11 November, 2015:
Damax Sebenza Pack has become the only company in South Africa to manufacture soft-crease clear boxes in-house, after installing a radio frequency (RF) welding machine that boasts a production capacity of 48 clear visual cartons per minute, thereby saving on overhead costs, while increasing productivity.
Damax Sebenza Pack is a division of Damax Plastics, specialising in the packaging and plastics market. It manufactures among other products, clear boxes made from PVC and PET material for the pharmaceutical, food and beverage, industrial, electrical, mechanical and cosmetics industry. The company recently moved to Damax Kahn and Kahn’s 1200 m2 premises in Kempton Park, in an effort to consolidate costs and streamline efficiencies.
Damax Sebenza Pack MD Brian Lovell highlights that the company will be delivering the first batch of clear carton boxes to a pharmaceutical company that packages animal medicine. “It’s a new clear carton technology for this country, no one else is making them in South Africa. Any other soft crease cartons in the market come from overseas,” he explains.
According to Lovell, the locally-manufactured machine officially went into production in October 2015, with positive results. “Our previous machine was hand-fed and required the material to be pre-folded. We had to manually de-roll the material, lay and flatten it, then die cut it. This new machine creates a soft crease carton, while the old one produced sharp edges that easily cracked.”
RF welding technology uses radio frequency electromagnetic energy to fuse plastic materials together. The electric field causes the polar molecules found in some thermoplastics to oscillate and orientate themselves. The molecules in the material move and get hot, and the combination of this heat under pressure causes the weld to take the shape of the die, creating the desired shape of the box.
RF welding technology uses radio frequency electromagnetic energy to fuse plastic materials together.The company will be delivering the first batch of clear carton boxes to a pharmaceutical company that packages animal medicine
Lovell indicates that during the welding process, two pieces of material are placed on a table press that applies pressure to both surface areas. When the press comes together, high frequency waves are passed through the small area between the die and the table where the weld takes place.
“The weld is created via RF, which is an oscillating wave with a frequency of 37,5 MHz. We feed the flat sheet to the machine, which flattens and die cuts it, then it comes out in a flat form which can be quickly and easily erected into a carton for the customer,” he elaborates.
Damax Sebenza Pack plans to incorporate printed rolls to the manufacturing process in future, as the RF welding machine has the ability to produce cartons with accurately-positioned prints. Lovell says that the machine will significantly reduce the amount of returned rejects and the losses incurred due to breakage, cracking and scratching during the manufacturing process.
Damax Sebenza Pack plans to incorporate printed rolls to the manufacturing process in future
“The cold winter temperature was particularly challenging, as it caused the material to crack on the crease. With the new and improved soft crease carton, the material boasts greater crack resistance, as the machine forms a hinge effect on it. Another major advantage of RF welding machine is that we are able to produce an improved product, quicker, at the same price,” he concludes.
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