Rotary Heat Sealing Process

Here's a product that utilizes all 3 of our patents during its converting manufacture process.

For the Pouched Gauze Pad (above), we slip-cut the gauze onto a web (see machine below).

Eventually, we form a seal around the part using our patented rotary heat sealing process. The end result is a pouched gauze pad, which is used for a scratch, open wound, burn, etc.

Converting Biophile Labs heat seals and die cuts millions of these annually. We can private label them, as well. The gauze product is typcially packaged in boxes of 10 or 20 pads, then we put them in a shipper and stack the shipper boxes on a skid. The final step is to either ship them to the customer or the sterilizer.  

Converting Biophile Laboratories, Inc.
441 Cedar Street
Fond du Lac, Wisconsin 54935

What is Rotary Heat Sealing?

Rotary heat sealing fuses multiple layers of materials by applying pressure and heat to specific areas that need to be joined. The sealed fusion may create a pouch or bag for other uses. During the converting process, a cleanroom component can also be "heat sealed" between two or more outer layers of materials.

When we rotary heat seal, we can make any shape a customer wants. We can also private label the part or the packaging. In this application, the packaging refers to the materials that we heat seal around the individual parts.

Save Money...
with In-Line Packaging

When we can streamline your production by combining multiple operations on one machine, there are many cost-efficiencies realized. The streamlined effort saves time and therefore a cost-savings for the customer. When converting processes are followed immediately, one after another as a continual operation on one machine, there is less chance of contamination - especially if the processes culminate with heat sealed packaging. This saves customers money at the sterilization phase.

Sequential converting processes that include packaging are referred to as "In-Line Packaging".
In-line packaging is our standard process for many wound care products, such as gauze pads and bandages (band-aids).

Product Examples

The part (shown on the right) is called a water wrap or filter wrap. Even though this is not a medical product, we heat seal the edges by crushing them; this prevents the fluid from flowing beyond the sealed edge. Customers use this part by wrapping it around a filter, as a seal on their device. We can also laminate several materials together before the die cutting and heat sealing stages.

Here is another product that is rotary heat-sealed with our patented process; then we die cut them out.

For this particular product, our CBL Converting Team performs a burst test as a quality inspection to ensure they hold up to our customer's standards.

The final rotary heat sealed sample (at right) consists of a non-woven material that we laminate together and heat seal to this final shape. This product is used for a dental application.

We run these in roll form and send the customer rolls of these parts that are ticked into the web.