LaserSharp® Laser Perforating for Flexible Packaging

LaserSharp FlexPak Services offers precision LaserSharp® laser perforating services for breathable packaging applications. This process creates accurate breathable features that enable vapor and gas exchange through controlled micro-hole size and location. Unlike mechanical perforating, laser perforated film exhibits holes that are uniform, strong, and clean of residue. This process has been proven for perishable foods in addition to microwaveable and rapid fill packaging (allowing for packing consolidation).

The LaserSharp® Perforating Process

LaserSharp® technology offers a non-contact, clean, fast, and processing method, capable of drilling entirely through a material or only penetrating select layers. Partial laser perforating at controlled depths facilitates vapor and gas exchange while maintaining a hermetic seal. This maintains a barrier between your product and the outside environment, making laser perforating an ideal choice for food products. Laser converting is also a high quality production solution because laser perforated film exhibit consistently uniform holes, free of residue and processing artifacts. Additionally, the heat of the laser beam cauterizes the edges of each perforation, strengthening the surrounding material.

The key to LaserSharp® perforating technology involves the advanced controls software managing our laser systems which constantly monitor and adjust the laser’s power to ensure consistent hole sizes, even at varying web speeds or material thicknesses. Laser microperforations are created by vaporizing flexible films, creating a perforation in the material for gas exchange, vapor release, or rapid fill applications. Lasers are capable of weakening desired layers of a material to produce perforations without compromising the barrier properties of a flexible film. Laser perforations can be precisely registered to print on a product’s package. Registration sensors and vision cameras integrated directly within the system automatically control processing in response to print cues to ensure pattern accuracy.

Traditional mechanical perforating methods often compromise the strength and integrity of a film as these methods puncture flexible films, creating unwanted tearing and inconsistent hole sizes. Alternatively, our laser perforating technology allows us to control the depth, size and pattern of perforations in a more accurate manner that traditional mechanical perforation methods are not able to offer. The number and location of perforations on a web can be easily and quickly adjusted to deliver a perforation pattern specific to your unique product.

Material Selection and Applications

Materials best suited for laser processing are those with a narrow liquid to vapor temperature range.  These include PVDC Barrier and Polyolefin Shrink films, Polyester, Polypropylene, Polyethylene, Nylon, and metalized films. Different materials absorb energy at varying rates, and therefore vaporize at different temperatures. Our adaptable laser processing systems adjust laser settings to meet the varying requirements of each flexible material.

Applications for laser perforating include:

• Breathable packaging that facilitates oxygen/carbon dioxide exchange to extend the shelf-life of produce and meats by eliminating condensation and gas build up
• Venting for rapid-fill applications, encouraging efficient palletizing and storage
• Steam-release features for microwaveable applications
• Targeted oxygen transmission rate (OTR) patterns
• Modified atmosphere packaging (MAP)

LaserSharp FlexPak Services will work with you to determine a personalized solution for your product using an extensive expertise and knowledge of laser technology. From microperforated bags for microwaveable steam-release features to achieving specific oxygen transmission rates, laser converting allows you to introduce value-added features to your packaging in cost-effective manner. To ensure the quality and consistency of our laser processing, LaserSharp FlexPak Services offers multiple quality checks. Oxygen transmission rate testing and microscopic analysis are both available on-site, and can be utilized to guarantee the laser perforating process.