LO Series - LaserOne Track
Laser Perforation Model LR1 Track
LaserOne speed, without compromising the hole
Spark Machinery laser systems are engineered to microperforate continuously moving films with high-precision CO₂ laser sources. The same technology can also cut, pre-cut and score the film. Scoring weakens the material in a controlled way without perforating it, which is how easy-opening solutions are made.
With microperforations starting from 50 µm, laser technology is widely used in Modified Atmosphere Packaging (MAP). The holes regulate airflow and gas exchange through the film, extending shelf life and preserving product quality.
Machine direction laser with galvo tracking
LaserOne Track shares its architecture with LaserOne Line: fixed heads that perforate in machine direction, integrated into your converting line. The difference is inside the head. A motorised single-axis galvanometer mirror follows the web while the laser fires, so the beam and the film move together for the whole pulse.
Because the beam compensates for the movement of the material, the hole is not stretched into a slot as speed increases. Where LaserOne Line reaches 150 m/min, LaserOne Track runs at up to 380 m/min with perfectly circular microperforations.
Every LaserOne Track leaves the factory with camera-based quality control installed. At these speeds the camera analyses up to 28 holes per second and the process corrects itself in real time, so the free area stays predictable across the whole reel.
Functioning of LaserOne Track model
How it works
The CO₂ laser source emits light pulses at a predetermined frequency. A beam expander collimates and widens the beam, the galvo mirror steers it along the machine direction, and a focusing lens 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 Track is designed as a unit to be integrated into film converting lines such as slitter-rewinders, extruders, printing machines and rewinders.
Key Features & Capabilities
Single-axis galvo scanner
A motorised galvanometer-based system with an optical mirror dynamically follows the moving web. It compensates for material movement and enables perfectly circular microperforations at speeds of up to 380 m/min.
Automation
The software gives independent control of each laser head and automatic correction of the holes. With automatic head repositioning, setup between production runs is fast and consistent.
Camera-based quality control, included as standard
On LaserOne Track, machine vision is not an option: it is installed on every machine. 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, the deviation from the theoretical diameter and the melting ring, which shows whether the laser focus is optimal. It also detects residual membranes thicker than 1 µm, which leave a hole looking open while compromising its permeability.
When a deviation is found, the control system adjusts the mirror tracking speed, laser power, pulse duration and focus* in real time. Production data is collected in a quality report for each reel, for full traceability.
Made for modified atmosphere packaging
Fresh produce keeps breathing after harvest. Micro-perforation lets packaging exchange a controlled amount of oxygen and carbon dioxide, so the atmosphere inside stays balanced and shelf life gets longer.
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 | 380 m/min* |
| Minimum hole diameter | Ø 50 µm |
| Beam delivery | Fixed head with motorised single-axis galvo scanner |
| 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 |
| Machine vision | Standard, up to 28 analyses/s |
* This value depends on the type of material, application and machine configuration.
Options
- Automatic laser head repositioning
- Auto focus
- Dancer roll
- Fume filtration system
- Trolley
Materials
Primary Applications
High-speed MAP
High-Output Fresh Produce Films
Perfectly round micro-perforations (50 µm – 200 µm) at up to 380 m/min, for Modified Atmosphere Packaging (MAP) on high-volume lines.
- Consistent free area for predictable gas exchange
- Calibrated perforation for salads, berries and vegetables
- Keeps pace with fast slitters, extruders and printing lines
Consumer convenience
Scoring & Pre-Cutting at Speed
Controlled weakening of the material without perforating it, for clean easy-open lines along the web direction.
- Cutting, pre-cutting and scoring with the same laser unit
- Easy-open features for pouches, sachets and stick packs
- Contactless process with no blade wear or dust
Line integration
In-Line Converting at Full Speed
A fixed-head unit with galvo tracking, designed for integration into existing converting lines.
- Continuous machine-direction operation up to 380 m/min
- Integration with slitter-rewinders, extruders, printing machines and rewinders
- Independent control of each laser head
Advantages & Benefits
Standard inspection module
Machine Vision Included
Every LaserOne Track ships with in-line machine vision. Up to 28 holes per second are analysed, and mirror tracking speed, laser power, pulse duration and focus* are corrected on the fly.
Web tracking
Galvo-Tracked Perforation
A motorised single-axis galvo mirror follows the moving web during each pulse, so holes stay perfectly round at up to 380 m/min.
Productivity
2.5× the LaserOne Line Speed
Up to 380 m/min compared with 150 m/min on LaserOne Line, with the same compact fixed-head architecture.
Quality & traceability
Less Scrap, Full Traceability
Real-time correction prevents non-conforming material, and a quality report is saved for every reel.
* Automatic focus correction requires the Auto focus option.
LaserOne Line vs LaserOne Track
Swipe sideways to see both models.
| Feature | LaserOne Line | LaserOne Track |
|---|---|---|
| Head architecture | Fixed head, fixed beam | Fixed head with motorised single-axis galvo mirror |
| Beam during the pulse | Stationary, the film moves beneath it | Follows the moving film |
| Maximum speed | 150 m/min* | 380 m/min* |
| Hole shape | Round at standard line speeds | Perfectly round at full speed |
| Machine vision | Optional | Standard |
| Minimum hole diameter | Ø 50 µm | Ø 50 µm |
| Perforation pattern | Continuous lines in machine direction | Continuous lines in machine direction |
| Integration | Slitter-rewinders, extruders, printing machines, rewinders | Slitter-rewinders, extruders, printing machines, rewinders |
| Ideal for | Entry-level laser perforation on standard-speed lines | High-output lines that need round holes at speed |
* This value depends on the type of material, application and machine configuration.
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