Watttron, a German startup specializing in digital heat-sealing technology, has secured contracts across multiple industries for its innovative “cera2seal” system, which promises to significantly enhance sealing performance, particularly for recyclable packaging using mono-materials. The patented technology has demonstrated impressive results, including up to 50% energy savings and a return on investment (ROI) within six months.
Over the past year, Watttron has won retrofit contracts in industries such as dairy, pet food, beverage, and pharmaceuticals. Its cera2seal solution uses precise, targeted temperatures to ensure reliable seals on complex packaging shapes and recyclable mono-materials, which are often challenging to seal with conventional methods.
“These contracts reflect the growing need for digital sealing solutions that not only cut energy costs but also improve sealing precision, reducing leaks and contamination,” says Dr. Sascha Bach, Chief Technology Officer at Watttron. “This contributes to greater sustainability, improved product quality, and reduced waste.”
Energy Savings and Faster ROI
The core advantage of cera2seal lies in its ability to deliver precise heat only where needed, avoiding the energy wastage typical of conventional sealing methods, which operate like a hot iron with a uniform temperature setting. According to Watttron, the system can save up to 50% in energy costs while compensating for productivity losses of up to 30%.
“Our precise temperature control process reduces both product and packaging waste, as well as labor losses,” explains Bach. “For retrofitted systems, manufacturers could see a return on investment within six months, depending on production volume.”
Ideal for Mono-Materials and Creative Packaging Designs
Watttron’s cera2seal system is particularly beneficial for sealing recyclable mono-materials, which are known for being difficult to bond effectively. The system’s flexible, pixel-based heating technology allows it to apply optimal heat even to complex shapes like round or polygonal packaging, ensuring durable and reliable seals.
Capable of handling a wide range of packaging, from yogurt pot lids and coffee pods to blood plasma pouches, cera2seal ensures consistent performance across industries. “For perishable food products, such as dairy, controlling moisture and maintaining product quality is critical. Our system seals peelable lids securely to rigid plastic containers, enhancing food safety,” says Bach.
Watttron’s digital heating process is also ideal for temperature-sensitive products like chocolate. By avoiding residual heat exposure, the system preserves the product’s properties, reducing waste and ensuring consistent product quality.
Technological Precision and Sustainability
The cera2seal system utilizes up to 16 heat pixels, each with its own temperature sensor, to deliver precise heat at the sealing point. Capable of reaching temperatures of up to 250 degrees Celsius, the system monitors temperature fluctuations 100 times per second, ensuring consistent bonding, even for materials with narrow processing windows like mono-materials.
“Temperature control at this level has not been possible before,” adds Bach. With heating rates up to 50 K/second and a power output of up to 200 watts per square centimeter, cera2seal is setting new standards for digital sealing in packaging.
Industry Collaborations and Future Plans
Watttron’s recent success has led to collaborations with major packaging machinery manufacturers, including Volpak, Mespack, and RA Jones, who are expected to integrate cera2seal into their machinery lines.
Looking ahead, Watttron will showcase its cera2seal technology at the Fachpack exhibition in Nuremberg, Germany, from September 24-26. Attendees can learn more about this cutting-edge sealing solution at stand 322 in hall 2.
