Ultrasonic Lamination Is a Truly Green Process

Beckmann Converting, Inc., the toll converter using ultrasonic bonding technology to laminate textile composites of nonwovens and other materials, contributes to the sustainability initiatives of its customers.

“Through constant communications with customers and the continuous improvement processes in our Quality Management System, the Beckmann Converting team is attentive to sustainability in all that we do. Our customers tell us this focus helps deliver important value to them by maintaining the outcomes of their own sustainability programs,” Ray Piascik, Director of Marketing and Sales, Beckmann Converting, Inc.

Ultrasonic laminating, by nature, is a highly sustainable process. It consumes a low amount of energy compared to other laminating techniques. Only the raw materials of the composite are used to form the bonding links at the laminate weld points – no adhesives or chemicals are added to achieve lamination. Highly uniform, consistent textile composites can be manufactured without degradation of the individual layers due to excessive heat or pressure, or by adhesives. All of this combines to maximize performance of the end-product, making it ideal for health care, filtration, and other applications where potential contamination is of concern.

Ultrasonic lamination uses conversion of acoustic energy to heat to form spot welds of specific size in exact locations, determined by the pattern of the bonding roll, across the laminated webs. This technique is an ideal method to join layers of different or similar materials (nonwovens, films, composites, or fabrics) into a single composite or laminate. Bonding occurs very quickly, and with repeatability resulting in visual uniformity. With attentive design of the laminating process to meet specification requirements for a given composite, non-compliant finished material product can be virtually eliminated.

The team at Beckmann Converting builds upon this core sustainability in several ways. Most laminates bonded ultrasonically contain no more than three or four layers. Beckmann’s equipment and processes enable up to seven different layers, opening the envelope of opportunity for the product designer to take advantage of this green technology.

Staff communicates closely with customer R&D and manufacturing groups to coordinate dimensions, both widths and lengths, of raw material rolls to minimize waste and scrap. The company works with several waste management companies to continually identify new opportunities for recycling and re-use of all trims and offcuts that are unavoidable on a laminating program. In some cases, customers arrange for collection and shipment of waste materials back to their own recycling stream.

All of the company’s laminating equipment has inline slitting capabilities, eliminating the need for secondary operations to prepare the finished laminate for “downstream” converting steps.

Customers can have confidence that investments they make in sustainability of their products will not be lessened as a result of the ultrasonic laminating process. In fact, they can rely upon Beckmann Converting to work closely with them to enhance the gains that they’ve made. www.beckmannconverting.com

A More Efficient Absorbent Boom Launched to Rapidly Contain Oil Spills and Speed the Recovery of the Surrounding Marine Environment

Booms, in the context of environmental protection, are physical barriers deployed in bodies of water to contain or control the movement of pollutants, debris, or other materials. Sorbent booms are primarily designed to absorb oil spills on the water’s surface, preventing the spread of oil and minimizing environmental damage. As an industry leader in spill control (including sorbent booms) and technical nonwovens, FyterTech Nonwovens now offers three different types of booms – Open Net Boom, Sock-InNet Boom and the recently launched AquaSpill Rapid Recovery Boom, as shown below.

AquaSpill Rapid Recovery Boom (as shown in Picture 1A) looks like most other commercially available boom. But, its construction is unlike any other sorbent boom on the market (as seen in Picture 1B). Sorbent boom, much like sorbent pads and rolls, relies not only on absorption but also on adsorption mechanism –where the spilled fluid is attracted to the spill control product’s available surface area. The AquaSpill Rapid Recovery Boom significantly improves performance and efficacy by creating many layers and crevices of additional beneficial surface area – leading to a much faster and more efficient oil spill response tool.

Traditional booms typically have a sleeve, or a plastic netting filled with meltblown polypropylene fluff, shredded pieces, or scrap. Although this gives it a more uniform shape, it does limit the oil spill’s access to all the absorbent material inside. The highly efficient AquaSpill Rapid Recovery Boom easily outperforms not only our other Spilfyter booms, but also all our major competitors as shown in the graph below:

Booming Benefits

AquaSpill Rapid Recovery Boom will have a significant impact on accelerating oil spill response and cleanup efforts. Here are some of the potential benefits and impacts:

1. Rapid Containment: Faster absorbing booms can quickly surround and contain oil spills, preventing the spread of oil to larger areas. By deploying these booms promptly, the initial containment can be achieved more efficiently, reducing the potential environmental impact, and allowing for quicker cleanup operations.

