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What happens when you bring together a state-of-the-art packaging equipment manufacturer, an innovative plastic welding technologies leader and an award-winning injection molder? A sophisticated new mono-material polyethylene (PE) packaging solution that was created from the combined expertise of Effytec<\/a>, Dukane<\/a> and Hoffer Plastics<\/a>. The efforts of this joint collaboration will be on display at Pack Expo in booths W-26018, S-1700 and S-4321 from November 3 to 6 in Chicago.<\/p>\n Brand owners \u2013 with packaging applications across health and beauty, food, personal care<\/a>, industrial products and more \u2013 will be excited to learn how they will benefit from the collaboration and expertise of respected industry innovators:<\/p>\n \u201cHistorically, the industry has been challenged in finding an affordable, efficient solution to seal mono-material films due to the complexities associated with films, spouts and standard sealing processes \u2013 including heat sealing and ultrasonic welding,\u201d said Roger Stainton, Effytec USA President. \u201cTogether, we\u2019ve created a solution that enables us to ultrasonically weld spouts to mono-material films in a one-step process that can produce 40 pouches per minute.\u201d<\/p>\n This solution is pivotal in the industry\u2019s shift toward mono-material packaging, which is essential for end user recyclability and eliminating landfill waste.<\/p>\n \u201cThe results of this collaboration meet the needs of brands and co-packers eager to bring a sustainable product to market,\u201d said Petr Vasko, Dukane\u2019s European Applications and Tooling Manager. \u201cTogether, we\u2019re delivering green technology, fast cycle times and precise sealing for modern, sustainable packaging lines.\u201d<\/p>\n Effytec began by producing a kit that could effectively integrate mono-material films onto its servo-driven GP32 form-fill-seal<\/a> machine. This kit included additional rollers to advance the film without stretch, pressure regulators, new metal alloy sealing bars to support better temperature transition, and other components that could overcome historical challenges of working with unique mono-material films.<\/p>\n The most critical component of this kit was the integration of Dukane\u2019s patented SynQro\u2122 ultrasonic welding technology. SynQro\u2019s\u2122 unique design drives ultrasonic energy through two sonotrodes from both sides of the spout in synchronized motion, delivering consistent and uniform seals. Its servo-controlled process provides infinite control over sealing force, ensuring the right amount of pressure for highly accurate and hermetic seals of these films to Hoffer Plastics\u2019 spouts.<\/p>\n Hoffer Plastics\u2019 P22 spout was an instant match to the technologies produced by Effytec and Dukane. The PE cap, which is a lightweight design that offers superior tamper evidence, greater seal integrity and compliance with choke-proof specifications, was an immediate fit with the solution due to the spout\u2019s standard design, which integrates energy directors critical for ultrasonic welding compatibility.<\/p>\n John Strubulis, product manager at Hoffer Plastics added, \u201cOur spouts have found a home in this partnership with Effytec and Dukane. We believe in the power of partnerships \u2013 especially one that leads to viable sustainable<\/a> solutions that accelerate customer success while minimizing our environmental impact. This innovative ultrasonic welding solution not only creates a mono-material spouted pouch that enhances recyclability for end users. It also reduces energy consumption by 70-80 percent compared to heat-sealing methods. We are grateful for our partnership with Effytec and Dukane and look forward to innovating even more together.\u201d<\/p>\n Those interested in learning more can visit booths W-26018, S-1700 and S-4321 at Pack Expo.<\/p>\n<\/div>\n\n
How Collaboration Created a Sustainable Solution<\/h4>\n