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Adhesive-free, Ultrasonic Elastic Attachment


Presented by: Thomas Ehlert
VP of RD&E
Aurizon Ultrasonics, LLC
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Meeting Agenda…

• A Little About Aurizon

• Overview of Ultrasonic Fundamentals

• Rotary Ultrasonics vs. Other Attachment Technologies

• Applications in Elastic Attachment

• Other Applications of Rotary Ultrasonics

• Discussion, Q&A
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Who Is Aurizon?…

• Spin-out formed from Kimberly-Clark’s Ultrasonic Technology team,


including manufacturing assets, people, and intellectual property
 Control 495 US and foreign patents as well as several pending applications

• Launched in August ’09 - Currently 25 employees: 13 R&E/Tech. Support,


5 Manufacturing/Operations, 7 Sales/Marketing/Business Support

• Business Focus
 Design, develop, manufacture and service high power ultrasonic systems that
offer customized solutions for industrial processes and applications

• Technology Platforms: Target Applications


 Rotary: Hygiene / Medical / Nonwovens; Packaging & Package Converting
 Nozzle: Industrial Spraying / Spray Drying; Combustion Processes
 Liquid: Food / Specialty Formulating; Chemical / Industrial Processing
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Why Aurizon ?…

• 30+ years and over $30 million invested in fundamental ultrasonics


R&D, applications development, and advanced acoustic tool modeling,
analysis, and fabrication

• Aurizon’s rotary technology has been custom engineered, developed,


and implemented on hundreds of sealing and converting applications
around the world

• Team experienced not just with ultrasonic equipment, but also with
process development, process integration, training, service and
support of ultrasonic systems in commercial production environments

• Customization expertise is the cornerstone of our business model -


“We offer capabilities, not catalogs”

• An open and eager development partner with ‘solutions seeking


problems’
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Kimberly, WI…

• 15,000+ square feet; 3.3 acres


• Includes:
 Offices
 Packaging / Electrical Lab
 Pilot Process Lab
 Machining, Manufacturing and Assembly
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Aurizon Ultrasonics Named to Inc. 5000
List for Second Consecutive Year
List recognizes America’s fastest-growing private companies
KIMBERLY, Wis. (Sept. 14, 2015) – Aurizon Ultrasonics has been named to Inc. magazine’s list of the 5,000 fastest-growing private companies
in America for the second straight year.

A manufacturer of high power ultrasonic processing equipment, Aurizon is number 3,102 on the list after debuting at number 4,412 in 2014. Over
the past three years the company has experienced a 112% growth rate.

“Making this list for a second year represents some great work by a dedicated group of employees,” said Greg Benrud, president. “We’ve
worked hard to become a leader in ultrasonics. We not only offer a better product, but a better experience for our customers who are looking for
an ultrasonic solution to their industrial process challenges.”

Aurizon’s has two primary technology platforms, their rotary systems for bonding and sealing materials, and their nozzle systems for enhancing
the atomization of viscous liquids. In each case these systems use high-frequency mechanical vibrations to deliver energy to the materials they
are processing. With the rotary technology, the vibrations cause materials, typically nonwovens or films, to heat and melt from the inside to join
together without the need for heat or adhesives. This technology offers a variety of advantages, including faster processing speeds, better
process control, and increased energy efficiency versus other conventional bonding and sealing methods. End use applications where this
technology is common include high speed personal care product converting and sealing flexible packages containing food and other products.
Aurizon’s ultrasonic nozzle technology utilizes high frequency vibrations to enhance or enable the atomization of highly viscous liquids. This
technology can be applied across a broad range of market applications, including spraying/spray drying of foods, chemicals, and other end uses
where improved atomization of viscous liquids can add value.

Aurizon Ultrasonics was created in 2009; however, its research team has been developing and expanding ultrasonic technology for more than
30 years with its origins dating back to the early 1980s as a technology team at Kimberly-Clark Corp.

The Inc. 5000 list is compiled by ranking each business’ percentage revenue growth over a three-year period. To qualify, companies must have
been founded and generating revenue by the first week of the starting calendar year, and therefore able to show four full calendar years of sales.
Additionally, they have to be U.S.-based, privately held, and independent—not subsidiaries or divisions of other companies—as of December 31
of the last year measured. Revenue in the initial year must be at least $200,000, and revenue in the most recent year must be at least $2 million.

