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THE FUTURE OF PACKAGING LASER SOLUTIONS FOR THE PACKAGING INDUSTRY WE THINK LASER
THE FUTURE OF PACKAGING
LASER SOLUTIONS FOR THE PACKAGING INDUSTRY
W E T H I N K L A S E R
In today’s consumer goods market thecustomers’ buying decision is stronglyinfluenced by shelf presentation andconvenient product handling.Thus, converters are more and more oftenasked to deliver innovative packagingsolutions which are one step aheadof the crowd. As glossy high-end printingis very common nowadays, new USPsneed to be found.
Laser-optimized packaging makeslife easierThe modern customer expects more thanjust nice printing! Lasers are the key technology for smart packaging with anadded value. Laser scribed easy-to-openlines and laser perforated monolayer filmsfor enhanced shelf life of perishable freshfood are already widely used in the food industry.
From Easy Opening to ModifiedAtmosphere PackagingLaser-optimized packaging is simply better.There is no need to explain the benefit ofa laser scribed easy tear line on a doypack, not only for the growing elderlypopulation. Various other aspects promotethe use of micro-perforated pouches forsalad and vegetables. Controlled oxygenexchange considerably enhances perisha-bles’ shelf life which also leads to lesswaste, reduces overall costs and helps toprotect the environment.
Discover howROFIN’s laser technologysmartens up your packaging!
LASER -The Key Technology for the Packaging Market
With more than 52.000 systems installedworldwide, the ROFIN group is a marketand innovation leader for lasers and laser-based solutions for industrial materialsprocessing. No matter whether it is cutting,welding, marking or surface treatment,whether it is a CO2, fiber, solid state,diode or ultra-short pulsed laser - ROFINoffers the optimal laser technology todayfor the applications of tomorrow.
ROFIN‘s CO2 expert group in Gilchingnear Munich is the market leader for laser-optimized flexible packaging and co-operateswith the major packaging converters. Thecomprehensive knowledge about packa-ging material gained during many yearsof experience helps to design new lasersources tailored for this important market.ROFIN develops laser processes for thepackaging industry on their own windingsystem and lab equipment. Customers arewelcome to send material for free trials.
STARPACK® CW
STARPACK® POUCH STARPACK® HP
STARPACK® WD STARPACK® AP
The StarPack® Product LineThe comprehensive but straightforward product line-up. Each StarPack model provides the basis for a tailor-made solution.
StarPack® CWCross web applications and free form scribing
StarPack® WDWeb direction scribing and perforatingwithin one process
StarPack® APCross web and web direction in onesystem
StarPack® HPHigh-power scribing and cutting of thickmaterial
StarPack® PouchFor integration in pouch making machines
ROFIN - The Market Leader for LaserSolutions in the Packaging Industry -the New StarPack® Line
Cross-web applications and freeform scribingStarPack ® CW systems are designed for selective scribing of packaging layers inthe cross-web direction. This correspondsto the typical manufacturing process ofbags and pouches. Beyond that, StarPack®
CW systems can make arbitrarily shapedscribing lines, suitable for re-closableflaps or circular easy tear lines in thecorners of packaging.
High performance scanner heads withwith 2 or 3 axes offer extremely fast beampositioning with an enormous workingfield. The goal is subtle, visually unobtrusi-ve scribing lines. Depending on the appli-cation, web width and other customer‘srequirements, ROFIN mounts up to 9 lasersources on a StarPack® CW system.Typically ROFIN‘s laser solutions are inte-grated into the slitter winder.
ROFIN‘s sophisticated controlling softwareassures precise laser beam positioningand complete web movement compensation.The selective weakening of packaging layersis achieved by precisely controlling thelaser energy. Three different wavelengthsfacilitate optimum adjustment to theabsorption properties of the selected packaging films.
MULTIPLE SCAN HEADS
ANY FORMS
UP TO 9 GALVOS POSSIBLE
StarPack® CW
STARPACK® CW
StarPack® WD
Web direction scribing and perfo-rating within one processWith up to 8 processing heads as a stan-dard - more are available on request -StarPack® WD systems handle almost anyweb direction application. The mainapplication area is the perforation ofpackaging films for fresh food to obtain acontrolled atmosphere within thepackaging. Hole sizes for this type ofapplication are in the range of 50 µm to300 µm depending on the material.Thanks to its newly developed controllingsoftware scribing and perforating can becombined within one process!The software allows the mixing of holesizes, scribing lengths and patterns all atthe same time. This allows for straightfor-ward cost-efficient manufacturing of packa-ging with controlled atmosphere and easyopening functionality in web-direction.
