In only a very short time the stand-up pouch has conquered a substantial market share and has began to replace diverse glass packaging. A trend that will continue in coming years. The flexible and resealable pouches with the practical spout are not only intuitive in their handling, they also address the to-go trend. They meet consumer demands for more mobility. The spout, in particular, becomes an integral element of the pouch and thus an important component for the consumer and processing technology.
That production of the flexible plastic packaging takes too long and for this reason is uneconomical, is a misconception. 'That's not how it is', Mike Landwehr, project manager at Pöppelmann FAMAC®, can report. 'Using the ultrasonic welding process we have not only improved the optical quality of the stand-up pouches, but at the same time were able to increase the cycle speed in production of the film pouches with welded spouts.' Thanks to its especially high processing speeds the process scores with consistently high cycle times – up to 200 spouts/minute can be achieved without any problems with considerably more efficient production.
Due to the low energy demand and the short cycle times, thew ultrasonic welding process is one of the most efficient connecting processes for thermoplastic components. Unsightly warping that would usually occur as a result of heat was eliminated. This is because the process uses mechanical vibrations to heat the film. The result is an optically flawless and stable weld that creates a high-quality product for the consumer. The fast change of welding tools is another advantage compared to other processes. The tools used in ultrasonic welding, for example, are merely pushed into and out of the welding press. This means that setting up for new products is not only very easy, but also very fast. Because the tools can be changed with just simple moves. Time-consuming waiting for tools to reach temperature are dispensed with.
In order to meet more stringent customer demands and fulfil individual, custom manufacturing needs, the packaging specialist from Lohne, Germany, has relied for a long time on cooperation in their partnership with the Widmann company, one of the internationally leading manufacturers and developers of film processing machines. 'The digitally controlled welding process allows easy reproducibility of the welding parameters and therefore rapid product change. This means that considerably less energy is used than in traditional welding processes. Which in turn leads to cost savings.', Achim Bauder, long-standing Widmann employee, knows. PP, PE, PET and PVC films, as well as barrier films, can be processed using the ultrasonic welding process. Even material combinations, for example single-material packaging or paper-PE combinations, so-called hybrapacks, are possible. For even more effective resource utilisation, even recyclable stand-up pouches can be produced. Integration of the welded spout in the flexible packaging has always been critically examined: poor quality, non-closable packaging or leaking contents were the concerns. But here, too – thanks to the ultrasonic welding process – the all-clear can be sounded.
Find out more about the Pöppelmann FAMAC® welded spout at: www.pouchbooster.com