Aurizon is one of only five Northeast Wisconsin companies to make this year’s list. Fifty Wisconsin companies are among the top 5,000.
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Ultrasonics Fundamentals
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Ultrasonic Vibration… Peak-to-Peak

Inches

• Acoustic frequencies at 20,000 – 40,000 cycles per second


• Electrical input converted into mechanical pressure waves
• Mechanical pressure waves create a compression and relaxation
of the materials to be bonded.
• Hysteretic losses within the material generate heat, which when
sufficiently high, melts and flows the materials.
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Ultrasonic Converter…
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Longitudinal Compression Wave…
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Key Components of Ultrasonic Systems…

 Power Generator
Amplifies voltage and adjusts the
frequency to match the targeted
resonant frequency of the system.

 Converter / Transducer
Changes electrical energy to mechanical
energy at a specified frequency.

 Waveguide / Booster
Transmits motion from converter to horn
and either amplifies or attenuates that
motion.

 Horn / Sonotrode
Delivers the ultrasonic motion to the
11
material being processed.
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Parameters that Affect Ultrasonic Processing…

• Time
 Usually determined by desired process speed

• Amplitude of Vibration
 Determines level of energy available for bonding

• Static Contact Pressure (Force)


 Force on the material determines efficiency of coupling with high frequency
compression

• Materials being Sealed


 Material properties determine susceptibility to heating
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What materials can be ultrasonically processed?


Materials that can be reheated and remelted

• Metals
 Not addressed today

• Thermoplastics
 Amorphous
o Random molecular structure
 Crystalline
o Orderly molecular structure
 Degree of Crystallinity Dictates Rate at which Vibrational
Energy is Converted to Heat
 Other Properties Including Melt Flow Characteristics Dictate
What the Material Does as it is Heated
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Rotary vs. Stationary


Ultrasonics
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Horn (Sonotrode) Vibration – Stationary vs. Rotary…

The primary output amplitude on


a stationary horn occurs in the
axial direction, parallel with the
axis of the ultrasonic stack.

The primary output amplitude on


a rotary horn occurs radially
around the disc circumference,
perpendicular to the ultrasonic
stack axis.
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Extensional Mode vs. Radial Mode of Vibration…

Radial
Peak-to-peak amplitude is
the displacement of the horn
during the expansion and
contraction

Extensional
Amplitude impacts both the
effective horn diameter/length and
velocity of the horn surface

Increasing amplitude increases


surface velocity which increases
instantaneous force and resultant
bonding capability
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Rotary vs. Conventional Stationary/Blade Horn Technology…

Rotary - Pros: Stationary / Blade - Pros:


• High speed, efficient processing • Wider width capability
possible due to “fly wheel effect” • Horn surface easy to harden
• “Point contact” makes sealing
more controllable and consistent Stationary / Blade - Cons:
• Effective with broad array of • Intense instantaneous power
polymers and materials (e.g. thick, demand due to 100% loading of
bulky, elastic) horn working surface
• Can induce shear (non-contact • Fixed gap can make intermittent
systems) in bond zone; enables material processing difficult
sealing of difficult materials
• Severe impact or loading on horn
face can lead to converter failure
Rotary - Cons:
• Amplitude variability across
• Narrower width capability
horn face
• Horn surface difficult to harden
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Extensional Mode vs. Radial Mode of Vibration…

Radial
Peak-to-peak amplitude is
the displacement of the horn
during the expansion and
contraction

Extensional
Amplitude impacts both the
effective horn diameter/length and
velocity of the horn surface

Increasing amplitude increases


surface velocity which increases
instantaneous force and resultant
bonding capability
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Radial Mode of Vibration…

Displacement of the horn


during the expansion and
contraction that occurs while
the horn is “breathing”

Rotary horns are designed


to vibrate radially, meaning
the primary (most efficient)
mode vibration causes the
horn to expand and contract
uniformly around the
circumference of the horn
surface
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Rotary vs. Conventional Stationary/Blade Horn Technology…

Rotary - Pros: Stationary / Blade - Pros:


