Why Use Ultrasonic Welding To Weld Poultry Belts?

In the modernization of the egg industry, the efficiency and safety of the packaging process directly affect the product's circulation quality and market competitiveness. Traditional egg strip welding technology often faces problems such as insufficient welding strength, easy damage to eggshells, and low production efficiency. However, the emergence of ultrasonic egg strip welding technology, with its unique physical principles and technological advantages, has become a key solution to the pain points of egg packaging, injecting new impetus into the automation and refinement of the egg industry.

1. Core Principles of Ultrasonic Poultry Belts Welding 

Ultrasonic welding technology essentially utilizes the energy generated by high-frequency mechanical vibration to achieve solid-state bonding between materials. Its application in egg strip welding requires precise matching to the specific needs of egg packaging. Specifically, the workflow of this technology can be divided into three key stages: 

    First, the energy conversion stage. The transducer in the ultrasonic welding equipment converts high-frequency electrical signals (typically 15kHz-70kHz) into mechanical vibrations. This vibration is amplified by an amplitude transformer and transmitted to the welding mold (welding head). At this point, the vibration frequency and amplitude of the welding head must be strictly controlled—too much amplitude will directly crack the eggshell, while too little will not provide the energy required for welding. Therefore, the industry commonly uses a frequency range of 20kHz-30kHz and an amplitude controlled between 0.05mm-0.2mm to balance energy and safety. 

    Second, the interface friction heating stage. When the welding head transfers vibrational energy to the welding contact surface of the egg (usually made of plastic, such as PET or PP), the molecules on the contact surface generate intense friction under high-frequency vibration, instantly producing localized high temperatures (generally 200℃-300℃, the specific temperature depending on the melting point of the plastic). This heat is concentrated only on the contact surface and is not conducted to the egg itself, avoiding the impact of high temperatures on egg quality, while also quickly bringing the plastic contact surface to a molten state. 

    Finally, there is the pressure solidification stage. While the contact surface is melting, the welding equipment applies a constant pressure (usually 50N-200N), allowing the molten plastic molecules to fully diffuse and fuse, forming a stable weld joint. Then, the vibration stops, and the pressure is maintained for 0.1s-0.5s until the molten plastic cools and solidifies, completing the welding process. The entire process takes only 1s-3s, much faster than traditional hot melt welding (5s-10s), and the tensile strength of the weld joint can reach 80%-95% of the plastic substrate itself, effectively preventing eggs from falling out during transportation due to packaging damage.

2. Development Trends of UltrasonicPoultry Belts Welding Technology 

As the egg industry's demands for automation, intelligence, and green technologies continue to increase, ultrasonic egg strip welding technology is also developing towards greater precision, intelligence, and environmental friendliness. 

    In terms of precise control, future ultrasonic welding equipment will incorporate AI visual inspection systems to monitor the welding position and eggshell condition of the egg strip in real time, automatically adjusting vibration parameters—for example, automatically reducing amplitude and pressure when a thin eggshell is detected, further reducing the breakage rate; simultaneously, it will accumulate optimal welding parameters for egg strips of different materials and specifications through big data analysis, achieving "one-click adaptation." 

    In terms of intelligent integration, the ultrasonic welding unit will be deeply integrated with Internet of Things (IoT) technology. Data such as equipment operating status, welding quantity, and fault warnings can be uploaded to the enterprise management system in real time. Managers can remotely monitor production progress via mobile phone or computer, achieving a "unmanned workshop" management model. Furthermore, the equipment will also have a self-cleaning function, reducing manual maintenance costs and increasing continuous operating time. 

    In terms of environmental protection and sustainable development, ultrasonic welding technology for biodegradable plastic egg strips (such as PLA material) will become a key research focus. Biodegradable plastics have a low melting point (approximately 160℃-180℃) and poor fluidity after melting, making them prone to weak welds with traditional welding techniques. Future ultrasonic equipment will achieve efficient welding of biodegradable plastics by optimizing the welding head structure and adjusting the vibration frequency, helping the egg industry achieve "environmentally friendly packaging throughout its entire lifecycle."