The StarPack® WD is designed toaccommodate up to 2 laser sources as astandard - more are available on request.As with all StarPack® systems, scribing andperforating is being synchronized with thepackage print. For optimum processing ofthick packaging films and demanding com-posite material at high web speed, thesystem can be equipped with ROFIN‘sweb movement compensation (WMC).
STARPACK® WD MODULAR SYSTEM ON 2 LEVELS
FINEST EASY-TEAR LINES VARIOUS MATERIALS
The universal solutionThe StarPack® AP (All Purpose) is thepackaging all-rounder, combining CW andWD functionality in one system. Thismakes it an ideal choice for complexmanufacturing processes and for converters who want to be perfectly preparedfor customers’ future requirements.
Each scribing and perforation applicationdiffers.Various components of a lasersystem have great influence on the properties of a scribing line or the size ofa perforated hole: laser source, galvo scanner or laser optics. The StarPack® APoffers the entire range that modern lasertechnology can provide for the packagingindustry.
ROFIN LASER SOURCES WITH DIFFERENT WAVELENGTHS STABLE FRAME WORKS
3 AXIS GALVO FOR CW SCRIBING FIXED OPTICS FOR WD SCRIBING & PERFORATION
StarPack® AP
Even different types of lasers can be inte-grated within one system. The StarPack APprovides the basis for future all-roundsolutions that enable you to meet allcustomer needs.
STARPACK® AP
Simple shapes at utmost webspeedHigh-end scanner heads scribe commonlyused semi- and quarter-circular openinglines at several hundred meters per minute.
Perforating of pressure valves formicrowaveable packagingPerforation of a row or a small area ofmicro holes enables a valve-likefunctionality for microwaveablepackaging. The steam which developsduring preparation escapes throughthe tiny holes.
PERFORATION OF PRESSURE VALVES CLASSIC PERFORATION OF BOPP
SIMPLE FORMS AT HIGHEST WINDING SPEED
DOUBLE EASY-TEAR LINE
COMPLEX FORMS CLASSIC EASY-TEAR LINE
Complex contoursUp to 9 lasers and deflection units realizehighly-complex scribing lines at high web-speed.
Dual easy-tear linePrecise double-spot focusing lenses areused for splitting the laser beam, resultingin dual easy tear lines which help to optimize easy opening.
Classic simple easy-tear lineEspecially single-portion sachets, e.g. forinstant coffee (3 in 1) require cross webscribing on the winder. Web speeds of upto 500 m/min are possible for this application.
Classical perforation of BOPP The StarPack® AP also handles the standardmicro perforation e.g. of pouches forsalads or vegetables. BOPP mono layerfilm is perforated with 3 - 8 micro holes.This enhances shelf life up to one week.Equipped with the innovative WMC module,perfect circular holes from 50 µm - 300µm diameter - depending on the material -can be perforated even at high web speed.
StarPack® AP - The Entire Rangeof ROFIN‘s Scribing and PerforatingKnowhow in One Solution
Compact solution for pouchmaking machinesThe space-saving, compact system, designedfor integration in pouch making machines,complements the range of laser systems foreasy opening. It provides a solution forfood producers who are looking for alaser scribing system that can be useddirectly after pouch forming or within theform fill and seal unit.
As web speed in pouch making systems isconsiderably lower than in slitter winders,100 W laser power is more than sufficientfor optimum scribing results. StarPack®
Pouch is the cost-efficient alternative usinglow power laser sources and simultaneously offers easy integration.
CUTTING OF SINGLE PORTION TRAYSSTARPACK® HP CARDBOARD CUTTING
POUCH - BOTH SIDES SCRIBEDSTARPACK® POUCH EASY OPENING OF PAPER TISSUE
StarPack® Pouch StarPack® HP
High power scribing and cutting ofthick packaging materialCutting and scribing of thick packagingmaterial such as cardboard and thermo-forming films is a promising newapplication area for laser systems.Compared to a laser, mechanical cuttingand punching techniques are prone towear and tear and require cost-intensivemodifications every time the packagedesign changes.
With laser sources from 1000 W to 2500 W the StarPack® HP cuts even thickpackaging material on-the-fly at full webspeed. A new high-end scanner systemhas been especially designed for this typeof application and laser sources with apower of more than 2000 W. With animpressive working area of over 1 m2
and at the same time very small spotsizes, the StarPack® HP is a true alternativeto a punch.