• High speed, efficient processing • Wider width capability
possible due to “fly wheel effect” • Horn surface easy to harden
• “Point contact” makes sealing more
controllable and consistent Stationary / Blade - Cons:
• Effective with broad array of • Intense instantaneous power
polymers and materials (e.g. demand due to 100% loading of
thick, bulky, elastic) horn working surface
• Can induce shear (non-contact • Fixed gap can make intermittent
systems) in bond zone; enables material processing difficult
sealing of difficult materials
• Severe impact or loading on horn
face can lead to converter failure
Rotary - Cons:
• Amplitude variability across horn
• Narrower width capability
face
• Horn surface difficult to harden
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Horn (Sonotrode) Vibration – Rotary vs. Stationary…

• Input Energy Axial


• Primary Output
Motion Radial

• Input Energy
Axial
• Primary Output
Motion Axial
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Rotary vs. Conventional Stationary/Blade Horn Technology…

Rotary - Pros: Stationary / Blade - Pros:


• High speed, efficient processing • Wider width capability
possible due to “fly wheel effect” • Horn surface easy to harden
• “Point contact” makes sealing more
controllable and consistent Stationary / Blade - Cons:
• Effective with broad array of • Intense instantaneous power
polymers and materials (e.g. thick, demand due to 100% loading of
bulky, elastic) horn working surface
• Can induce shear (non-contact • Fixed gap can make intermittent
systems) in bond zone; enables material processing difficult
sealing of difficult materials
• Severe impact or loading on
horn face can lead to converter
Rotary - Cons:
failure
• Narrower width capability
• Amplitude variability across horn
• Horn surface difficult to harden face
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Consequences of Horn-to-Anvil Contact…

Impact force to traditional blade horn surface transmits axially to the


convertor often leading to cracks in the horn or damage to the ceramics in
the converter.

Rigid Frame

FORCE

FORCE

FORCE

FORCE

FORCE
Impact force to radial surface of horn does not FORCE
transmit axially to the converter. No damage.
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Rotary Ultrasonics vs. Other


Attachment Technologies
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Other Attachment Techniques Compared to Ultrasonic Technology…

Adhesives
• Offer the most substrate flexibility
– Ultrasonic attachment is dependent on the properties of the thermoplastics
• Ongoing cost of raw materials usage, storage, transportation, etc.
• Higher system energy costs
• Process delay associated with system heat-up/cool-down cycles
• Process delay to clean adhesives from process equipment
– Due to overspray, bleed-through, etc.
• Negative product effects
– Stiffness, tackiness, bleed-through, blocking, etc.
• High-speed, intermittent spray limitations / challenges
• Safety
– High temperature raw materials, applicators, hoses, pumps, melters, etc.
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Other Attachment Techniques Compared to Ultrasonic Technology…

Thermal Bonding
• Capability impacted by material properties
• External application of heat can reduce speed capability
– Ultrasonic causes heating of the materials from the inside out
• Higher system energy costs
• Process delay associated with system heat-up/cool-down cycles
• Potential product damage due to over-exposure to heat
• Safety considerations due to high temperature equipment

Compression Pressure Welding


• Capability impacted by material properties
• Waste and variability due to speed-dependent attachment strengths
– At times an added adhesive system is used to overcome these limitations
• Can be a high-wear process
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Applications in Elastic
Attachment
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Aurizon Signs Exclusive License Agreement to
Manufacture and Market Elastic Technology
Patent, owned by CERA France, used to secure elastics to nonwovens for disposable absorbent products

KIMBERLY, Wis. (Nov. 17, 2014) – Aurizon Ultrasonics has entered into an exclusive license agreement with CERA
France to enable the manufacture and sale of its patented rotary ultrasonic bonding technology to secure elastic
strands into nonwoven structures used in articles such as diapers and adult incontinence undergarments.
Personal Care and Hygiene products often use elastic strands secured in nonwovens to prevent leakage or improve fit.
Most manufacturers secure these elastics with adhesives; however, adhesives have several drawbacks including being
expensive, messy and creating a stiffness that can make the garments uncomfortable to wear. Adhesives are also
under increasing scrutiny as being environmentally unfriendly.
“Rotary ultrasonic bonding systems can be a great solution to improving the products in this category,” said Bob Cool,
executive vice president of marketing at Aurizon. “The challenge has always been securing the elastics so they don’t
detach from the nonwoven causing the products to lose their stretch, otherwise known as ‘creep.’ Aurizon’s rotary
ultrasonic systems can solve this challenge and enable high speed entrapment of the elastics in a variety of product
executions.”
According to Cool, Aurizon’s engineers are completing an upgrade to their pilot process that will enable demonstration
of elastic processing in nonwovens at speeds up to 2,000 ft/min (610 m/min.) This license agreement with CERA paves
the way for Aurizon to work with OEMs and end users to enable faster commercial implementation of the technology.
“We are very excited to have partnered with CERA France through this agreement. The industry today is motivated to
reduce or eliminate the need for costly adhesives. We feel we can leverage our expertise in ultrasonic bonding of
nonwoven structures to enhance both the process speed and the quality of the elastic articles being produced,” said
Cool.
The agreement gives Aurizon access to customers in the United States, Canada, Japan, Australia, Switzerland, the
United Kingdom, Liechtenstein, Sweden, France and Italy.
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Continuous Elastic Attachment…


