LASER SOLUTIONS FOR THE PACKAGING INDUSTRY

WE THINK LASER

THE FUTURE OF PACKAGING

In today’s consumer goods market the custo-mers’ buying decision is strongly influencedby shelf presentation and convenient producthandling. Thus, converters are more andmore often asked to deliver innovativepackaging solutions, which are one stepahead of the crowd. As glossy high-endprinting is very common nowadays, newUSPs need 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 ModifiedAdmosphere 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

LASER -A Key Technology for the Packaging Market

With more than 49.000 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 Starnbergnear 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 lineup. 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, StarPackCW systems can make arbitrarily shapedscribing lines, suitable for re-closableflaps or circular easy tear lines in thecorners of packaging.

High-performance 3-axis scanner headsoffer extremely fast beam positioning withan enormous working field. The goal issubtle, visually unobtrusive scribing lines.Depending on the application, web widthand other customer‘s requirements, ROFINmounts up to 9 laser sources on aStarPack CW system. Typically ROFIN‘slaser solutions are integrated into the slitterwinder.

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® WD

Web-Direction Scribing andPerforating within One ProcessWith up to 32 processing heads StarPackWD systems handle almost any web directionapplication. The main application area isthe perforation of packaging films for freshfood to obtain a controlled atmospherewithin the packaging. Hole sizes for thistype of application are in the range of 50 µm to 130 µm. 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 to accom-modate up to 4 laser sources. As with allStarPack systems, scribing and perforatingis being synchronized with the packageprint. For optimum processing of thickpackaging films and demanding compositematerial at high web speed, the systemcan be equipped with ROFIN‘s web movement compensation.

STARPACK® CW STARPACK® WD MODULAR SYSTEM ON 2 LEVELS

FINEST EASY-TEAR LINES VARIOUS MATERIALS

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 - 130 µmdiameter can be perforated even at highweb speed.

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 StarPack® AP - the Entire Rangeof ROFIN‘s Scribing and PerforatingKnowhow

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

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. StarPackPouch is the cost-efficient alternative usinglow power laser sources and simultaneously offers easy integration.

CUTTING OF SINGLE PORTION TRAYSSTARPACK® HP 2000 W ROFIN LASER SOURCE

POUCH - BOTH SIDES SCRIBEDSTARPACK® POUCH IN THE POUCH MAKER

StarPack®

PouchStarPack® HP

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. EspeciallyPolypropylen can be processed considerablyfaster 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.

High-Power Scribing and Cuttingof Thick 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.

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 (%)

FRESH APPEARANCE OF PRODUCE

The smart software solution to definehigh-precision perforation parameters

StarMAPModified AtmospherePackaging

STARMAP SOFTWARE

At the time a consumer is in front of asupermarket shelf with fresh produce, thedecision what to buy is rather simple. It hasto be the salad or vegetable which appearsto be the freshest! The one, the customer isthinking, this pack was just placed in theshelf. Yellowish, sallow looking produce isthe loser in the shelf and will end up with a50% discount sticker or even in the garbagebin. It is not new that perforation ofpouches will lead to a longer shelf life.But what is the right amount of perforatedholes for what fresh produce?

With StarMAP, design and optimization ofModified Atmosphere Packaging filmsbecomes a breeze. The new software solu-tion uses a scientific approach and aUSDA approved database for calculatingthe optimum number and size ofmicro-perforations for a certain productand pack geometry. To provide the bestpossible shelf life and product quality,StarMAP takes the following parametersinto account:

� Product: fruits, vegetables,whole/fresh cut

� Product volume� Storage temperature� Type of packaging film� Packaging geometry

� Reliable calculation ofmicro-perforation data

� Fast and flexible adaption to varyingproducts and packagings

� Less costly and time consumingtrial & error

� Reduced waste� Streamlined production� Easy and comfortable user interface� Optional device for measurement of

respiration rates on site

StarMAP can be used with any ROFINweb-direction laser perforating solutionslike StarPack WD and StarPack AP.

StarMAP brings numerous benefits to filmand packaging suppliers and foodprocessors:

Based on product respiration and packagepermeability rates, the software calculatesthe number and size of micro-holes,required to achieve the optimum O2/CO2

balance in the head space of thepackaging. This prevents anaerobicconditions and minimizes productrespiration.

Micro-perforated film

CO2 CO2 CO2 CO2

O2 O2 O2 O2

MATERIAL TYPE CONSIDERED CONTROLLED CO2 / O2 EXCHANGE

SIZE OF POUCH CONSIDERED

PACKAGING FORMAT CONSIDERED

WEIGHT OF PRODUCT CONSIDERED

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- andSoftware

� Simple and user-friendly measurement process

� Automatic database update� Individual and seasonal

MAP-optimization

VISIONPERFOCONTROL OBSERVATION SCREEN

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

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.

VARIOUS PRODUCTS - REGIONS - GROW & HARVEST CONDITIONS

O2-Check Kit - individualMAP-optimization package

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

O2-CHECK KIT HIGH END VISION SYSTEM

STARFLEX SOFTWARE

Specifications Sample

StarPack® WD CW AP Pouch HP

Free Form Contour Scribing no yes yes no yes

Multiple Head Web DirectionScribing yes (x)* yes yes (x)*

Max. Number of IndividualScribing Lines 4/8/16/24/32 1 - 9 CW 9 2 1

WD 4/8/16/24/32

Number of Lasers 1 - 9 1 - 9 1 - 9 1 1 - 9

Power per Laser 100-600 W 100-600 W 100-600 W 100-200 W 1000-2500W

Number of Super fast Galvo Heads - 1 - 9 1 - 9 - 1 - 9

Tailor made Safety Housing (Kl 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

(x)* Galvo mirrors can be switched to a fixed position to scribe in web direction.

GET FREE SAMPLES!

For ordering contact:

co2systems@baasel.de

WD - WEB DIRECTION CW - CROSS WEB

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WE THINK LASER

LASER MICROROFIN-BAASEL LasertechGmbH & Co. KGPetersbrunner Str. 1b82319 StarnbergGermanyPhone +49(0)8151-776-0Fax: +49(0)8151-776-4159E-mail: sales@baasel.de

LASER MACROROFIN-SINAR Laser GmbHBerzeliusstraße 8722113 HamburgGermanyPhone:+49(0)40-733 63-0Fax: +49(0)40-733 63-4100E-mail: info@rofin-ham.de

LASER MARKINGROFIN-SINAR Laser GmbHDieselstraße 1585232 Bergkirchen-GündingGermanyPhone:+49(0)8131-704-0Fax: +49(0)8131-704-4100E-mail: info@rofin-muc.de

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UK: Phone +44-(0)1327-701-100E-mail: sales@rofin-baasel.co.uk

US: Phone: +01-847-483-6300E-mail: info@rofin-inc.com

SOLUTIONS FROM A SINGLE SOURCE

WWW.ROFIN.COM/PACKAGING