs, awnings, automotive, as well as for industrial products.


Supplies industrial [CO.sub.2] lasers for sealing, cutting, and drilling materials such as nylon, acetal, PE, PS, rubber, acrylic, silicone, and PP.


Supplies impulse or optional straight heat-sealing machines for blister packs and food or pharmaceutical trays. Most machines can be equipped with card feeders and product unloaders. Models offered include the following: 1) the SOCI unit, a four-station rotary machine with two heads that seal with each machine cycle; 2) the JAJ4 unit, a four-station machine for peel packs, blister packs, and lidding applications where reel-fed systems are not possible; 3) the ILSI model, an impulse or optional straight heat sealer.


The Drader "Injectiweld" system is a hand-held welding gun that continuously feeds and melts a rod of thermoplastic (HDPE, ABS, PP, PS) and extrudes it under pressure as a continuous bead in the weld zone. The hot tip of the gun melts surface of the substrate to be joined (of the same polymer as the welding gun), and the extrusion pressure causes an intimate joining of the and substrate, in what the company calls a "true weld." Operation requires connection to electric power and shop compressed air.



Company's ultrasonic plastic assembly systems weld, stake, seal, seam, and degate plastic parts and products. Dukane 20- and 40-kHz ultrasonic welding systems, ranging in power output from 350 to 2000 w, are said to consume less energy, improve quality, and eliminate need for fasteners or adhesives. Company's extensive line of ultrasonic equipment, recommended for applications in automotive, appliance, biomedical, electrical, textile, toy, and aerospace industries, includes rugged microcomputer-controlled press and thruster systems, SRT series rotary parts-handling systems, ultrasonic hand-gun and probe systems, and precision machined ultrasonic horns and fixtures.

The new Ultra-Com microcomputer for controlling and monitoring ultrasonic welding operations, enhances the performance, accuracy, and productivity of the company's heavy-duty thruster/ press systems. It allows processors to assure the same amount of material melts in the joint each time for fewer rejects.



Emaweld system for electromagnetic welding uses inductive energy to create fusion bonds between thermoplastic parts. The system consists of a generator, water-cooled coils and special, magnetically active preforms. The preforms are fitted between parts and heated electromagnetically by the generator and coils. Fusion temperatures are reached in seconds. The system reportedly can weld most thermoplastics quickly and cleanly, and is said to be especially effective in attaining reliable pressure-tight structural bonds. It also handles large or irregular shapes. The system is built as a turnkey operation and is widely used in the medical, consumer, automotive, filter, battery and container markets.


Offers its Ener-Seal induction cap sealer, a noncontact system which establishes a magnetic field that heats the foil in the cap liner and creates a hermetic seal.

Company's systems are solid-state for high reliability and low maintenance and are reportedly effective and efficient with their "instant on" capability and an automatic frequency control which provides constant flux density, unaffected by the number of caps under the sealing head. Company uses various unique coil designs to handle virtually any application, regardless of container material, size, shape or product fill.



* Heat equipment to stake together pieces of dissimilar materials using heat, pressure and time.

* Ultrasonic heat equipment for manual, pneumatic, semi-automatic or fully automatic assembly/installation of metal inserts in thermpolastics.

* Automatic assembly equipment which can put together any number of plastic or metal parts, electronically inspect the individual parts or finished assemblies, and move to a packaging station.


A complete line of high-temperature hot-air tools are available, including hand-held benchtop systems. Company's Serpentine Heating Element design results in a hot-air tool capable of extremely high temperatures - up to 1600 F.


Specializes in lightweight, low-cost hand tools for heat-sealing plastic film and bags in thicknesses from 1/4 to 10 mil. Sealing lengths extend from 7 to 36 in. Adjustable temperature is controlled over a range from 150 to 475 F. Simple operation and one-step sealing are claimed. TFE-coated sealing edge is easily changed by loosening two screws.


Equipment, bonding agents, and technology are offered for high-speed induction bonding of thermoplastics. Welds are achieved by magnetically generated heat produced when magnetic particles in the bonding agent are exposed to an RF field. The bonding agent is applied as a liquid, hot-melt, die-cut film, powder, ribbon, filament, or coextrusion. Welded bonds are achieved in TP polyester, polycarbonate, PP, HDPE, nylon, PPO/ PPE blends, FEP fluoropolymer, ABS, PVC, and many TP elastomers, among other materials.


