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Telsonic is able to provide advice and recommendations on materials and concepts for industries wishing to adopt the ultrasonic Cut ‘n’ Seal process.

Many everyday items such as product packaging, wound dressings, filter membranes, cosmetic cleansing pads and clothing labels all require concise sealed edges to ensure product integrity and eliminate the risk of de-lamination in products that are often multi-layered.

Furthermore, products that come into contact with the skin must be comfortable to use and free from frayed or ragged edges that could cause irritation to the user.

The answer to these issues of integrity, comfort and consistency can often be found in ultrasonic technology, applied using the Cut ‘n’ Seal principle.

The Cut ‘n’ Seal process can be used for shape cutting of any product, where collated layers of non-woven, woven man-made textiles, laminates or even single layers that may be prone to fraying, require a joined and smooth edge.

The process can also be used where flexible textile layers require to be joined to thin rigid substrates, as in the case of wound care and respiratory or occupational health products such as face masks.

The process rule of thumb for ultrasonic Cut ‘n’ Seal is that some layers of the product must be thermoplastic, or at least have 40 per cent thermoplastic content.

Interlayers of non-thermoplastic material – for example, special paper layers within specialist process filtration products – can be accommodated by the fusing of other thermoplastic layers.

Cutting through products without sealing can be achieved on materials that do not have any thermoplastic layers.

The ultrasonic Cut ‘n’ Seal concept eliminates many of the issues that result from the use of alternative technologies.

Using heat to cut and seal can often leave unsightly discolouration on the product, together with an uneven and sometimes rough surface finish along the edges.

Mechanical cutting knives or blades are prone to edge wear, which in turn can lead to not only inconsistent product quality, but the resultant system downtime associated with tool changes.

This method may also cause unacceptable damage to delicate products.

While the Cut ‘n’ Seal concept is becoming widely used to produced finished components, it also has applications downstream of the finished assembly process, especially where individual components need to be collated.

Continuous Cut ‘n’ Seal processing is also prominent in many converter type industries producing bulk synthetics for consumer products.

The very nature of the ultrasonic process means that it is measurable.

This is a key benefit in applications that are safety critical in nature or require validation, as in the medical device industry.

Additional features of the ultrasonic Cut ‘n’ Seal process include the fact that there are no consumables and no environmental issues associated with recycling or the disposal of chemicals, as can be the case with certain adhesives, plus the efficiency of the process helps to reduce energy costs.

Ultrasonics are also applied to many food cutting applications.

Products such as bakery goods, energy bars, cheese, pizza, pies and so on, all benefit from the use of ultrasonic cutting technology.

The cold, vibrating sonotrode (ultrasonic cutting blade) reduces friction and product reactive forces during the cutting process and also cleans itself of stray food particles.

The results are clean and reproducible cuts, free from deformation and thermal degradation of the product.

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