Ultrasonic welding of thermoplastic materials by sector Poultry

La ultrasonic welding represents a technologically advanced and highly efficient solution for combining thermoplastics employed in the poultry sectorparticularly in the construction and maintenance of strategic components such as the manure conveyors and the egg ribbons. This is a well-established technology that is still expanding rapidly, thanks to the increasing focus on automation, hygiene and durability of livestock facilities in Europe and Italy.

What is ultrasonic welding and how it works

La ultrasonic welding is a joining process without the use of glues, solvents or mechanical elements. It is based on the use of high-frequency acoustic waves (typically between 20 and 40 kHz) to generate localised heat between two thermoplastic surfaces, which melt due to internal friction caused by vibration and weld together once cooled.

In the poultry industry, this technology is ideal for welding materials commonly used to transport pollen e eggs.

Advantages over other methods

Compared to other joining technologies (such as heat welding, bonding or mechanical stitching), ultrasonic welding offers numerous competitive advantagesincluding:

• Absence of contaminantsno use of glues or solvents, ideal for environments requiring high standards of hygiene.
• High mechanical resistanceThe joints are strong, durable and able to withstand cyclic loads.
• Precision and speedThe process is highly repeatable and suitable for mass production.
• Reducing operating costsminimum maintenance and optimised production cycle.
• Compatibility with health and food regulationsperfectly smooth welds, without cracks or dirt build-up.

These advantages are crucial to ensure business continuity in poultry plants, where the efficient waste management (such as pollen) and the delicacy in transporting eggs represent critical needs.

Industrial applications: chicken and egg tape

Two significant examples of the application of ultrasonic welding in the industry:

Manure conveyor belt

The pollen tape is an essential component in breeding systems, particularly in the batteries for hens. Ultrasonic welding makes it possible to:

• realise longitudinal and transverse joints perfectly hermetic,
• avoid the accumulation of organic material,
• resist frequent washing with disinfectant agents.

The use of seamless welded tape improves the hygiene performance of the farm and reduces downtime due to breakdowns or jams.

Egg ribbon

The egg conveyor belt requires flexibility, regularity of movement and gentleness in contact with the product. Ultrasonic welding makes it possible to achieve:

• smooth and uniform surfaces that prevent the shell from breaking,
• seamlessly integrated with the rest of the tape,
• adaptability to the bending radii of automated systems.

Again, the precision of ultrasonic welding is superior to traditional methods and allows reliable transport even over long distances or with varying gradients.

Technical requirements: frequencies, powers, machinery

For poultry applications, Sonomax Srl provides solutions that typically operate at:

• frequencies of 40 kHz,
• powers between 250 and 400 wattsconfigurable according to the type of welding,
• portable systems according to the customer's production requirements.

Le Sonomax ultrasonic welders are designed to offer maximum flexibility and adaptability even in dusty or humid environments, typical of the livestock sector. They are available in both manual version for minor maintenance work.

Reference Standards

The solutions proposed by Sonomax Srl are designed for high technical reliability and easy integration with customers' quality control procedures.

The answer from Sonomax Srl

With over 20 years of experience in the field of ultrasonic welding, Sonomax Srl stands out as a reliable partner for operators in the poultry sector. Thanks to an approach geared towards customised design and constant technical support, the company is able to:

• analysing specific needs of the farm or plant,
• customise machine configuration and the accessories for conveyor belts,
• offer staff training e rapid after-sales service and on time throughout Europe.

Discover our models of manual welders.