Offers fully computer-controlled ultrasonic welding machines with built-in quality control system. Singlehead and multihead systems are available with sound enclosure and various automation features. Features offered include simplistic menu-driven keypad programming, complete memory resident welding programs, graphic display of the welding process, alpha numeric fault message display, indexed quick changeover tool system, and power output levels up to 3000 watts.


Markets RF high-frequency plastic welders/sealers in models ranging from 1-kw to 150-kw output with pneumatic or hydraulic presses. A complete line of accessory materials-handling equipment such as rotary indexing turntables, side-to-side shuttle slide tables, and automatic roll-feed indexing mechanisms is also available.

In addition, company supplies pre-machined brass electrode die rule and diemaking apparatus for in-house fabrication of RF heat-sealing dies/electrodes normally used with RF welding/ sealing equipment; and RF sealing dies for users of RF sealing equipment who require professional diemaking services.

Company also imports other machinery and die-supply products associated with plastic sealing.



Offers its Hydra Sealer line of hot-plate welding equipment for sealing plastic parts. High strength, hermetic seal, high production rates and ability to weld unusual part designs are reported advantages. The equipment ranges from small, low-production table models to high-production machines capable of welding parts up to 4 sq ft. Applications include such parts as appliance pumps, air-conditioning ducts, automotive batteries, automotive reservoirs, taillight assemblies, gas tanks, other containers, and more.


IN-X Automated Systems Div. builds automatic and semi-automatic equipment and systems for installing inserts thermally, ultrasonically, or mechanically. Company also makes threaded inserts for plastics.


The following welding equipment is made by Italian companies:

* Heat sealing for film (bagmaking, wrapping).

* High-frequency welding (for stationery, packaging, automotive parts, medical items, and inflatables).

* Ultrasonic welding for assembling molded and/or extruded parts.

Contact office for information on suppliers.


Offers a line of RF heat sealers from 1 to 50 kw. Units can be custom-designed for a specific application (e.g., medical products, protective clothing, awnings, truck tarps, waterbeds). Auxiliary equipment offered includes shuttles, turntables, in-line automatic indexers, plus automatic robot units such as material feeders, board loaders and printing units. Company's electronic die shop is available for fabricating heat-sealing dies. Electronic die rule kits and Carmo vinyl precuts such as medical fittings, grommets, snap fasteners, and valves are also offered. Complete turnkey systems are available.


Hot-air welders are supplied for tack and hand welding of all weldable thermoplastics, including high-temperature materials. Standard hand-held models require compressed air and 110-volt a-c (350 to 900 w). Portable models have a built-in air compressor. Units and their electric heating elements are made of stainless steel. Company also supplies a complete set of standard tips and tools for tack welding or welding with round rods, and a heating device for bending thermoplastic sheets.


Air-operated heat-sealing and welding units with electrically controlled dwell time are available in pressure ranges from 1/2 to 10 tons. Presses have thermostatic control; heated heads range from 2 x 4 in. to 20 x 30 in.


High-speed hot-gas welders feature six interchangeable "located-heat" elements with welding temperatures of 450-1150 F. Wattages are 250 to 750 with heat concentrated at the tips for easy barrel handling. Company also offers portable air compressors, extra-long barrels for high-heat applications, and a wide variety of tip configurations. Specially engineered nitrogen-saving units are available that can reportedly cut nitrogen consumption by 50%. Company also makes equipment to bend and weld thermoplastic sheets for fabricating tanks, hoods, etc.; and specialized contact welders for plastic pipe.


Supplies induction heating power supplies and work-handling systems for bonding. Also offered are induction cap-sealing generators for hermetically sealing membranes to plastic containers.


Manufactures a hot-wire seamer, called the Sur-Bon Seamer, that can join most thermoplastics and trim waste. Widths from 12 to 75 in. can be accommodated. Company also offers the Engel line of heat-cutting and heat-sealing units, ranging from small hand-held units to large slitting and sealing models.


Offers its hand-held, 20-kHz ultrasonic welder that incorporates an automatically controlled pneumatic clamp. Unit weighs 5 lb and is powered by a 500-, 1000-, or 1500-watt generator. An assortment of welding tips, anvils, timing and energy-control options are available. The welder can be retrofitted to existing ultrasonic systems.