WMC – Precision perforation atall timesThe packaging industry calls for perforationwith perfect and consistent quality. Thebetter the perforation the bigger the shelflife advantage. Multi-chamber trays requiredifferent perforation to optimize the storagelife of the contents in all particular chambers.
STARPACK® WD - PULSED LASER ONLY
STARPACK WD - PULSED LASER ONLY STARPACK® WD - PULSED LASER WITH WMC ABSORPTION (%) - WAVELENGTH
The right wavelength makes thedifferenceThe various polymers which are commonlyused in the packaging industry show different absorption properties at 10.6 µm,which is the industrial standard wave-length of CO2 laser sources. Especiallypolypropylene can be processedconsiderably faster at shorter wavelengths.Consequently, lasers with 10.25 µm wave-length realize tremendous higher scribingand perforating speeds for PP-based polymers.
ROFIN is the only laser manufacturer whohas the capability to drive its developmentof new laser sources towards the benefit ofthe flexible packaging companies. The result is a CO2 laser range from 10.60 µm to 10.25 µm to 9.35 µm atvarious power levels.
ROFIN‘s web movement compensation(WMC) system provides completecompensation of web movement andsafeguards perfect circular holes of thedesired size under all conditions. Thusproduction waste is reduced significantlyand maximum web speed more thandoubles. The solution encompasses acomprehensive speed range, from 0 m tomore than 380 m per minute and can befitted and retrofitted in all StarPack® WDand AP systems.
10m/min 50m/min 100m/min 150m/min 200m/min 250m/min
10m/min 50m/min 100m/min 150m/min 200m/min 250m/min
ROFIN – CO2 Systemswith Own Developments for theFlexible Packaging Industry
Typical Transmission Spectrum for clear PP Film (24 µm)
Wavelength (µm)
Transm
ission (%)
StarFLEXThe All-in-one Graphical User Interface forAll Laser Systems
STARFLEX SOFTWARE
CHOICE OF LANGUAGES
COMFORTABLE AXIS ADJUSTMENT
StarFLEX The software developed by Rofinfor all flexible packaging applicati-ons
StarFlex can control web direction andcross web systems at the same time. Eachlaser source and processing head can beactivated separately. All necessary para-meters, like offset, rapport length andtrigger features can be intuitively adjustedand saved to the layout. Each laser canrun with a different layout and parameterrecipe. To create a layout the access to theRofin editors VLM and WD is embeddedin StarFLEX.
In addition, various components likemotorized focus axis and positioning axiscan be easily controlled by the software.These settings are saved in the parameterrecipe as well. An automatic powermeasurement allows you to record thequality of your laser.
Quality, convenience and safetywith the graphical user interfaceStarFLEX
A sophisticated trigger control allows youto guarantee your customer a 100% checkof the eye marks. Each missed mark isreported and you can define when thesystem will automatically stop.For operator convenience the language ofthe software can be changed by one click.Meanwhile more than 12 languages areavailable. For your safety you can defineaccess rights for different employees.
StarFLEX provides the following information:
� Current web speed� Running length� Real time distance of trigger rapport� Number of trigger� Detailed workload status of
each laser system� Processing time
StarMAPThe Smart Software Solution to DefineHigh Precision Perforation Parameters
To provide the best possible shelf life andproduct quality, StarMAP takes thefollowing parameters into account:
� Product: fruits, vegetables,whole/fresh cut
� Product volume� Storage temperature� Type of packaging film� Packaging geometry
StarMAPThe smart software solution to pro-vide precisely the number of holesfor various packaging designs
When shopping fresh products customersdefinitely choose the products, which lookfresh.
It is well-known perforation of thepackaging film extends product’s shelf lifeand preserves its good looks for a longerperiod of time – but how many holes forwhich product?
ROFIN’s StarMAP software has the ans-wer! It provides the ideal hole number of acertain size to guarantee high productquality of the packed goods. Based on anUSDA approved database it uses ascientific approach to calculate correcthole number for an optimized OTR value.This makes long test series become history.
MATERIAL TYPE CONSIDERED
WEIGHT OF PRODUCT CONSIDERED
STARMAP SOFTWARE
Reliable calculation of the holenumber for different productsbased on your own database
The software can be used with any ROFINweb direction laser system solution forperforation like StarPACK® WD andStarPACK® AP.
