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Fabric & Film Processing Systems

Because fabric & film applications tend to be so specialized, we offer only a few standard fabric & film processing products. This way, we're not locked into predetermined mechanical specifications or limitations. We've got the flexibility to accommodate your particular feed rates, material thickness and widths, or handling requirements so we can design and build the system that meets your needs - not provide you with a system that may give you more, or less, equipment/features than necessary.

When designing and building fabric & film processing systems we specify the same 15kHz, 20kHz , 30kHz and 40 kHz ultrasonic thrusters, generators, and process controllers from our iQ product lines that are used for ultrasonic plastics assembly. Typical fabric & film installations are multiheaded systems, which take full advantage of our narrow profile thrusters' close center-to-center positioning.

New Dukane Servo for seal & cut applications

DDSM 20/40 Ultrasonic Sewing Machine

Ultrasonic Fabric & Film (UFF) Slitters

Ultra-Cutter Ultrasonic Cutting Systems

Rotary 30kHz Ultrasonic Sonontrode (Horn)

iQ Series EZ Ultrasonic Stapler

iQ Series i220 Integrated Ultrasonic Valve Bag Sealer

iQ Series Ultrasonic Hand Held Systems


New Dukane Servo for seal & cut applications

Machine Features

  • Dukane patented ultrasonic 20kHz 4.8kW iQ Servo press system
  • The 1-Step Ultrasonic seal & cut eliminates the need for costly 2-step manufacturing processes
  • The ultrasonic sealed edge is clean and eliminates material fraying
  • Dukane patented servo Melt-Match® technology allows precision velocity control during the
    sealing phase of the process
  • Servos' superior accuracy allows absolute distance control to +/- 1µ. The accuracy and
    velocity control of the servo minimizes tooling wear.
  • Melt-Match® technology allows for stronger seals with repeatability that cannot be matched by
    traditional pneumatic ultrasonic welders
  • Ideal for woven and non-woven materials



 



 


DDSM 20/40 Ultrasonic Sewing Machine

  • Dual frequency machine - can be used with either 20 kHz or 40 kHz equipment
  • LED display for easy process monitoring
  • 19" (483mm) throat
  • Independent controls for slitting and rotary anvil welding
  • Edge guiding, rewinding, and feed rolls can be used with the DDSM 20/40
  • Can be operator controlled or integrated into an existing line
Downloads

Data Sheet:  DDSM 20/40 Ultrasonic Sewing Machine  (72 kb)

 

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Ultrasonic Fabric & Film (UFF) Slitters

Dukane UFF-1 and UFF-2 slitters are designed to slit and seal wovens, nonwovens and knitted fabrics containing at least 65% thermoplastic (synthetic) material.

Machine Features

  • Fraying and unraveling are eliminated
  • Slit edges are cleanly cut
  • Easily integrates into material handling devices such as winders or looms
  • Can traverse web to splice rolls together or cut lengths
  • Lightweight and compact design allows for versatility
  • 40 kHz quiet operation
  • Offset mounting of horn and anvil prolongs tooling life with renewable contact areas
  • Easy changeover
  • Standard Dukane 1 inch diameter anvils
Downloads

Data Sheet:  UFF-1 Sonic Slitter  (543 kb)

Data Sheet:  UFF-2 Sonic Slitter  (66 kb)

 

 

 

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UFF-1

UFF-2


Rotary 30kHz Ultrasonic Sonotrode

Dukane's Rotary 30kHz Ultrasonic Sonotrode (Horn) is ideal for sealing thin films and non woven materials. The unit can be easily integrated into automation. The Rotary horn design eliminates drag issues associated with conventional static ultrasonic sonotrodes. Ultrasonic bonding is a greener solution than conventional heat sealing as power consumption is greatly reduced, requires no adhesives and produces no smoke or fumes. Applications for the rotary horn include film sealing for packaging machines, bonding of nonwoven materials and many others.

For application feasibility please contact Alan Baxter at abaxter@dukane.com
 

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iQ Series EZ Ultrasonic Stapler

The new iQ EZ Stapler makes blister/clamshell sealing easier than ever. The welding process itself is activated with a foot-switch once the packaging material is properly positioned. The easy to learn process helps make for faster cycle times.

Dukane's patented iQ 30kHZ 600 watt generator controls the iQ EZ Stapler. With custom tooling, a wide variety of weld patterns or spot welds can be created. The stapler can be put on a workbench, or wall-mounted on its own support structure.

The iQ EZ Stapler can weld films, non-woven materials, coated and laminated packaging, and foil packages. Thermoplastics such as PET, PERG, PE, PP, PVC and PVA are all appropriate for use.

Like all of Dukane's Intelligent Assembly Solutions products, the iQ EZ Stapler can be integrated into an automated system.
 

  • Use with Dukane Patented iQ Ultrasonic 30khZ generator technology
  • Seals clamshells blister packs efficiently and economically
  • Wide variety of sealing anvil patterns
  • Small foot print
  • Vertical or horizontal mounting capabilities
  • "Green" sealing solution
  • Multiple units can be used with iQ MPC for multi point welding on larger applications
  • Simple EZ set up
  • Reduces operator fatigue from conventional hand probe systems.
  • Consistent results with weld by energy

 

Downloads

Data Sheet: iQ Series EZ Ultrasonic Stapler (1017 kb)

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iQ Series i220 Integrated Ultrasonic Valve Bag Sealer

The new iQ Series i220 Integrated Ultrasonic equipment is designed for sealing valve bags. This equipment provides a hermetic seal to thermoplastic valves on bags used for packaging powders, food and hydroscopic products.  This prevents product loss, moisture intrusion or pest infiltration.

Features:

  • The i220 Integrated Bag Sealer is available in 20 kHz frequency and power levels from 1200 to 2400 Watts with patented Trigger by Power feature.
  • The Ultrasonic Generator housed within the press gives the machine a smaller footprint, easy installation and mobility.
  • Ergonomic features like adjustable bag shelf height, tall column mount, mobile cart with lockdown wheels and two handed adjustable tie-down safety switches makes the equipment safe and user friendly.
  • Ultrasonic horns are made of titanium.
  • Rugged Construction using the highest quality components provides superior performance, precision, and reliability.
  • Equipment can be configured as standalone single-station or integrated into automation systems, depending on customers packaging need.

 

 

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iQ Series Ultrasonic Hand Held Systems

New Dukane iQ hand probe shown with ultrasonic fabric slitting horn.  Allows you to seal and cut fabrics in one operation.  Excellent for cutting straight lines and contours.   Available in 30kHZ & 40kHz.

 

For more information: iQ Series hand held systems.

 

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