Offers an all-purpose industrial heat gun for applying shrink tubing and solder preforms, welding plastics, bending, softening and forming thermoplastic materials, and curing epoxies. Gun is available with an optional pinpoint attachment for welding plastic. A built-in stand is standard. Also shrinks plastic film surfaces for shrink packaging - Master Model H6510A, 750 F; and VT750B variable temperature heat guns to 1000 F.


Builds ultrasonic welding equipment and related tooling. Standard line consists of a 20-kHz welding press with power supplies from 350 to 1200 w. A hand-held model or tabletop press is available with a 100-w power supply, thruster capabilities, and 50 kHz. A 20-kHz handgun is standard. Automated systems can be made to order. A standard rotary indexer is available with multiple stations.

Company also specializes in spin-welding equipment that reportedly can handle applications that are not feasible with ultrasonic welding.



Offers a complete line of ultrasonic and spin-welding units. Microprocessor or standard ultrasonic bench welders are available in 20, 30 and 40 kHz with power ranging from 900 to 2700 watts. Probe systems are available in 20 and 30 kHz with power supplies of 900 to 1800 watts. Hand units are 30 kHz with power of 600 watts. The 20 and 30 kHz bench welders are equipped with a head that levels to the part, as well as pretriggering, dynamic triggering, electronic bottom stop and factory-installed wiring for semi- or automatic plug-in operation. The continuous-welding ultrasonic system for fabric and film sealing has a rotary horn which reportedly seals at up to twice the speed of conventional methods while maintaining a consistent quality seal. The Mecasonic Spin Welder seals circular axis parts made of PP, PE, PVC, nylon and most other thermoplastics.


Manufactures spin welders for cylindrical and spherical plastic parts, hot-blade fusion welders, 1/2- to 5-ton heat-stake/ swage units, and custom-built assembly systems. Spin welders range from 1 to 5 hp with low/high torque, a-c and d-c drive, and can handle parts from 1/2- to 24-in. diam. Indexing via turntable or lineal conveyor with automatic load/unload turnkey systems are also available.


Manufactures thermal-impulse sealers for thermoplastic film. Sealing length is up to 24 in., producing 2-mm-wide flat seals.


Company's line of spin welders ranges from bench-type models for small parts to free-standing machines that weld up to 24-in.-diam parts. Available options include: tachometer, trimmers, and automatic loaders and unloaders, as well as test stations. These state-of-the-art spin welders have dual palm buttons for operator safety when initiating the weld cycle and a solid-state programmable controller to monitor all functions of the machine operation. The basic spin welder is designed as a modular unit, which can be incorporated into automated lines. Company also designs and builds dial-index and in-line machines to automate the welding process.


Company's induction capsealer is reportedly the first 100% solid-state, air-cooled generator designed specifically for heating a foil inner seal. This system is said to require only half the water for cooling the unit and about half the power of vacuum-tube equipment and reportedly requires no warm-up period.

Built-in feedback circuits are designed to maintain constant output. Units handle closures at line speeds up to 200 ft/min, and the company reports FCC certification for the system.


Offers custom-manufactured contact heat-welding equipment.


Sells induction and dielectric processing systems. Induction machinery provides localized heating for plastic forming, coating, and foil sealing. Fully automated, turnkey, or manual-handling systems are offered ranging from 1 to 300 kw and 450 kHz to 5 mHz. Dielectric systems feature company's patented Macrowave process for high-speed SMC preheating, epoxy and plastisol curing, sealing and bonding. Automated or manual systems are available, ranging from 1 to 200 kw and 12 to 120 mHz. Feasibility studies are also offered.


A full line of RF heat-sealing equipment ranges from hand-held units to rotary turntables 28 ft in diam. Presses are available to 30 tons. Generators are frequency-stabilized, FCC-certified, and available in power outputs from 500 w to 100 kw. Individual presses and generators are offered, and the company specializes in tray-type shuttles, roll-feeding, and rotary systems. These systems are usually sold as an integrated unit to ensure reliability and accuracy. All generators incorporate a completely solid-state, arc-sensing unit. Other accessories are available that match generator output to the workload. Integral electric and seal-checking units are also available that will alert the operator if sealing quality deteriorates.


Manufactures RF heat-sealing and thermo heat-sealing equipment and accessories. RF heat sealers are available from 4 through 30 kw. Accessories include side-to-side shuttles, rotary and in-line indexers, and heated platens. Company offers its "Current Monitor," which uses current, not time, to control the welding cycle. The device prevents under- and over-welded parts.

