Monitor perforation quality in real time

IT CAN be difficult to monitor and ensure the consistent quality and diameter of micro holes in transparent films. These holes usually have diameters of less than 120 microns while the packaging film moves 100-400 m/min, according to ROFIN, a leading provider of laser-optimized flexible packaging. Recently, the company introduced a cutting-edge laser solution for this purpose. 

 

 

 

The first of its kind, the VisionPerfoControl can monitor perforations of hole diameter and percentage roundness in real time. To work precisely, each laser perforation head is fitted with a camera and the output of each camera is processed using pattern recognition software to record the dimensions of the holes. This allows for validation of the micro perforation process and eliminates incorrect set-up (e.g. focus error) from affecting the output from the perforation system. The recorded data documents 100% perforation quality of the processed material.

 

Many converters use the company’s StarMAP, a smart software solution for designing micro-perforation based on a product’s oxygen-transmission rates and individual storage conditions. It contains USDA approved database for more than 160 products (fruits, vegetables, whole / fresh cut). Introduced to the market in 2013, it offers package optimization possibilities which used to be reserved for big players. 

 

To choose the right micro-perforation pattern for a fresh product, say mangoes, the user has to determine the oxygen-transmission rates using the O₂ Check Kit. A sample of the product is placed in the sensor-equipped test-box and then in the climate cabinet. The software will record the oxygen-transmission rates over time and generate a new database record for this specific product. This new solution will help even small and medium-sized converters to offer individually and seasonally optimized modified atmosphere packaging for fresh produce.