World market leader, ultrasonic specialist and family-owned company all in one:
Based on sustainable ultrasonic technology, SONOTRONIC Nagel GmbH develops and produces high-tech systems for joining plastics.
Our special machines, standard machines, assemblies and components are used worldwide in various industries. We are the market leader in mechanical engineering for special machines in the automotive industry. Our machines are used for joining and punching plastic parts in automotive exteriors and interiors at well-known OEMs. We realize concepts for one-man operation up to automated production lines. In addition, we develop and produce for all plastic processing industries, the packaging industry, the food industry, for the textile industry and the environmental industry.
Our experience in joining plastics makes us your specialist for ultrasonic welding, but also punching, riveting, embossing and cutting with ultrasound - and this since 1974. Alternatively and also as a hybrid solution, the processes hot plate, infrared or hot air are used.
Our expanding technology company with over 300 employees has its headquarters in Karlsbad, Germany, and international subsidiaries in the USA, Spain and China.
The high demands in the packaging industry must also be met in joining and cutting technology: convenience, sustainability, flexibility, but also efficiency and cost savings.
Our systems and solutions for sealing, cutting and die-cutting different types of packaging are based on highly developed ultrasonic technology. The extremely gentle process makes ultrasonic technology ideal for packaging heat-sensitive goods. There is no heating of the contents because the tools are cold. Because the seams are completely gas- and liquid-tight, ultrasound makes it possible to seal and simultaneously punch out packages in a single step. Even product buildup in the sealing area does not affect the seam quality, so there is significantly less waste.
Environmentally friendly process with lower energy consumption
Compared to other thermal processes, the energy consumption of ultrasonic sealing is very low. Energy is not supplied continuously, but only during the sealing time. The effort required for maintenance and cleaning of the suitably adapted ultrasonic systems (IP68 possible) is also reduced, since the ultrasonic tools are self-cleaning and are not contaminated by packaging material or product residues.
Appropriate seam geometries for demanding packages
When developing the ultrasonic tools and anvils, we adapt the seam geometries individually to the requirements of the packaging and the properties of the packaging materials. Ultrasound makes it possible to produce seals with peel or tight material and form-fitting seals.
Optimized packaging materials for versatile applications
In order to produce optimum fusion bonds, the packaging materials must have thermoplastic sealing layers. Thus, ultrasound is also suitable for cardboard or paper, as well as packaging materials of more complex structure. In order to better adapt the packing materials to the ultrasonic technology, they are continuously optimized together with the manufacturers.
Fewer packaging materials and no additives
Packaging companies save on packing materials with ultrasound, as it can be used to process both laminates and monofilms reliably and tightly. Only a small amount of film overhang is required in the sealing area for the preferred narrow seams. In addition, no additives are used in ultrasonic sealing, resulting in the possibility of sorted disposal.
More efficient processes with results that can be validated
Process and setup times are very short with our ultrasonic systems. This significantly increases the productivity of packaging machines. Permanent monitoring of sealing parameters ensures process control and reliability. They can be transferred to external EDP systems via an interface.
Modular systems and individual solutions
The versatility of ultrasonic technology enables numerous applications. With modular systems and individual solutions, we meet the requirements of our customers and their packaging tasks - from standard formats to special custom formats. Depending on the application, we also integrate applications for zippers or valves.
Our ultrasonic sealing system for vertical (VFFS) and horizontal form fill and seal (HFFS) machines delivers absolutely tight seals and is extremely material and energy efficient. The cold tools compress the tubular bag for sealing. The ultrasonic vibrations of the sonotrodes then cause the molecular chains in the sealing area to break up, generating heat, and new compounds are formed. Sealing seams of outstanding quality are produced in a very short time. The use of ultrasound reduces the number of faulty seals, since the product itself does not heat up. In addition, filling material located in the sealing area is separated by the ultrasonic effect during the sealing process. The quality of the resulting seam and the barrier layers of the pouch film remain unaffected.