Company will design and build special systems to customer's specifications.


Manufacturers electrical plastic welding equipment for industrial and automotive applications. Equipment includes a hot-air welding gun, assorted tips and elements, welding rod stock, four models of heat guns, and a lightweight heat gun said to have an almost indestructible element that can heat to temperatures of 1100 F with no cooling cycle. The welders, with a variable heat range of 400-900 F, are said to be capable of bonding PVC, ABS, PP, or PE at speeds of 4 ft/min. A portable, self-contained unit is available.


Formerly Packaging Industries Group, product line includes laboratory heat sealers and formers, high-frequency sealers, in-line and turntable systems for stationery and office supplies, medical devices, blister sealing, inflatables, and other plastic-to-plastic heat-sealing applications.


Offers a versatile fusion-bonding machine. Side platens are accessible so that tooling can be moved in and out of the equipment easily. Setup is said to be easy, and changes from one tool to another can be kept to a minimum.

Company also offers a hot-air staking machine in various sizes that reportedly makes heat staking more efficient and simpler. Tooling for this machine is also available.


Equipment for heat-sealing plastic covers on containers can handle either roll stock or individual cover feed. Equipment is said to be easy to adapt to different shapes.


Manufacturing ultrasonic horns, tooling equipment, and a microprocessor controller dubbed the RX 1000. The latter is a retrofittable control that can be installed on any manufacturer's ultrasonic welder. Company also manufactures complete systems that can include index tables, shuttles, hot stamping, pad printing, automatic loading and unloading, spin welding, heat sealing, and automatic insertion.


Manufactures a complete line of ultrasonic plastics assembly systems capable of welding, inserting, staking and reforming thermoplastic components. Equipment is available in three frequences (15 kHz, 20 kHz, and 36 kHz) and power outputs from 200- to 4000-watts. Microprocessor-controlled systems are available that monitor and report conditions during each process cycle and compensate for variable to give consistent results. Operating parameters such as time, energy and trigger force are easily entered the through the microprocessor keypad. Up to nine jobs can be stored and sequenced. Options include CRT monitor, hard-copy printer, linear encoder, which allows accurate welding by distance, and SPC and PC interface capabilities. Welders with conventional timer controls also are available for those applications not requiring the features of a microprocessor control.

In addition to bench-top welders, company offers the 1096S slimline actuator, which is designed for use in automated systems where space is at a premium.

Large compact hand-held welders which are available with many accessories are suited for assembling large parts or those with hard-to-reach joint surfaces.


Ultrasonic assembly equipment for welding, staking, and inserting is available. The Sureweld series includes a four-year warranty on 1000-, 900-, 600-, 400-, 200- and 50-w systems. All are adaptable with company's built-in micro-computer controller and can be modified for automated operation. Company also supplies Cavitron 800- and 1600-w units which have automatic frequency and power control.

Applications include welding thermoplastics, inserting mechanical fasteners, degating parts, 20 series splicing film, and cutting and sealing fabrics. The new Lacemaster 20 series combines cut and seal operation and is available in 900- and 1200-w models. Custom design and feasibility recommendations are available for tooling.


Produces a full line of heat and ultrasonic inserts for use in plastics as well as heat-insertion equipment for cost-effective installation. Free application engineering services ensure specification of the best part and system for each application.


Offers an automatic plastic heat-riveting machine for sealing up to 50 rivets simultaneously. Unit automatically feeds parts on a powered conveyor, then separates, locates, rivets up to 50 projections simultaneously, and discharges items on the conveyor to the next operation. Machine cycle time is 24-30 sec. Automatic web unwind/rewind stands, weld/scrap winders and automatic splicing machines with speeds of up to 800 ft/ min are also available.


Builds special machinery for its hot-air staking ("hot-cold upset") process. A hot-air gun blows flow-controlled air across the plastic boss, which is then upset with a cold rod that extracts the heat from the plastic to form any shape head desired. Because the boss is thermally reformed with hot air and not mechanically formed, there reportedly is no tendency to delayed stress-cracking, as may be caused by ultrasonic staking or orbital riveting. Higher strength assemblies are said to result, as material around the boss reportedly is undamaged by the assembly process. Machinery cost is said to be 40-60% less than for ultrasonic staking and 10% less than conventional heat staking. Any number of bosses on various planes and/or angles can be upset at the same time. Assembly time is said to be less than 10 sec, regardless of the number of bosses.


