Customer needs:
A leading manufacturer in the medical technology sector was faced with the challenge of safely and reliably welding plastic spouts to infusion bags made of film material. As the products are designed for medical use, it was crucial that the sealing process meet the strict requirements for seam quality. Precise control over the sealing process was necessary to ensure the highest standards of tightness, resilience and hygiene.
The aim was to develop a robust, controlled and reproducible sealing process that would fulfill the high quality requirements of medical technology and ensure a tight, secure connection between the spout and bag.
Our solution:
To meet the requirements, the customer implemented the RESISTRON impulse sealing technology from ROPEX. This technology uses defined and controlled electrical pulses to bring the heating tape precisely to the required sealing temperature and then cool it down again immediately afterwards. This technology enables exact control over the entire welding process in real time, ensuring a uniform and tight sealed seam. The system also enables active monitoring of temperature and pressure, ensuring consistent, high-quality weld seams.
Based on the customer’s requirements, ROPEX developed a customized 3D sealing tool that is particularly adapted to the shape and size of the plastic spout. The heating tape lies on a silicone base for possible tolerance compensation, which in turn was attached to the aluminum base body. The welding process was controlled by the high-precision RES-5450 temperature controller, which offers the customer precise temperature control via a user-friendly display.
A crucial part of the solution was the integrated water-cooling system, which rapidly cools the seam immediately after the sealing process. Rapid cooling ensured that the spout was firmly and securely sealed to the bag. The water cooling also made it possible to increase the cycle rate, which significantly increased production capacity. In addition, ROPEX calculated the optimum system components, including the booster and cooling unit, to ensure seamless integration and operational reliability.
Customer benefits:
By introducing impulse sealing technology, the customer was able to benefit from several decisive advantages:
• No warm-up phase for the tools: thanks to impulse technology, there was no need for a warm-up phase. This led to faster commissioning and helped to save energy, which significantly increased the overall efficiency of the production process.
• Tight, smooth seams thanks to precise temperature control: The exact control of the sealing parameters resulted in uniform, high-quality weld seams that met the stringent requirements of medical technology. The seams were consistently tight and reliable.
• Customized overall solution: The uniquely developed 3D sealing tool and the adapted system components (booster, cooling unit) ensured that the solution was perfectly tailored to the customer’s needs and the specific requirements of spout sealing.
• Products ready for sale from the first bag: As the impulse sealing technology is ready for immediate use, the first bag was ready for sale without the need for any set-up time or pre-material.
• Simple tool maintenance: The robust design of the welding tool and simple handling ensured a low-maintenance, long-term solution.
• Robust and reproducible process: The sealing process is highly precise and was able to run reliably and repeatedly at all times, which ensured long-term production quality.
• Ensuring customer satisfaction: Thanks to active control, tight and uniform seams are ensured, thus meeting the high requirements of medical technology.