Blisters, trays, bowls and cups
With the patented modular sonotrode table, blisters, trays or cups can be sealed and die-cut in a single step. This eliminates the need for subsequent die-cutting equipment and shortens the packaging process.
Since the sonotrodes that transmit the ultrasound are arranged to form a flat sealing area, the sonotrode table can be used regardless of format. It is sufficient to simply exchange the anvil plate or the pick-up tool in order to change the packaging format. This results in great flexibility in packaging design.
In the case of format-dependent packaging solutions with ultrasound, we adapt not only the pick-up tools to the packaged goods, but also the sonotrodes themselves. Depending on the application, sealing and punching tasks are also combined here.
Our ultrasonic systems are used, among other things, for sealing pre-made stand-up pouches and flat pouches. However, various special formats are not only sealed, but also ultrasonically punched or cut. Applications of zippers or valves can also be integrated.
The biggest advantage of ultrasound over other technologies is that the pouches are sealed absolutely tightly, even if the sealing area is wetted with filling material. The mechanical pre-compression of the cold sealing tools and the subsequent ultrasonic action displace the product from the sealing area. The taste of the product remains unchanged.
Cartons coated with a sealable surface are also suitable for ultrasonic processing. In the case of beverage cartons, this coating is usually made of PE. Ultrasound is used to seal the closures, which are also made of PE, firmly to the sealing layer of the carton.
Another application of carton in packaging is sealing with blister trays. The layer on the carton must be adapted to the material of the blister. The transparent blisters, usually thermoformed from PET, allow the product to be optimally displayed, while the welded carton serves to convey product information.
When it comes to ultrasonic tube sealing, SONOTRONIC has already realized various projects, for example a joint development with the company Tubex_Wasungen: a tube without a shoulder is ultrasonically sealed.
Compared to conventional tubes, the SL-T® shoulderless tube from Tubex Wasungen saves up to 40% of material. At the same time, the ultrasonically welded cap forms a homogeneous unit with the tube, thus avoiding unwanted residues in the cap and opening up new possibilities in tube design for the tube manufacturer. The shoulderless tube thus enables the realization of ecological, functional, sustainable and, above all, cost-conscious packaging. The production process and the diverse design possibilities of the tube have already received several awards, including the German Packaging Award.
In addition, the tube sealing unit from SONOTRONIC seals the ends of tubes securely and tightly.
As your partner for packaging solutions with ultrasound, we accompany you from product development to product launch.
In our application technology laboratories, we investigate your packaging tasks and carry out tests, sample work and development projects for you. We use state-of-the-art analysis and testing methods to find the optimum solution. With our many years of experience and our special know-how in the field of ultrasonic technology, we also succeed in solving difficult packaging tasks.
We adapt our innovative ultrasonic systems individually to the various requirements and customer wishes, or design special custom-made constructions. We develop and manufacture our systems both for installation in new lines and for integration into existing lines.
All our ultrasonic systems for packaging technology are perfectly matched and comply with protection class IP68. With the consistent quality and environmental management according to the proven standards DIN EN ISO 9001 and DIN EN ISO 14001 in our company, we meet the requirements of our customers.
SONOTRONIC Ultrasonics Technology Nagel GmbH offers you products from these product groups:
SectorThe products and/or services can be used in the following branches of industry.
- Food and luxury food (e.g. meat products, fruit and vegetables, confectionery; tobacco products) (919)
- Beverage (e.g. soft drinks, liquid dairy products, beer, spirits) (581)
- Pharmaceuticals (e.g. drugs such as tablets, ointments; infusion solutions) (672)
- Medical devices (e.g. implants, infusion sets, X-ray equipment) (462)
- Cosmetics (e.g. perfumes, creams, make-up) (622)
- Chemicals (e.g. varnishes, adhesives, cleaning agents) (535)
- Automotive (e.g. body parts, headlights, tyres) (515)
- Health care (e.g. body care products, hygiene products) (590)
- Pet food (e.g. wet food, dry food, food snacks) (593)
- Non-food, other consumer goods (e.g. textiles, toys, jewellery) (618)