Chase Machine and Engineering
The hygiene market is one of the nonwovens industry’s largest segments. Baby diapers and adult incontinence products along with feminine hygiene products are unique in their usage compared to products in other industries as they contact the user for a period of time. This requires the material to be soft and flexible in nature along with the ability to wick and absorb fluids. By combining layers of various nonwovens, each designed with their own unique characteristics, manufacturers have the ability to create application specific products.

Over the years, the challenge has always been the same. Products need to be softer, more flexible, lighter and more absorbent too. Fortunately, ultrasonic technology is a great solution for these challenges.

Ultrasonics is a clean and efficient method of embossing, laminating, slitting and splicing synthetic materials. And from a quality standpoint, the consistency of the bond or pattern is unmatched.
Other technologies such as sewing for instance, produces holes, which create leak paths while also requiring the use of consumables such as needle and thread. Gluing requires the purchase of consumables as well, adding cost to the final product. In addition, glue adds weight, reduces breathability and may effect flexibility. Finally, glue systems must be cleaned and serviced frequently to prevent blockages, which effects quality and generates waste.

The ultrasonic process uses the actual chemistry of the fibers that, when exposed to the technology, melt the fibers creating a molecular bond that is superior to that of an adhesive. An ultrasonic bond penetrates through the fabric unlike adhesives that sit upon the surface of nonwovens. Furthermore, the bond won’t breakdown like some adhesives when exposed to heat or fluids
For over 40 years, Chase Machine and Engineering has been designing and building custom machinery with a primary focus on the integration of ultrasonic technology for continuous and intermittent web converting applications. Working with the industry’s leading suppliers of ultrasonic technology, Chase supplies ultrasonic laminators, embossers, slitters and splicing equipment to manufacturers of nonwoven materials and converters to produce a variety of products.

Chase’s facility, located in Rhode Island, has a dedicated lab for continuous ultrasonic testing. Customers may send product samples to Chase in order to collect invaluable data such as bond strength, embossing quality, slit quality, power requirements and processing line speed. Information that is crucial in determining quality, feasibility and payback.
www.chasemachine.com

Emerson
Emerson’s Branson ultrasonic technologies have provided reliable and energy efficient manufacturing solutions for nonwoven fabrics used in personal hygiene, infection-control, PPE and other products where strong, hermetic seals and consistent quality are required.

The Branson DCX Series is a family of four ultrasonic welding power supplies that are purpose-built to optimize every facet of nonwovens manufacturing. The DCX S power supply offers closed-loop amplitude control, programmable starting ramp-up times and multiple weld modes for continuous cutting, seaming and bonding operations. The DCX A and F power supplies offer additional capabilities, including enhanced weld parameter settings to achieve consistent weld quality through continuous system monitoring and closed-loop control of the welding process. Their versatile Fieldbus and Ethernet/IP communications capabilities also make it simple to combine multiple welders into a single network that communicates with a PLC to enable real-time weld data collection and distributed weld quality control. All DCX Series power supplies offer space-saving designs with multiple form factors—horizontal, vertical with side mount, rack mount and rear plane mount—to simplify system layout and installation.

Standing behind every solution are Emerson engineers at its network of world-class application labs. At a customer’s site or Emerson’s, Emerson’s talented engineers can test materials, troubleshoot application problems, explore and develop ideal nonwovens production parameters, and deliver solutions that ensure repeatable, high-quality production.

Emerson offers best-in-class technical support and training through quality aftermarket maintenance, reliability, and performance programs. So, whether a customer manufactures at a single site or has several locations across multiple continents, Emerson’s global network of 70 technical centers, sales and local offices will help keep operations compliant and running at peak efficiency.
www.Emerson.com/Branson

Herrmann Ultrasonics
Elastic thread handling and fixating can be complicated and costly when it comes to producing hygiene products. Herrmann Ultraschalltechnik GmbH & Co.KG, Germany, has developed a novel way of fixating elastics, which allows uncomplicated thread handling, reduces the risk of breakage, increases the process window and lowers production costs.

The innovative process creates a tunnel between the two layers of nonwoven, through which the stretched elastic thread is guided. Specific designed bonding areas are created, the thread is anchored, then relaxes after cutting the product and is clamped by the weld spots. A wide range of material combinations, different threads (dtex), elongations and speeds have been successfully tested. Easy positioning of multiple threads is one of many advantages of this development.

This new anchoring process can be executed intermittently or continuously. Further innovations in controlling the signal of the ultrasonic generator ULTRABOND allow for “triggering” the ultrasonic vibrations extremely fast in the right places rather than inducing a continuous signal. Thus format-dependent tools are no longer needed, as the areas to be bonded can be configured freely while rendering a format anvil drum unnecessary. With less costs for tools and less time for format changes, the Overall Equipment Efficiency (OEE) is greatly increased.

Multi-dimensional process monitoring is possible by combining the generator signal feature with the proven MICROGAP technology by Herrmann, which controls the gap in the bonding area and ensures a constant bonding quality and direct system feedback.

Herrmann Ultraschall works closely with its American subsidiary Herrmann Ultrasonics Inc. in Bartlett, IL. Uwe Peregi, president of Herrmann Ultrasonics Inc., says: “This new process, we call ‘Anchoring’, will support our North American customers even better, as they strive to create products that are softer and more sustainable.”
www.herrmannultrasonics.com

Sonobond Ultrasonics
For ultrasonic assembly of personal hygiene products, manufacturers most often request Sonobond Ultrasonics’ SeamMaster Ultrasonic Sewing Machines. This equipment produces strong, fully sealed barrier seams with ultrasonic vibrations, eliminating the leaking issues caused by stitch holes, glue gaps, fraying or unraveling.

The SeamMaster’s rotary operation – similar to a conventional sewing machine – channels the ultrasonic vibrations to soften and fuse synthetic materials. This creates soft-to-the-touch seams that are also sealed, secure, and ultra-reliable.

These smooth and sealed seams are comfortable to the skin as needed for such products as incontinence panties designed for children and adults. The SeamMaster bonds water-repellent material to form the panties’ insert pocket and/or inner lining, providing an essential leak-resistant barrier. The SeamMaster is also the preferred ultrasonic machine for making other PPE items such as medical gowns, face masks, caps and booties.

Since costly needles, thread, glues and other consumables are no longer needed, manufacturers can realize substantial production savings. Additional measures required by traditional assembly methods to ensure leak-proof seams are also eliminated, which can boost output by more than 25%.

The SeamMaster provides sealed, leak-proof seams for disposable hygiene products made with 100% synthetic woven or nonwoven materials, or blends with up to 40% natural fibers. These include pillow covers, mattress pads and mattress covers required by those with incontinence issues. Additionally, lint-free gauze and wound dressings with sealed edges can be produced with the SeamMaster.

Sonobond offers no-obligation viability testing, using a manufacturer’s own materials and applications, to produce sample assemblies before a machinery purchase, in order to confirm its equipment satisfies its customer’s specific requirements. Sonobond also provides service and technical support before, during and after installation, ensuring its equipment is properly incorporated into the production process.
www.sonobondultrasonics.com