Ultrasonic Sealing Vs. Heat Sealing

ultrasonic tube sealing machine


Now the two most popular ways for packaging and production to seal are heat sealing and ultrasonic sealing. How do these procedures work, and what factors influence companies’ decisions? To better understand the differences between heat sealing and ultrasonic sealing, we shall first define each:

Heat Sealing

To create a seal, heat sealing involves melting plastic with metal bars, pressing the two materials together, and then letting them cool.

Ultrasonic Sealing

This technique involves using a sealing tool to create a high-frequency vibration, which changes the molecular composition of the plastic tubing. The plastic softens as its molecules vibrate, and when compressed between two surfaces using a sealing anvil, the resulting connection forms the seal.

To help you choose, we’ll compare and contrast ultrasonic sealing with heat sealing, taking a look at the benefits and drawbacks of each.

Heat Sealing Advantages

Fast, effective, and ideal for high-speed operations is heat-sealed packaging. It completely encloses single or multi-product packaging and offers covering all around. When compared to other types of packaging, heat sealing is more cost-effective and requires less initial investment.

🔵 Issues with heat sealing

Heat sealing often encounters the following issues:

  1. When first turning on the machine, heat sealing jaws take longer to reach the temperature required to melt and fuse the plastic.
  2. The sealing jaws stay hot for a while after usage, which may make cleaning and post-production more labor-intensive and even dangerous for workers if they aren’t cautious.
  3. Because of the disruption in the heating process, goods containing liquids, such as salad dressings, drinks, condiments, and other similar products, have more leakage when sealed.

Ultrasonic Sealing Advantages

Using an Ultrasonic Tube Sealing Machine might be the better option if you’re having problems with the heat sealer not meeting your requirements. One of the many benefits of ultrasonic sealing is that it:

Effective Sealing

Using ultrasonic seal, packages may be molecularly sealed to perfection, even when there is product residue in the seal region. An ultrasonic seal’s superior accuracy means less chance of leakage, cleaner machinery, and manufacturing equipment, and lengthens the shelf life of a product. This technique of sealing works well with solids as well as liquids.


Ultrasonic sealing is versatile for binding many different types of materials and films because of its low working temperature.

Low food wastage

Because ultrasonic packing does not generate any heat, it is perfect for preserving perishable goods like chocolate, dairy products, pharmaceutical items, and many more that are either frozen or otherwise sensitive to heat.

Lower use of energy

Ultrasonic seal doesn’t release any heat as it doesn’t need any. The quantity of energy used is drastically decreased because of this component. Not only that, heat sealing machines continue to take energy even when they are not in use, as they continue to emit heat.


Auto Ultrasonic Plastic Sealing Machine MWPF-1

Ultrasonic Tube Sealing Machine


Reduce waste

Ultrasonic sealing reduces raw material waste and material consumption per bag compared to heat sealing. This is because it achieves a smaller, more concentrated seal area. Material savings like this may add up to substantial savings in large-scale manufacturing runs.

Minimal maintenance

Because it is less mechanically demanding, ultrasonic sealing reduces the frequency and severity of machine replacements as well as maintenance needs.

🔵 Ultrasonic Sealing Disadvantage

One drawback is that the tube sealing speed is lower than hot-air or heat sealing.

Is ultrasonic sealing preferable to heat sealing?

Keep in mind that heat sealing often results in a more durable seal because of its wider characteristics. Ultrasonic sealing, on the other hand, may save raw material wastage due to its smaller seal. Before deciding on a seal width, it is important to think about how it will look.

Investment costs and returns

The initial investment in ultrasonic sealing more than compensates for itself through lower resource costs, which is a big plus. These cost reductions mainly affect:

Decrease of raw materials

In comparison to traditional sealing methods, ultrasonic sealing results in a smaller seal with less material used. These minor savings will add up to significant savings in the long run. An advantage of being able to seal through contamination is the reduction of product waste.

Less use of energy

Because ultrasonic sealing only draws energy when it seals, it is far more economical than heat sealing as it does not create any heat at all.

Less upkeep 

Due to their resistance to severe temperatures, such as frequent heating and cooling or the removal of Teflon tape from the seal bars, ultrasonic welding systems need less maintenance.

Given that heat sealing usually results in lower pieces per minute, speed is another consideration. Making an informed decision on the best process for your tube filling and sealing needs requires careful consideration of your unique products, specifications, and uses.

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