Automatically produce and package 120 FFP2 masks per minute

"From fleece to packaging" - the innovative production line enables the fully automatic manufacturing and packaging of 120 high-quality FFP2 masks per minute. (Image source: Schneider Technologies)

The standard converter used for contour welding was specifically developed for continuous welding mode. An offset contour at the edge of the seam ensures a stable amplitude. (Image source: Schneider Technologies)

In the production line, masks can be made from up to five nonwoven layers. (Image source: Schneider Technologies)

During the welding of the ear bands, the special design of the welding stations and the configuration of the oscillation systems and sonotrodes ensure the correct execution of each individual weld point. (Image source: Schneider Technologies)

For the welding of the L- seam, which is carried out continuously, the masks are rotated. (Image source: Schneider Technologies)

From the idea to the commissioning of the world's most modern production system for FFP2 protective masks, just ten months passed. The plant, with ultrasonic solutions for continuous and timed ultrasonic welding from Weber Ultrasonics, enables the fully automatic production and packaging of 120 masks per minute.

It is Easter Sunday 2020, the first wave of COVID-19 is gripping the world when Stephan Schneider reads a report about the mask chaos: respiratory protection and FFP2 masks are practically unavailable in Europe, and if they are available, only at inflated prices from Asia and sometimes questionable quality. The article inspires the diploma engineer and passionate machine builder to develop his own FFP2 mask and the necessary production technology, aiming to establish a secure and competitive mask production "Made in Germany" in the long term. Founded in 1998, Schneider Technologies GmbH + Co. KG specializes in the development, design, and construction of special machines and production lines for a broad customer base, for example from the automotive, electrical, sanitary, and chemical industries. A core competence lies in automating and rationalizing manufacturing and assembly processes.

Mask and plant technology developed in parallel

With the production of personal protective equipment and ultrasonic welding, which is a crucial manufacturing step in mask production, the company has entered new territory. "To get a feel for the thermoplastic material, so-called nonwovens, from which the masks are made, their processing, and what needs to be considered, all project participants received training from the Institute for Textile Technology (ITA) at RWTH Aachen," reports Stephan Schneider. Together with the ITA, the mask design was also developed, tailored to European heads.

Similarly pragmatic was the approach to planning the production line. Detailed research on the machines available on the market provided clues on where to start to achieve significantly better quality, performance, and availability. Accordingly, the production technology was designed to be highly automated and almost unmanned. The goal was to produce 120 units instead of the previously maximum possible of 60 masks per minute. High plant availability, a stable construction, and integrated packaging were also top priorities. These requirements, along with expertise from over 400 custom machinery projects, influenced the conception of the production technology. "Since welding processes, especially the welding of ear straps, are quality-critical processes, we sought a partner with experience in mask welding," explains the managing director.

Technical solution, consulting, and support decisive

Stephan Schneider chose ultrasonic equipment from Weber Ultrasonics AG, one of the world's leading manufacturers of ultrasonic components for welding, cutting, and cleaning, as well as modular solutions for attaching ear straps. The decisive factors were the technological concept of the welding solutions, the company's extensive experience in processing nonwovens, and the fact that Weber offers generators, converters, and boosters for mask welding as standard components, with only the sonotrodes being customized. This allowed us to make rapid progress in this area without costly and time-consuming development work. Additionally, the good, solid advice and very open communication, for example about solutions for attaching the ear straps and the design of the rollers, impressed us from the first meeting. We therefore decided spontaneously on Weber and did not speak to other manufacturers," adds Stephan Schneider. The component manufacturer also provided comprehensive support during the verification of process parameters. This was done through welding tests in Weber's technical laboratory using Schneider's original mask material. It consists of three different nonwoven layers, with the middle layer being a pre-bonded composite material. "Our goal is not only to produce high-quality masks with the production line but also to sell the production technology. To be able to respond flexibly to customer-specific requirements, the system is designed to process up to five nonwoven layers," notes Stephan Schneider.

Fully automatic production with continuous and timed welding

The production line is equipped with a total of seven ultrasonic welding systems. The Industry 4.0-capable Sonic Digital HS3 welding generators, each with 2,000 watts of power, feature five welding modes, ensuring reliable continuous and timed welding. Furthermore, innovative functions ensure maximum process safety. These include, for example, the Teach-In, which automatically determines the optimal start frequency and control parameters of the connected oscillation systems, and the Sonoscan function, which identifies the correct working frequency. Temperature tracking calculates frequency shifts caused by temperature changes and automatically compensates for them as well.

After placing the nonwoven rolls on the coilers, the fully automatic process begins with inserting the nose bridge. Then, the contours of the mask are welded in a continuous process. The titanium welding converter used here was specially developed for uninterrupted applications. For smooth switching from continuous to timed processes, an intermediate buffer is integrated, from which the masks are initially printed with the manufacturer's details, CE mark, and test number in a printing unit. Subsequently, the ear straps are welded in two stations. The special design of the ear strap welding stations and the configuration of the oscillation systems and sonotrodes made of titanium ensure the correct execution of each individual weld point. Another buffer follows, as the subsequent shaping of the masks and the welding of the L-seam are also performed in continuous processes. In the next step, the masks are cut out, automatically transferred to a tubular bag packaging system, and individually packed. Finally, an automatic sorting of ten or twenty masks with subsequent packaging into sales cartons takes place, which are then placed into transport cartons by a robot. The requirement "from nonwoven to packaging" has thus been fully met.

All process steps are monitored via sensors and camera systems, and the results are continuously compared with predefined setpoints stored in the control system. This allows masks that are not produced or packaged correctly to be automatically sorted out before and after packaging.

The innovative manufacturing line enables the hygienic production of up to 100 million high-quality FFP2 masks per year in Europe's high-wage countries at competitive prices, rivaling Asian competition. "We are convinced that the leading mask welding technology and Weber Ultrasonics' unwavering support helped us implement this project with high quality in less than a year," concludes Stephan Schneider.