High-frequency dielectric heat-sealing equipment from 1 to 100 kw is designed for welding, heat sealing, embossing, and die cutting supported and unsupported vinyls and other thermoplastics. Solid-state, harmonic-free units, custom or standardized, are reportedly frequency stabilized to meet and surpass FCC requirements. Accessories include board feeders, indexers, inserters, shuttles, turntables, quick-disconnect features, temperature-controlled platens and tools, dies, and fixtures. Looseleaf binders and disposable medical products reportedly can be produced at rates up to 80,000/day with one operator. F-series models feature circuitry said to require an average of 32% less energy than comparable heat sealers.


Manufactures a full line of ultrasonic welding equipment, as well as tooling for welding, staking, forming, spot welding, inserting, tube sealing, and continuous film sealing. Equipment ranges from small hand-held units to large automated systems. Welding can be continuous, timed, depth-controlled, or microprocessor-controlled with q-c functions. All power supplies incorporate a variable power control for fine amplitude adjustment between normal booster ranges.


Manufactures electric impulse heat sealers with 14- and 18-in. jaws, manual heat sealers with 6-in. jaws, heat-sealing irons with heat controls, and heating elements for specialized sealing applications.


Manufactures a line of semi-automatic thermal-impulse sealing machines for films, foams, fabrics, and laminates used in both packaging and fabricating. Sealing capacity ranges from 4 to 240 in. and seal widths extend from 1/8 to 4 in. Over 250 models of 13 basic machine types are built, with modified and custom equipment also available. Sealers can be integrated into automatic packaging systems. Units can seal contours and trim in various shapes, open or closed, symmetrical or irregular.


Manufactures linear vibration welders, hot-plate welders, and tooling for joining thermoplastic assemblies. Both technologies provide strong, repeatable structural bonds and hermetic seals. Cycle times generally range from 6 to 30 sec, depending on size or complexity. Vibration welders feature variable high frequency, small amplitude ([+ or -] 30 mil), and hydraulic clamping for parts up to 55.5 x 25 in. Hot-plate welders feature smooth, controlled motions for delicate assemblies, complex parting lines, or flexible components. Parts to 24 x 48 in. can be accommodated. Both processes can be fitted to conveyors, rotary tables, or pick-and-place robot loaders.


Manufactures RF heat-sealing equipment which can be built to user specifications for various applications. Optional equipment to increase productivity such as shuttles, turntables, indexers, material feeders and board loaders is also offered. Company has it's own in-house die facility for the manufacture and repair of tooling. Carmo vinyl heat-sealable components, such as snap fasteners, medical fittings, grommets and valves are also available.


Distributes 1) Vertrod Corp.'s thermal impulse sealers and welders for plastic film and sheet, 2) Packaging Aids Corp.'s impulse heat sealers for film and bags and 3) Heat Sealing Equipment Co.'s heated jaw sealers and simple packagers. Full stocks of spare parts and complete repair services are maintained for owners of above-mentioned sealers and packagers.


A line of dielectric heat-sealing equipment is offered. Company also manufactures supplementary equipment including dies, fixtures, and loading trays.


Company is the sole U.S. representative of Leister (Switzerland) hot-air tools. Equipment is designed for field applications, as well as for building into other machinery. The Variant automatic welding machine is designed for 0.8-in. and 1.6-in. overlap welds at speeds up to 39.4 ft/min. Welding equipment and accessories include hand-held, electronically controlled hot-air tools rated at 260 w up to heat sources rated at 39 kw.


Blister heat-sealing machines are offered with platen areas ranging from 10 x 10 in. to 25 x 50 in. Over 36 different types of blister sealers are available, ranging from manual-feed units to completely in-line automatic heata sealers, rotary-type heat sealers, belt and tray sealers, and special units that heat seal and trim at the same station. Seal and Trim machines are offered up to 160 tons with platen areas from 8 x 10 in. to 36 x 48 in. Company also offers complete in-line, form-fill-seal units with platen areas from 5 x 7 in. up to 25 x 25 in. Custom designs and modifications are available. A complete line of vacuum/pressure forming equipment also is available.
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Title Annotation:1991-1992 Manufacturing Handbook and Buyers' Guide
Publication:Plastics Technology
Date:Jul 15, 1991
Previous Article:Decorating, printing, finishing systems: product lines reviewed.
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