Ultrasonic technology – a great choice for the environment

Electrical Motion Serie – elektrisch betriebene Ultraschallschweißmaschinen. © RINCO ULTRASONICS / Electrical Motion series – electrically operated ultrasonic welding machines. © RINCO ULTRASONICS

Nachhaltige Tragetaschen aus Maisstärke mit Ultraschall geschweißt. © RINCO ULTRASONICS / Sustainable carrier bags made from maize starch and welded using ultrasonic technology. © RINCO ULTRASONICS

Gewürzstreuer aus biobasiertem Kunststoff. © RINCO ULTRASONICS / Herb and spice shaker made of bioplastic. © RINCO ULTRASONICS

Using ultrasonic technology offers numerous eco-friendly benefits when manufacturing products. As an example, ultrasonic welding consumes significantly less energy than thermal welding.

Another of its green credentials is that it does not need any solvents or other additives, allowing materials to be used more efficiently and making it easier to separate materials for recycling.

Using ultrasonic welding technology in food applications also creates accurate cuts, promoting conditions that are extremely clean and precise. Not only that, but it is hardly ever necessary to clean blades.

Production waste is reduced and less food needs to be thrown away. All in all, the advantages that ultrasonic technology brings help ensure that production is more sustainable.

Sustainable plastics processing with ultrasonic technology

One of the properties of plastics is a long life – something that brings both benefits and challenges. While the inherent durability of plastics creates products that last longer, managing the waste they create can be difficult when products reach the end of their lives. This is why plastic disposable products are not the most eco-friendly choice. Despite this, plastic products and components with sophisticated technology have a useful role to play in many sectors of industry and make conditions more sustainable. To name one example, plastic is used in mobility applications to provide heat insulation or serve as a lightweight option that makes it possible to cut down on energy and resources. As a material, plastic does not weigh much and demonstrates both thermal and electrical insulation capabilities – and it can even insulate sound. Its flexible nature allows it to accommodate even complex designs, and in most cases it can be processed with only small amounts of energy.

In recent years, there has been increased investment in research focusing on renewable resources, biodegradable plastics and how to implement circular economy and recycling processes, the aim being to help create more sustainable ways of managing the resources that our planet provides. RINCO ULTRASONICS is actively involved in this, contributing its extensive expertise in ultrasonic technology to numerous projects. RINCO ULTRASONICS develops ultrasonic welding and cutting machines for plastics processing.

Equivalent weld seam quality with maize starch

Test welds on materials made of maize starch have shown that the properties of weld seams on carrier bags made of this material are identical to weld seams on carrier bags made of plastic, and can be welded without the need for any additional resources. As a result, these welds deliver exactly the same standards of quality and durability, and maize starch proves a successful substitute for synthetic fibres. Not only that, but the carrier bags can be composted easily after use.

Ultrasonic technology reduces energy demand

To take an example from the medical industry, a project conducted for a RINCO ULTRASONICS customer in this sector demonstrated impressive energy savings of 78%. This outstanding reduction was achieved by replacing a pneumatic ultrasonic welding machine with a new, equivalent model: an electrically operated machine from the Electrical Motion series. In the process of manufacturing filters for ventilators, the Electrical Motion ultrasonic welding machine made it possible to cut down energy demand by more than three quarters.

The welding cycle time was also halved from two seconds to one – and the weld seam quality was even improved.

Weldability of bioplastics

When made of bioplastic, a herb and spice shaker is a modern gadget that is not only a handy tool, but a more environmentally friendly one too. A key point to consider when switching from conventional plastic to bioplastic to create the same product design is whether the design can actually be retained in its current form. Test welding on a RINCO ULTRASONICS ultrasonic machine has shown that a new, identical herb and spice shaker made of biomaterial achieves the same outcome as one made of thermoplastic.

Ultrasonic technology: the conclusion

Ultimately, ultrasonic welding is a sustainable joining method that does not require the use of solvents or other additives, making it easier to separate materials for recycling. In addition, ultrasonic welding is energy-efficient and improves the environmental impact of products for users. Compared to thermal welding, ultrasonic welding achieves a significant reduction in energy demand. Additionally, it is worth switching from a pneumatic ultrasonic welding machine to an electrically operated one on account of the huge energy savings that can be attained.

It is extremely important to take a prudent approach when handling natural resources and food. From this point of view, using ultrasonic technology for cutting food offers a range of advantages: it creates clean, reproducible cuts and minimises the amount of waste created during production. Not only that, but it is rarely necessary to clean blades – cutting down on the use of water and cleaning agents, and reducing the impact on the environment as a result.