Ultrasonic Spout and Fitment Sealing for Gable-Top Cartons

Join Rigid Fitments Without Adhesives

Ultrasonic energy is delivered directly to the spout or fitment joint, producing a strong, reliable seal that helps prevent leaks and preserve package integrity. Eliminating adhesives removes a consumable from the process and simplifies the equipment needed to form the joint.

Efficient and Safe for Washdown Environments

Liquid-food filling lines demand equipment that can withstand aggressive cleaning routines. Dukane's sealed probe and transducer options use stainless-steel and titanium construction, sealed connections, and high-flex leads to support hygienic machine designs and repeatable operation in washdown areas.

Localized Ultrasonic Energy Transfers Only at the Joint

High-frequency ultrasonic vibrations generate localized heat at the fitment interface. Minimal heat transfer outside the weld zone helps protect the carton, spout, and filled product while reducing burn marks, discoloration, smoke, odors, and residue associated with heat-based processes.

Integrate Process Control and Traceability

100% digital ultrasonic generator gives flexibility in your welding process with multiple modes. When configured with the iQ AiM™ platform and iQLinQ™, the sealing station gives access to set, enable, configure, diagnose, and collect data in an intuitive environment developed for Industry 4.0.

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Ultrasonic Spout Fitment Sealer
Ultrasonic Spout Fitment Sealer
Ultrasonic Spout Fitment Sealing on Gable top cartoons

Overview

Dukane's ultrasonic spout and fitment sealing solution is designed for gable-top carton equipment used in dairy, beverage, and refrigerated liquid-food production. The system brings together the generator, sealed converter or probe, booster and sonotrode, supporting fixture, and application engineering needed to produce a controlled joint around the fitment.

The compact ultrasonic assembly can be engineered into new or existing filling lines. Because the process does not depend on large heated sealing bars, machine designers can reduce thermal management requirements, simplify maintenance, and place the sealing function closer to other high-speed packaging operations.

Applications

Ultrasonic spout and fitment sealing is well suited for gable-top cartons used to package juice, plant-based beverages, liquid eggs, dairy products, and other refrigerated liquid-food products.

Key Features

  • Strong spout-to-carton seals. Controlled ultrasonic welding helps prevent leaks and maintain package integrity.
  • Adhesive-free joining. Eliminates adhesive supply, application equipment, and related consumables.
  • High-speed capability. Short ultrasonic cycles support demanding gable-top carton production rates.
  • Hygienic, washdown-ready options. Sealed probes and converter designs support sanitation-intensive production areas.
  • Minimal thermal exposure. Localized energy protects heat-sensitive products and package materials.
  • Digital process control. Monitoring and traceability support quality assurance and regulated food-production requirements.
  • Lower maintenance burden. No heated sealing bars means fewer thermal components to service and less wear from continuous heating.
  • Compact integration. The ultrasonic stack can be configured for new equipment and retrofit installations.
  • Cleaner operation. Reduced smoke, odor, residue, burn marks, and discoloration compared with heat-based sealing methods.
  • Support for sustainable package design. Adhesive-free joining can simplify material structures and support recyclable packaging initiatives.

Is our Fabric & Film Processing Systems the right fit for your application?

Easily replicate a proven welding process from one Infinity system to another with the 100% digital all-electric control. No adjustments to pneumatics are needed.