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Key Advantages of Ultrasonics over Adhesives…
Saves on material costs
• No costly adhesive materials and complex adhesive delivery systems
• Can utilize lower cost nonwoven/film substrates
– No adhesive bleed-through
• Can utilize lighter weight elastic materials without compromising performance

Increases production line efficiency


• Can increase your process uptime while lowering your process waste
– robust to process and web upsets such as substrate splices, elastic splices, machine
stop/start events
– Automatically re-threads during full speed run if strand breakage occurs
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Robust Attachment Process…
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Key Advantages of Ultrasonics over Adhesives…
Saves on material costs
• No costly adhesive materials and complex adhesive delivery systems
• Can utilize lower cost nonwoven/film substrates
– No adhesive bleed-through
• Can utilize lighter weight elastic materials without compromising performance

Increases production line efficiency


• Can increase your process uptime while lowering your process waste
– robust to process and web upsets such as substrate splices, elastic splices, machine
stop/start events
– Automatically re-threads during full speed run if strand breakage occurs
• Can be retrofitted to your existing capital asset bases

Improves product comfort and performance


• Maximizes elastic performance
– Near pure elastic response without adhesive creep
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Charting the Course of Comfort…
The higher the tension in the elastic strand, the less comfort your customer will
experience. With Aurizon's ultrasonic entrapment technology, we are able to reduce
the tension and give your customer a more comfortable experience. Notice the lower
tension of the ultrasonic-entrapped elastic versus glue (orange line compared to grey
line). Ultrasonics has little impact on the pure elastic strand performance while
offering maximum softness and less stiffness (orange line compared to blue line).
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Key Advantages of Ultrasonics over Adhesives…
Saves on material costs
• No costly adhesive materials and complex adhesive delivery systems
• Can utilize lower cost nonwoven/film substrates
– No adhesive bleed-through
• Can utilize lighter weight elastic materials without compromising performance
Increases production line efficiency
• Can increase your process uptime while lowering your process waste
– robust to process and web upsets such as substrate splices, elastic splices, machine
stop/start events
– Automatically re-threads during full speed run if strand breakage occurs
• Can be retrofitted to your existing capital asset bases
Improves product comfort and performance
• Maximizes elastic performance
– Near pure elastic response without adhesive creep
• Maximizes fabric softness
– Eliminates the stiffening effect of adhesive
• Enables customized aesthetics
– Size, shape, frequency of gathers is selectable
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Elastic Entrapment Samples…
Bonded Samples
• 680 decitex elastic fiber
• 13 gsm SMS
• 1500 ft/min
• 30 kHz bonder

Bond Pattern
• Multi-crevice pattern
• Soft feel bond
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Key Advantages of Ultrasonics over Adhesives…
Saves on material costs
• No costly adhesive materials and complex adhesive delivery systems
• Can utilize lower cost nonwoven/film substrates
– No adhesive bleed-through
• Can utilize lighter weight elastic materials without compromising performance
Increases production line efficiency
• Can increase your process uptime while lowering your process waste
– robust to process and web upsets such as substrate splices, elastic splices, machine
stop/start events
– Automatically re-threads during full speed run if strand breakage occurs
• Can be retrofitted to your existing capital asset bases
Improves product comfort and performance
• Maximizes elastic performance
– Near pure elastic response without adhesive creep
• Maximizes fabric softness
– Eliminates the stiffening effect of adhesive
• Enables customized aesthetics
– Size, shape, frequency of gathers is selectable
– Continuous or intermittent attachment of elastic to substrate
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Intermittent Attachment via Slip Zones…