2. Increased Efficiency: The faster absorption rate (as indicated in the graph above) of these booms allows for more efficient oil recovery. As the oil is absorbed more quickly, it can be removed from the water surface at a faster pace, facilitating a more rapid and effective cleanup process. This can help to minimize the overall duration of the cleanup operation and reduce the potential long-term environmental consequences.

3. Enhanced Environmental Protection: By containing and absorbing oil spills rapidly, faster absorbing booms help to protect and speed the recovery of sensitive ecosystems and wildlife. They limit the spread of oil, reducing the potential for contamination of coastal areas, wetlands, and other environmentally sensitive habitats. This can help mitigate the impact on marine and coastal wildlife, including birds, fish, and marine mammals.

4. Improved Safety for Response Teams: Faster oil spill absorbing booms can contribute to the safety of cleanup workers. By accelerating the absorption of oil, the exposure time for workers who are involved in the cleanup operation can be reduced. This minimizes their contact with hazardous materials and potentially harmful substances, improving their safety and well-being during the cleanup process.

5. Cost Efficiency: Faster oil spill absorbing booms can also lead to cost savings by reducing the overall time required to remove the surface oil from the affected area. This can benefit both the organizations responsible for the cleanup and the taxpayers who may bear the financial burden.

Larger Impacts

Speeding up the recovery of the surrounding ecosystem is of utmost importance. You can easily extrapolate the benefits of a more efficient absorbent boom to the many environmental issues that concern our world including the protection of marine life and habitats as well as the mitigation of pollution in our oceans and major bodies of water.

AquaSpill Rapid Recovery Boom can play a crucial role in protecting marine life by minimizing the spread and impact of oil spills. Oil spills can have toxic effects on marine life, including fish, sea birds, shellfish, and other aquatic organisms. By quickly containing and absorbing the oil within a confined area, the booms limit the exposure of marine organisms to the harmful substances present in the oil. This reduces the risk of immediate and long-term damage to their health and ecosystems.

By absorbing the spill faster, you can also limit the spread of pollution, ease cleanup efforts and allow response teams to focus on rehabilitation and recovery sooner. Effective and efficient oil spill response, facilitated by the fastest absorbent booms, demonstrates a commitment to environmental responsibility. This commitment to responsible practices and protecting the environment will positively influence public perception and stakeholder relationships.

It’s important to note that while faster absorbing booms can offer significant advantages, they are just one component of a comprehensive oil spill response plan. Effective oil spill response requires a combination of strategies, including containment, recovery, and proper disposal of the collected oil. Furthermore, prevention measures and stringent safety protocols should be in place to minimize the occurrence of oil spills and protect the environment proactively. Besides, the effectiveness of booms also depends on factors such as prompt deployment, proper installation, and appropriate maintenance. www.liquidsafety.com

Bekaert Bekipor® Filtration Media Performance

Filtration of hydraulic fluid is a key process in many industries, such as aerospace, mining, construction and others. It ensures the cleanliness and performance of hydraulic systems, which can be greatly affected by contaminants and corrosion. However, conventional filter media, such as glass fiber or cellulose, have limitations in terms of efficiency, durability and disposal.

Bekaert Bekipor® filtration media is a porous web of sintered, stainless steel fibers that can be used for various filtration applications. It can be made of different alloys and have a monolayer or multilayer graded structure. It can also be pleated and welded to create flexible filter elements.

This filtration technology offers several advantages over traditional media in hydraulic filtration. This robust media ensures fluid cleanliness even under harsh operating conditions like vibrations, high dust load, temperature and pressure. Moreover, metal fiber media offline cleaning of metallic hydraulic filters had been proven and can extend the filter usability. As shown in plot below, cleaning can be optimized to decrease its environmental impact per gram of cumulated caught dust. After a low number of reuses, metal fiber filter becomes less impactful than typical disposable hydraulic incumbent filter. Metal fiber media is fully recyclable, as the steel fibers can be separated from the filter element and reused for other purposes. This reduces the environmental impact of disposal and supports the circular economy. In contrast, conventional filter media often require incineration or landfilling, which generate greenhouse gas emissions and waste.

Bekipor® media is a responsible filtration technology that outperforms conventional media in terms of efficiency, durability and recyclability. www.bekaert.com