The software is bringing numerous benefitsto film and packaging suppliers as well asfood processors e.g.:
� Reliable calculation ofmicro-perforation
� Fast and easy adaption to different products and types of packaging
� Less costly and time consumingtrial & error
� Reduced waste� Easy to use and comfortable user
interface� All contained database information
is yours� Optional device for measurement of
respiration rates on site to create your own additional database
time and generate a new database recordfor this specific product. With this newsolution every converter will be able tooffer individually and seasonally optimizedmodified atmosphere packagings for freshproduce.
� All-in-one package, includes hard and software
� Simple and user-friendly measurement process
� Automatic database update� Individual and seasonal
MAP-optimization
StarMap comes with an USDA approveddatabase of more than 160 products(fruits, vegetables, whole / fresh cut). Thisdatabase is a good point to start from. Butthere is still room for optimization andmajor converters are already addressingthis point.
However oxygen-transmission rates offresh food vary, as growing area andharvest time have a certain influence.With the O2-Check Kit, ROFIN now opensthe same possibilities for small and medi-um-sized converters. It comes with a sen-sor-equipped, air-tight container, a highlytemperature-stable climate cabinet andsmart evaluation software.
With O2-Check Kit adapting your micro-perforation pattern to varying circum-stances is a breeze. Just put a sample inthe sensor-equipped test-box and place itin the climate cabinet. The software willrecord the oxygen-transmission rates over
VARIOUS PRODUCTS - REGIONS - GROW & HARVEST CONDITIONS
O2-Check Kit - Individual MAPOptimization Package
O2-CHECK KIT
VISIONPERFOCONTROL OBSERVATION SCREEN
True, real-time monitoring of the perforati-on process to ensure consistent quality anddiameter of the holes is a demanding task.Typically, perforation holes have diametersless than 120 microns while the packa-ging film moves with some 100 m/min.Consequently, there have been no ready-to-use solutions on the market up to now.ROFIN is the first supplier to offer true real-time monitoring of perforation hole diame-ter and percentage roundness. Each laserperforation head will be fitted with a high-speed camera and the output of eachcamera is processed using pattern recogni-tion software to record accurately thedimensions of each hole.
VisionPerfoControl
VisionPerfoControl allows for validation ofthe hole perforation process and elimina-tes the possibility of incorrect set up (e.g.focus error) from spoiling the output fromthe perforation system. Furthermore, therecorded data documents 100% perforati-on quality of the processed material.
� True, real-time monitoring ofperforation quality
� Checking roundness and diameter� No production waste due to
incorrect set up� 100% quality control documentation
HIGH END VISION SYSTEM
Specifications
WD - WEB DIRECTION CW - CROSS WEB
StarPack® WD CW AP Pouch HP
Free Form Contour Scribing no yes yes no yes
Multiple Head Web Direction Scribing yes (x)* yes yes (x)*
Max. Number of Individual Scribing Lines 2/4/6/8 1 - 9 CW 9 2 1 more on request WD 2/4/6/8 more on request
Number of Lasers 1 - 9 1 - 9 1 - 9 1 1 - 9
Power per Laser 100-650 W 100-650 W 100-650 W 100-200 W 1000-2500 W
Number of Super Fast Galvo Heads - 1 - 9 1 - 9 - 1 - 9
Tailor-made Safety Housing (class 1) & Frame Works optional yes yes yes optional
Web Width up to 1800 mm up to 1800 mm up to 1800 mm up to 1800 mm up to 1800 mm
Web Speed (depending on material) 700 m/min 600 m/min 600 m/min 600 m/min 600 m/min
Web Movement Compensation (WMC) yes no yes no no
(x)* Galvo mirrors can be switched to a fixed position to scribe in web direction.
WWW.ROFIN.COM
ROFIN-BAASEL LasertechGmbH & Co. KGZeppelinstraße 1082205 GilchingGermanyPhone +49 8105-3965-0Fax: +49 8105-3965-4159E-mail: [email protected]
ROFIN-SINAR Laser GmbHBerzeliusstraße 8722113 HamburgGermanyPhone +49 40 733 63 0Fax: +49 40 733 63 4100E-mail: [email protected]
ROFIN-SINAR Laser GmbHDieselstraße 1585232 Bergkirchen-GündingGermanyPhone +49 8131 704 0Fax: +49 8131 704 4100E-mail: [email protected]
Benelux: Phone +31 78 69310 37E-mail: [email protected]
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CN: Phone +86 21 68552216E-mail: [email protected]
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Find further representatives andpartners on www.rofin.com/worldwide
© COHEREN
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ROBI/Selected options and detailed technical specifications on request. All data are subject to change without further notice.
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