TOLL PERFORATION SERVICES

Stewarts of America Inc. offer toll perforation services. There are no bad or good perforating methods… there is simply a perforation method they suits your requirements and which operates within the parameters you require. 

PRODUCT DEVELOPMENT
With our toll perforation site and laboratory, we can offer companies assistance with initial product development. Calculating the correct MVTR (Molecular Vapor Transmission Rate) or OTR (Oxygen Transmission Rate) is not always a perfect science. Therefore we have a developmental site that offers low production capability and laboratory that give you the results. This unique capability tied with the fact that our machine shop is setup for one-off pieces as well as high production runs mean that we can make a pinned sleeve specifically for your application, run your material, and give you results for you to make a determination.

If you choose to purchase one of our perforation machines, the pinned sleeves purchased for the trialing will be made to fit the machine that you purchase, optimizing the R&D cost.
Whether you want your material to breathe, to be more absorbent, to allow transfer of a liquid or gas, or to tear in a certain direction.... we can help.

CONSULTATION
Our perforating experience covers a wide range of applications. From poultry to PVC films, we have perforated it all. Ask our clients, we enjoy a challenge, and our engineers are here to solve your perforation quandary. Our agents are available world wide. Simply contact us, and if possible, we will arrange for an meeting at your facility to discuss a specific application. We also offer video conferencing, and tele-conferencing to better explain our solutions to you.

PILOT RUNS
Are you a converter and your customer making a decision about perforations in their material? Do you not yet have the justification to purchase a perforator? No problem. With our toll perforation services we offer cost effective solutions that allow you to make the minimum investment, while satisfying the client. Once the business is established, you can continue to allow us to perforate your product, or you can purchase your own machine from us, with full knowledge of the results you can expect.

TOLL / CONTRACT PERFORATION
If you do not have the space or need for additional equipment in your plant, let us perforate your material for you. Your material will be taken care of by our state-of-the-art machinery, and experienced staff. You send it, we perf it, and we send it back to you. That simple. Please contact our office for descriptions of the hole patterns and hole sizes we currently have to offer. We also offer slitting capabilities to complete the package.

Our toll perforation facility is capable of the following methods of perforation:

Hot needle perforation
Hot needle perforation is perfect for applications that require a high level of permeation across the substrate. Hot needle perforation is a cost effective method of placing many or few precise holes in a web, works well on plastic, foil, paper, textiles, non-woven fibers, laminated materials, foams and thin-gauge metals. Hot perforators are servo-driven, to ensure precise perforations with densities of 3000 holes per square inch.

Cold needle perforation
Cold perforation is the most economical and simple method of perforating. The tapered pin used in cold needle perforation punctures a hole in the substrate and elongates the material on the back of the hole. Cold perforation is preferred in applications such as weed blocking films and moisture barriers.

Thermal (flame) perforation
Thermal or “flame” perforation is perfect for ultra high density hole patterns that are required all the way across a web. This type of perforation produces precise and consistent holes.
The flames create perforations that are very clean and free of chads. Flame perforation is similar to hot needle perforaiton as it creates a re-enforced welt around the hole, which makes the material more resistant to tearing. Therefore a thinner material may be used as a substitute to thicker material as it offers the same strength, resulting in a cost savings.

This technology can only be used on bi-oriented substrates such as BOPP, PET, Mylar, Melinex, Hostaphan, Nylon etc.

Vertical Punch perforation
Die and punch sets can be used for thicker materials, or materials that require large gauge holes. The material is sheared by the sharp edges of the punch and die, and the chad is removed by a vacuum system. Punch perforation works well for holes over 1mm. One will see punched perforations in fruit produce bags and on photographic tape. Other examples include ticket punching. Punches can be designed for a desired hole shape and design.

ESD (Electro static discharge) perforation
ESD is ideal for applications that require very small and precise perforations. ESD limitation is the actual hole placement, as electricity arcs between two electrical contacts. There are multiple contacts spread across the web. This technology is appropriate for thin paper and plastics.

Laser perforation
Laser perforation is useful when a low amount of holes are to be placed precisely in a web. Laser perforations look similar in many respects to hot needle perforations, however lasers can be altered to provide an elongated hole if required. Lasers can perforate plastic, paper and other thin-gauge materials. Laser perforation can be adjusted on the fly to ensure an accurate hole in the material being perforated.

Perforation can also be performed in register, which is useful in packaging applications. Laser perforation is cost prohibitive, however.  The machinery required is tenfold that of mechanical methods of perforating. As with all perforating methods, one must understand the benefits of a specific technology to justify the costs.