Jarry Bachmann, founder, Pocket Shot, approached the firm after his drinks brand was having issues on the production line with rejects.
The top contour of the laminated plastic looks like a bottle top and the sealant needs to seal through alcohol caused by splash back on the surfaces during filling.
Hot and cold seal
Jeffrey Frantz, director of marketing and product development, Branson Ultrasonics, said Pocket Shot initially used a heat-seal process that first melted the plastic for joining followed by a cold seal to smooth out voids and wrinkles.
“The package seals were adequate enough to launch the product but once production volume reached high-speed levels 30 plus per minute the hot/cold seal led to leaks,” he said.
“When the Ultrasonic seal compresses the material it disperses any contaminant in the area and welds it.”
Single serve pouch
Bachmann said the single serve alcohol pouch comes in 11 different flavors sold in 27 states.
“It’s just an easy way to carry alcohol but the problem is, you don’t want it to leak. We wanted to make sure we had a package that would not leak at all,” he said.
“We didn’t think the Branson equipment would fit on our particular machine to begin with, but it did. I started the brand with five flavors and now we have added cinnamon cherry vodka, cinnamon honey whisky, peppermint and cinnamon schnapps. In total 11 products.”
Vertical form fill seals
As well as Pocket Shot, Frantz said Branson is focusing on vertical form fill seals on flexible packaging.
“A heat seal maybe three eighths to three quarters of an inch wide but our seal is typically less than an eighth of an inch,” he added.
“The Ultrasonic capital investment is higher than a traditional heat seal. We feel if manufacturers do the right ROI calculations it will be less expensive in the long haul.
“We are trying to prove to people that are comfortable with heat seal that we have an advantage long term.”
Frantz said the company plans to focus on rigid packaging next and a tamper evident zip strip for blister packs, where users currently rely on adhesives or shrink wrap around a package to protect it.