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Intermittent Attachment via Slip Zones…


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Other Intermittent Attachment Techniques…
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Custom Systems & Configurations…
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Custom Systems & Configurations…

#1 – Elastic strand
entrapment /
Intermittent
#2 – Elastic cuff
construction and #3 – Cuff tack down
attachment to core / core / intermittent
continuous
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Aurizon Ultrasonics and INVISTA
Announce Joint Development
Aurizon Ultrasonics and INVISTA announce joint development of bonding equipment
and stretch fibers for the construction of stretch laminates
KIMBERLY, Wis. (Sept. 17, 2015) – Aurizon Ultrasonics – a leading supplier of ultrasonic processing equipment to the
hygiene industry – and INVISTA – one of the world’s largest integrated producers of polymers and fibers, and owner of the
LYCRA HyFit® brand sold into the hygiene industry – have announced they are cooperating on a new joint development
project.
This project will focus on the collective development of novel ultrasonic bonding equipment and novel stretch fibers for the
construction of stretch laminates, without the use of hot melt elastic attachment adhesives. The desired outcome of this
collaboration is a step-change advancement allowing hygiene producers to improve product fit and comfort without the cost
and complexity of glue.
“We are thrilled to join efforts with INVISTA, the market leader in stretch fibers, to further advance next generation stretch
materials for the hygiene market,” said Greg Benrud, Aurizon president. ”Our current technology to ultrasonically secure
elastics in nonwovens without the need for adhesives can enable lower material costs, increased operational efficiency and
improved product comfort and performance. We believe this collaboration will provide an opportunity to leverage the
strengths of both companies and accelerate further development of exciting new materials and processes for our
customers.”
“INVISTA is excited to explore the combination of Aurizon’s cutting edge capabilities in ultrasonic bonding with our market
leading research and development team that has delivered continuous innovations to our LYCRA HyFit® fiber offering,” said
Scott Blackadar, INVISTA global vice president. “We believe that step change innovations in diaper design and cost
reduction will result from this joint effort. We look forward to collaborating with Aurizon and discovering the potential synergy
between our new fiber innovations and Aurizon’s high speed rotary ultrasonic bonding technology.”
About Aurizon Ultrasonics
Aurizon Ultrasonics was created in 2009; however, its research team has been developing and expanding ultrasonic technology for more than 30 years with its origins in Kimberly-Clark Corporation. Aurizon’s expertise and patented technology
make it a leader in high-power, high-speed ultrasonic processing and provide a solid foundation for creating customized solutions to meet the needs of the hygiene industry. By partnering with each customer and working together to develop a
comprehensive, customized solution for their manufacturing challenges, Aurizon invites companies to “experience better” by increasing their productivity, reducing their costs and improving their outcomes. Aurizon is an INDA member and has
been named one of Inc. magazine’s 5,000 fastest-growing private companies in America in each of the last two years.

About INVISTA
INVISTA is one of the world’s largest integrated producers of polymers and fibers, primarily for nylon, spandex and polyester applications. With a business presence in over 20 countries, INVISTA delivers exceptional value for its customers
through market insights and technology innovations, along with a powerful portfolio of some of the most recognized global brands and trademarks in their respective industries including: COOLMAX®, CORDURA®, LYCRA®, POLARGUARD®,
SOLARMAX®, SUPPLEX®, TACTEL®, and THERMOLITE®. More information on INVISTA can be found at www.INVISTA.com and on personal care offerings at HyFit.INVISTA.com.

LYCRA HyFit® is a trademark of INVISTA


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Other Applications of Rotary


Ultrasonic Technology
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Aurizon’s Ultrasonic Equipment Platforms…
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Horn (Sonotrode) Examples…


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Bond Formation Expertise…
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Anvil Design Examples…


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Anvil Design Examples…


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Shape Cutting Anvil…


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Simultaneous Cutting/Bonding…
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Embossing Examples…
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Aurizon Pilot Line…


