Key Features and Benefits
Product Performance
The OptiBonder™ enables manufacturers to reduce material usage and create thinner, more discreet hygiene products, particularly regarding side seam construction. By combining a precision servo actuator with patented Bond Balance Technology and dual encoder feedback, the system delivers highly controlled bonding with minimal quality variation.
Bond Balance Technology
Dukane’s patented Bond Balance Technology helps equalize bond strength across side seam bonds, reducing variation between leading and trailing bonds.
This results in more consistent seam quality, improved product performance, and reduced risk of weak bonds in high-speed production.
Dual Encoder Feedback
Dual encoder feedback monitors both servo position and actual system movement, providing enhanced process visibility and control.
This enables early detection of mechanical variation, supports predictive maintenance, and helps ensure consistent bonding quality over time.
It also provides precise measurement of system movement in real units, giving manufacturers greater insight into dynamic bonding conditions.
Active Force Control (AFC)
Dukane’s proprietary Active Force Control regulates applied force with one of the fastest response rates in the industry, enabling precise, real-time adjustment during bonding.
This control improves bonding accuracy, supports consistent energy delivery, and maintains stable performance across high-speed production environments.
Precision Bonding Control
The OptiBonder™ provides precise control over force, position, amplitude, and frequency throughout the bonding process. This minimizes variability and ensures consistent bond formation across a range of nonwoven materials.
This enables stable, repeatable bonding performance in high-speed manufacturing environments.
Quick Open Function
The OptiBonder™ features a quick open function that rapidly retracts the system under high-force conditions.
This helps prevent material wrapping, significantly reduces downtime, and improves operator safety by minimizing pinch-point risk.
Real-Time Data and Process Control
Dukane’s OptiBonder™ is equipped with iQ LinQ™ software, providing real-time process data directly to operators and plant systems without the need for manual data extraction or offline analysis.
This enables continuous monitoring, faster decision-making, and seamless integration with PLCs and plant-wide data systems.
The system supports common industry communication protocols, including Ethernet/IP, Profinet, and digital I/O interfaces.
Automated Interactive System Setup
The system includes a guided, interactive setup process built into the HMI, helping ensure proper configuration and reducing reliance on manual setup procedures.
This simplifies operation and improves consistency during system setup and changeover.
Easy Integration and Compact Design
The OptiBonder™ is designed for seamless integration into both new and existing converting lines, with or without an additional electrical enclosure.
Its compact design and minimal hardware requirements provide one of the smallest automation footprints in the industry.
Energy-Efficient Cooling
Multiple cooling methods are available to maintain optimal horn temperature during operation. The system supports forced air or compressed air cooling, providing flexibility while maintaining consistent bonding performance and energy-efficient operation.