LO Series - LaserOne Line
Laser Perforation Model LR1 Line
The Entry-Level Laser Perforator for MAP Packaging
Discover the most economical and efficient way to integrate laser technology into your flexible packaging lines. The LaserOne Line by Spark Machinery is our entry-level laser processing system, specifically engineered for the continuous processing of moving webs.
Designed to operate seamlessly in the machine direction (MD), the LaserOne Line utilizes a highly reliable fixed laser configuration without scanning heads. This streamlined, scan-free approach drastically reduces complexity and costs, making it the most affordable solution on the market for converters looking to upgrade their capabilities without a massive initial investment.
Functioning of a fixed laser perforation line
Description
The CO₂ laser source emits light pulses at a predetermined frequency. A beam expander collimates and widens the beam. A focusing lens then concentrates it onto a small, precisely defined area of the moving film. The energy of the beam sublimates the material, opening a clean microperforation with no contact and no tool wear.
Integration
LaserOne Line is designed as a unit to be integrated into film converting lines such as slitter-rewinders, extruders, printing machines and rewinders. The heads can be positioned across the web width manually or, as an option, by motorised positioning set from the operator panel.
Key Features & Capabilities
The Most Cost-Effective Solution: A fixed-beam, scan-free architecture ensures the lowest cost of entry, maximum reliability, and minimal maintenance.
Machine Direction Processing: Dedicated to continuous web perforation, scoring, and pre-cutting directly along the web's flow.
Precision Micro-Perforation: Achieve highly accurate and repeatable hole diameters ranging from 50 µm to 200 µm, ensuring optimal gas exchange for MAP applications.
High-Speed Performance: Built to keep up with your production flow, operating at speeds of up to 150 m/min.
Versatile Applications: Your all-in-one entry-level tool for breathability (perforation) and consumer convenience (scoring and pre-cutting).
Machine Vision and Self-Correction
For applications requiring high-precision microperforation, Spark Machinery can integrate a camera-based vision system. It inspects every hole in real time, detects deviations and automatically corrects the process without stopping production.
With image capture in as little as 1 µs, the system performs up to 28 analyses per second without slowing down the line. For each hole it measures:
the free area, which determines gas exchange;
the deviation from the theoretical diameter;
the melting ring, to verify that the laser focus is optimal.
It also detects residual membranes thicker than 1 µm, which leave a hole looking open while compromising its permeability. Production data is automatically collected in a quality report for each reel, ensuring full traceability.
When deviations from the target values are detected, the control system adjusts laser power, pulse duration and focus (with optional Auto-Focus) in real time. This compensates for small variations in material thickness, blend and temperature and keeps perforation consistent with the working recipe.
This combination of real-time inspection and self-correction reduces manual checks, scrap and downtime, improves process efficiency and ensures consistent production quality.
Industry 4.0 and remote support
Built for Industry 4.0, the machine is managed from a touch-screen panel where your operators store every perforation parameter as a recipe, and it connects to your factory systems to exchange production data with your MES or ERP. Through remote assistance our technicians check parameters, diagnose faults and update the software without waiting for a site visit, and support your team live during commissioning or when a new recipe is set up.
Technical data
| Laser source | CO₂ |
|---|---|
| Laser source power | 80–1,000 W* |
| Maximum speed | 150 m/min* |
| Minimum hole diameter | Ø 50 µm |
| Wavelength | 9.3 µm, 9.6 µm, 10.2 µm or 10.6 µm* |
| Cooling system | Liquid |
| Pulse frequency | Max. 200 kHz |
| Minimum firing time | 4 µs |
| Hole inspection rate | Up to 28 analyses/s (with Machine Visionl option) |
* This value depends on the type of material, application and machine configuration.
Options
- Camera-based hole quality control
- Automatic laser head repositioning
- Auto focus
- Dancer roll
- Fume filtration system
- Trolley
Materials
Primary Applications
Fresh Produce & MAP Packaging
Controlled micro-perforation (50 µm – 200 µm) designed for Active & Equilibrium Modified Atmosphere Packaging (EMAP).
- Calibrated gas exchange for salads, berries, and vegetables
- Maintains target OTR/WVTR without film rupture
- Prevents condensation and fungal growth inside the pack
Continuous Scoring & Easy-Open
Precise depth-selective scoring along the web flow, enabling clean, straight tear lines on multilayer packaging.
- Effortless tear initiation for pouches, sachets, and stick-packs
- Scores the outer film layer while preserving inner barrier layers
- Eliminates mechanical blade wear, dust, and tear deviation
In-Line Converting & Slitting
A compact fixed-optic unit engineered for non-stop processing, easily retrofitted into existing converting machinery.
- Continuous machine-direction operation up to 150 m/min
- Direct integration with slitter-rewinders and pouch machines
- Low maintenance overhead with zero moving optical parts
Advantages & Benefits
Autonomous Closed-Loop Quality Control
An optional in-line machine vision system that continuously inspects micro-perforations and automatically recalibrates laser parameters on the fly.
- Real-time inspection of hole diameter (50–200 µm) and geometry on the moving web
- Adaptive power and pulse tuning to compensate for substrate thickness variations
- Ensures targeted, repeatable OTR levels throughout the entire production run
- Eliminates manual checks and prevents out-of-spec MAP batches from shipping
Dynamic Speed-to-Power Matching
Integrated encoder feedback matches laser output directly to web speed up to 150 m/min, preventing under- or over-processing.
- Uniform hole sizing and scoring depth during ramp-up, steady run, and deceleration
- Eliminates film burns, pinhole flaring, and unperforated start-up lengths
- Seamless operational synchronization with slitter-rewinders and pouch lines
Barrier-Safe Selective Scoring
Contactless thermal scoring vaporizes targeted outer film layers while leaving internal barrier and seal webs completely unharmed.
- Precision depth control preserves gas-barrier properties on multi-layer laminates
- Clean, predictable tear lines for consumer-friendly easy-open formats
- Zero blade wear, zero mechanical tension, and zero particulate contamination
Reliable Fixed-Beam Architecture
A direct optical path purpose-built for continuous machine-direction converting, stripping out costly galvo-scanner complexity.
- Lowest entry barrier and capital expenditure for industrial laser converting
- No moving mechanical optics for near-zero routine optical servicing
- Compact footprint engineered for rapid retrofit into existing production lines
Contact us - Get in touch with our experts
READY TO INTEGRATE?
Bring High-Precision Laser Processing to Your Web Line
Write us at info@sparkmachinery.com