PROCESSING | PLASTIC POUCHES


Welding concept speeds up spout sealing


Petr Vaško, European applications and tooling manager at Dukane in the Czech Republic, explained a new ultrasonic welding concept that could speed up production of items like pouches.


He said the company’s SynQro


process performs welding of a PE mono-material to a spout in a single step using two ultrasonic stacks and advanced process control.


When used in a spout sealing


application, SynQro seals a spout or nozzle inserted in a pouch or contain- er from both sides in a single step. Ultrasonic bonding creates a tight, uniform seal that is resistant to leaks and other forms of damage. Ultra- sonic energy seals through product residues without damaging the seal and maintains product integrity. It is aimed at spout-sealing applications


Right: Constantia’s EcoLam is a range of PE laminates with extra heat resistance, for use in pouches


Heat resistance Dietmar Lenko, vice president consumer innova- tion & product sustainability at Constantia Flexi- bles, said the company’s EcoLam is a PE laminate with extra heat resistance, for use in pouches. It has developed a range of grades with increas- ing barrier performance. EcoLam itself is an orient- ed PE/PE structure, while EcoLamPlus uses a barrier version and EcoLamHighPlus a metallic or alumini- um oxide layer. Materials are printable by gravure or flexo, can be laminated by extrusion and solvent- based or solvent-free adhesive. They also boast high transparency and a heat-resistant outer layer. A low seal initiation temperature ensures a wide opera- tional window, while different grades add different functionality such as easy tear or high stiffness. EcoLamPlus has been used to create stand-up pouches with fragrance release concept – such as a fabric conditioner for Unilever – which it redesigned in PE/PE from the original PET/PE. The product has been launched commercially in South Africa. Separate to this, it can be used stand-up pouches with a spout. In this case, it was for a liquid soap, replacing a previous PET/PE container. Drop resist- ance and shelf appearance were maintained. It also has a good water and oxygen barrier. In another example, it was used for a stand-up pouch with zipper – us- ing 35% PCR. The company also offers its Ecover mono-PP laminates for pouches – in which oriented PP replaces PE. It has been used to make a new mono-material pouch with high barrier properties thanks to an SiOx layer. It has enough heat resistance to


24 FILM & SHEET EXTRUSION | July/August 2025


for packaging liquids or semi-liquids to prevent leakage or spillage during storage or transport. The process compares favourably


with a traditional ultrasonic welding system – which uses three or four steps – and with traditional heat- based systems, which can lead to contamination if product stays in the sealing area, he added. � www.dukane.com


withstand sterilisation during retort processing, which ensures food safety. It is also microwave compatible and is available in different shapes and sizes, with features such as zip and spout. Ecover has been used to make baby food pouches


Low SIT Berry Global has introduced a sealant film with a low seal initiation temperature (SIT). Entour Set is a 23-micron PE film – and would be combined with an outer film with a higher SIT. The new structure would replace a typical multi-layer (and multi-material) version. The Entour Set low haze sealant film has enhanced stiffness for good body texture and a sealing initiation temperature (SIT) of 80-85°C. It is combined with an outer layer of Entour Bold, whose SIT is 140°C. Advantages of a higher outer SIT and a lower


inner SIT include: good sealing at lower sealing bar temperatures; the chance to increase packaging line speed and minimised deformation of the outer MDO-PE film.


Entour Set can also incorpo-


rate 35% PCR according to Neal Geryl, business development director at Berry Global. This has been used to make fertiliser bags, in a co-operation between Berry Global, machine manufac- ture Syntegon and final customer DCM. A high gloss creates luxury appeal, while there is strong sealing with no deformation in the MDO outer film. The overall stiffness of the body gives good sensory rigidity of the back, allowing it to remain standing. MDO PE outer layer films are


www.filmandsheet.com


IMAGE: CONSTANTIA FLEXIBLES


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