Using data to achieve the perfect packaging process

Data is also the new oil in the packaging industry: it helps to make the process even safer, even more efficient and even faster. We show how companies can digitize their packaging process with ultrasonics to gain a competitive advantage.

Digitalization is playing an increasingly important role in the modern packaging industry, especially when it comes to sealing packaging with ultrasonics. Measuring and analyzing digital data enables precise process control in real time, which helps to reduce rejects and optimize the entire production process. 

But how does digital data acquisition work in ultrasonic sealing and what advantages does it offer?

How digital data is collected during ultrasonic sealing

Ultrasonic sealing creates vibrations that are applied to the sealing area of the packaging. The films bond at a molecular level due to the frictional heat generated while pressure is simultaneously applied. 

This process can be monitored in real time using modern sensors and control technology. As there is direct contact between the welding tool and the packaging material, key parameters such as welding force, amplitude, frequency and time can be precisely measured. This data is saved in the generator and is ready for further evaluation.

Real-time control of the sealing process

Real-time control is one of the biggest advantages of digital process control. By continuously monitoring the parameters, deviations can be detected and corrected immediately. This enables high precision and consistency in the sealing process. 

For example, the system immediately detects deviations in the distance, for example if there are two pouches in the sealing station. In this case, the generator can send a signal directly, which initiates the rejection of the packaging. 

This is a major advantage, as it was previously almost impossible to identify individual leaking packaging, or only with a great deal of manual effort. Automated quality control during sealing with ultrasonics therefore saves enormous resources.

Process optimization through data evaluation

Another important aspect of digital process control is the ability to use the collected data for process optimization. By analyzing the data, trends and patterns can be identified that provide indications of possible improvements in the sealing process. 

In addition, it is also possible to optimize processes for specific parameters - for example, if the process needs to run as quickly as possible but there are more tolerances in the strength of the seal.

Conclusion

Digital process control for ultrasonic sealing of packaging opens up new opportunities for the packaging industry to increase the efficiency and quality of its production processes. 

Real-time monitoring of critical parameters can reduce reject rates and increase the safety of the packaging line. 

In addition, data evaluation offers valuable insights for continuous process optimization. The digitalization of ultrasonic sealing thus represents an important step towards more efficient and sustainable packaging production.

Use data to pack your Ready Meals more efficiently than ever before. Find out more!