Medical Manufacturing & Outsourcing - Version A. April 2021 - 4

Adapting to Manufacturing
Challenges of COVID-19
Basi-cally, ultrasonic
welders convert electrical
energy to high-frequency
mechanical vibration,
which is transmitted
through tooling into
thermoplastic nonwoven
material. The vibration
creates frictional heat
that melts the material,
an operation that can be
focused and utilized to:
* Cut or slit a large
roll of nonwoven
Ultrasonic welds strongly bond even small items like the ties on
fabric into narrower
a disposable surgical mask at a fraction of the cost of stitchery
or glue and can be used immediately. (Credit: Emerson)
strips (cut edges are
simultaneously seamed/
sealed ultrasonically).
to complete all eight machines in just
 ond two pieces of nonwoven
*B
18 weeks, start to finish. Pressed for
fabric into finished seams of
time, their project managers requested
surgical garments, or attach
Branson ultrasonic welding technology
loops or ties to caps, surgical
to equip the four welding stations
masks, or other types of PPE.
needed in each mask-making machine.
* "  Quilt " multiple layers of different
Through Consonic Pty., the regional
nonwoven material into masks
representative, Foodmach request
and respirators or other medical
expedited deliveries from Emerson.
absorbent or infection-control
Emerson responded quickly, shipping
products. For example, in N95
the first group of welders in just
and high-grade surgical masks,
14 days, with two more shipments
the quilt typically includes an
to follow. In all, Emerson's North
inner and outer spunbond layer of
American-based manufacturing
meltblown polypropylene, which
facility delivered 34 welding units,
to-gether provide structure and
enough to outfit all eight maskprotection for a middle layer of
making machines and allow for two
meltblown polypropylene fibers.
welding units as spares. Each unit
The middle fiber layer is electrically
included a 20-Hz Branson DCX power
charged to capture and hold
supply, a matched converter and
extremely small particles, such
booster, plus application-specific
as those of the COVID-19 virus.
weld tooling and training, locally
Ultrasonic welding is remarkably
produced and supplied by Consonic.
energy efficient because the welder
With the help of Emerson's global
consumes power only when it is
supply chain and local customer
cutting, slitting/sealing, or bonding
support, Foodmach completed and
the nonwoven fabric. Because the
delivered all mask-making machines
welder generates heat instantly
to MedCon on schedule. This effort
through vibration, there's no need for
helped put MedCon on track not only
constant energy consumption, such
to meet its 29-fold production goal in
as that required for preheating a heat
November but also to continue meeting
knife, for example, or maintaining it
Australia's PPE requirements amid the
at the proper operating temperature.
worsening global COVID-19 situation.
Compared with other methods
for cutting and bonding nonwovens,
Ultrasonics: A Natural for
ultrasonic technology offers significant
Manufacturing Nonwoven PPE
advantages. By producing strong,
Ultrasonics are a natural fit for
repeatable seams and joints without
production of nonwoven products.
4 APRIL 2021

the need for or glues or adhesives, it
eliminates the risk of contamination
and the need for setup time and space
for drying. It replaces the time and
effort of sewing as well, along with
the tiny thread holes that can harbor
possible microbial contaminants.
Ultrasonic seams are ready for
use as soon as they are produced
and are capable of withstanding
repeated sterilization processes.
The ultrasonic welding process can
even be used in cleanrooms.

Conclusion

In times of crisis, every
organization is challenged to
balance great urgency - the need
to adapt to sudden and unexpected
circumstances - with the need for
continued focus on key values, vital
personal and business relationships,
and the long-term planning and effort
needed to ensure a bright future.
To adapt to the COVID-19 crisis
while continuing its operations, the
Automation Solutions business of
Emerson, for example, is responding
with urgent attention to employee
and customer safety in every
interaction, with an emphasis on
making distance training, learning,
and equipment support tools
available in key languages, and with
increasingly rapid response to the
vital, fast-changing supply chain
needs of its global customers.
The company is staying focused
on the long term by developing new
products, improving the applicability
and performance of technologies,
and leveraging the vast resources of
the company's global organization
and supply chain to give customers
and partners competitive advantage.
This article was written by Vernon
Murray, President of Branson
Welding and Assembly at Emerson.
He has global responsibility for
sales, operations, finance, quality,
human resources, engineering,
product marketing, and management
for the Branson business. For
more information, visit http://
info.hotims.com/79410-340.

MEDICAL MANUFACTURING AND OUTSOURCING SPECIAL REPORT


http://info.hotims.com/79410-340

Medical Manufacturing & Outsourcing - Version A. April 2021

Table of Contents for the Digital Edition of Medical Manufacturing & Outsourcing - Version A. April 2021

Medical Manufacturing & Outsourcing - Version A. April 2021 - Cov1
Medical Manufacturing & Outsourcing - Version A. April 2021 - Cov2
Medical Manufacturing & Outsourcing - Version A. April 2021 - 1
Medical Manufacturing & Outsourcing - Version A. April 2021 - 2
Medical Manufacturing & Outsourcing - Version A. April 2021 - 3
Medical Manufacturing & Outsourcing - Version A. April 2021 - 4
Medical Manufacturing & Outsourcing - Version A. April 2021 - 5
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