• 2000 fpm maximum line
speed
• Table capable of
incorporating up to two
Aurizon bonder designs
simultaneously
• Web handling includes two
driven unwinds, vertical
folding, driven nips, web
guides and tension controlled
winder
• Process rolls of material up to
36” diameter and 12” wide
• Capable of bonding, cutting,
embossing, laminating, etc.
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Cost–in–Use Calculators…
Aurizon Ultrasonics Current Technology Rotary Ultrasonic Technology Incr/(Decr) Notes / Assumptions
Cost in Use Model $/SU %
Product: Snack Bars
Standard Unit (SU): 1000 Bars
Process Name: Fin Seal
Productivity
Schedule (Hrs/Yr): 7,200 7,200 -

Max Speed (SU/Hr): 1.800 1.800 - 0.0% Assumes 300 bars/minute and no speed increase with ultrasonics

Delay-Sealing (%) : 4.00% 1.00% (0.03) -75.0% ~5 minutes every 2 hours; 75% reduction possible vs. heat seal

Delay-Other (%) : 10.00% 10.00% - No change?


Productivity (SU/Hr): 1.55 1.60 0.05 3.5%

Direct Materials UOM $/Unit Net Units/SU $/SU $/Unit Net Units/SU $/SU $/SU

Product Ounce $ 0.50000 1,000.00 $ 500.00 $ 0.50000 1,000.00 $ 500 $ - Assumes a 1.0 oz product weight

Film MSI $ 0.15000 22.50 $ 3.38 $ 0.15000 20.00 $ 3 $ (0.4) Able to reduce fin size by 0.5" total

[Material 3] $ - - $ - $ - - $ - $ -
[Material 4] $ - - $ - $ - - $ - $ -
[Material 5] $ - - $ - $ - - $ - $ -
Total Materials $ 503 $ 503 $ (0) -0.1%

Direct Conversion UOM $/Unit Net Units/ Process Hr $/ Process Hr $/SU $/Unit Net Units/ Process Hr $/ Process Hr $/SU $/SU

Labor Man-hour $ 70.00000 1.00000 70.00 $ 45.22 $ 70.00000 1.00000 70.00 $ 43.70 $ (1.524)

Energy-Sealer kWh $ 0.14000 5.00000 0.70 $ 0.45 $ 0.14000 0.25000 0.04 $ 0.02 $ (0.430) 95% reduction in energy vs. heat seal

Energy-Other kWh $ 0.14000 10.00000 1.40 $ 0.90 $ 0.14000 10.00000 1.40 $ 0.87 $ (0.030) No additional impact on energy??

Maintenance-Sealer Month $ 2,000 0.00137 2.74 $ 1.77 $ 500 0.00137 0.68 $ 0.43 $ (1.342) 75% reduction

Maintenance-Other Month $ 2,000 0.00137 2.74 $ 1.77 $ 2,000 0.00137 2.74 $ 1.71 $ (0.060) Other impact?

[Other 1] $ - - - $ - $ - - - $ - $ -
[Other 2] $ - - - $ - $ - - - $ - $ -
Total Conversion 77.58 $ 50.12 74.86 $ 46.73 $ (3.387) -6.8%

Gross Direct Cost/SU $ 553 $ 550 $ (3.76)

Reject Rate $ 0.05 $ 0.04 -1.00% 20% reduction

Net Direct Cost/SU $ 583 $ 573 $ (9.99) -1.7%

Annual Production (SU) 10,588 11,073 485 4.6%

Annual Cost Savings on Current Production: $ 105,754

Value of Annual Production Increase: Enter value of $500.00 $ 242,352 $0.50 profit on each bar
incremental capacity
($/SU)>
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Aurizon Ultrasonics at your Service…

• Design, develop, manufacture and service high power ultrasonic systems


that offer customized solutions for high speed materials
processing/converting

• Proven high speed rotary applications in operation for over 30 years.

• Exclusive IP rights for multiple years to come.

• Over 300 years of combined knowledge and expertise in-house

• Please see our tabletop display and take the opportunity to speak with
us!
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Contacts…

Dan Sorensen
Sales Director
Dan.Sorensen@AurizonUltrasonics.com
+1 (920) 750-5087

Tom Ehlert
VP Research, Development &Engineering
Tom.Ehlert@AurizonUltrasonics.com
+1 (920) 750-5083

Greg Benrud
President
Greg.Benrud@AurizonUltrasonics.com
+1 (920) 750-5082
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Thank You!
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Questions?