High-Precision Laser Systems for Smart Packaging
Non-Contact Laser Technology: Offers a high-speed, maintenance-free alternative to traditional mechanical perforation.
Zero Mechanical Stress: Eliminates tool wear and material deformation during processing, ensuring flawless product functionality.
Industrial-Grade Reliability: Engineered for heavy-duty, 24/7 continuous production with minimal maintenance requirements.
Instant Digital Changeover: Enables rapid, software-controlled switching between different perforation and scoring patterns with zero downtime.
Extreme Processing Accuracy: Delivers unmatched precision, maintaining consistent hole diameters from 50 to 200+ microns across all types of films and foils.
Scalable Efficiency: Boosts overall production throughput via a scalable architecture designed to seamlessly adapt to your manufacturing needs.
Our Laser Micro Perforators
Laser vs. mechanical perforation
| Key difference | Laser | Mechanical (needle, punch & die) |
|---|---|---|
| Technology | CO₂ laser beam, no contact with the film | Needles, or a punch and die, in contact with the film |
| Hole size | Microholes, down to a few tens of microns | Limited by the size of the needle or the punch |
| Pattern | Set in software, changed with a recipe | Fixed by the tooling, changed by hand |
| Precision over a run | Constant: nothing wears | Drops as the needles or the punch wear |
| Maintenance | No tooling, no consumables | Regular tool replacement |
| Scoring and easy-open | Same unit, no extra tooling | Requires dedicated tooling |
| Quality control | Camera inspection in line, corrected automatically | Offline sampling |
| Best for | MAP, breathable films and easy-open packaging | Large holes, high hole counts, thick materials and clean die-cut shapes |
-
High-precision laser micro-perforation, scoring, pre-cutting, and engraving of moving film webs, enabling controlled and repeatable material processing without mechanical contact.
-
Designed for advanced packaging needs including MAP/EMAP packaging, easy-open features, and breathable films used across food, pharmaceutical, and automotive sectors. Ensures extended shelf life, user convenience, and optimal material performance.
-
CO₂ laser-based systems, machine-direction converting or equipped with galvanometric scanning heads (Model LaserScan), adjustable parameters including pulse frequency, laser energy, and processing speed. Supports full integration with vision inspection and control systems for real-time monitoring and alignment. Industry 4.0-ready architecture with touchscreen control, recipe management, and remote diagnostics capability.
Integrated Camera Vision Inspection System
Spark Machinery's Camera Vision Inspection is an advanced, inline machine vision technology designed to guarantee zero-defect laser perforation through real-time monitoring and dynamic autocorrection.
Why Integrate Machine Vision in Laser Perforation?
Unlike traditional methods that rely on statistical post-production sampling, our proprietary optical inspection system analyzes the micro-perforation process continuously. This ensures absolute precision for critical applications like Modified Atmosphere Packaging (MAP) and films for pharmaceutical applications.
- 28 Hz Control Frequency: High-speed optical scanning processes data instantly, maintaining maximum production line speeds without compromising inspection quality.
- Micron Membrane Detection (> 1 Micron): High-resolution cameras detect even the smallest unperforated residual membranes, blockages, or irregular hole geometries down to 1 micron.
- Real-Time Autocorrection: The system features a closed-loop feedback mechanism. If the vision system detects a deviation in hole diameter or quality, it automatically adjusts laser power and pulse duration in milliseconds to correct the process on the fly.
- Automatic Focus on 3D Scanning: On 3D scanning heads the vision system also drives the motorised Z axis, keeping the beam in focus across working areas up to 1,800 × 1,800 mm. Focusing is no longer a manual setup step: the machine finds and holds the right focal plane by itself, for fully automatic operation from the first metre of the reel.
Spark Machinery vs. Traditional Inspection
| Feature | Traditional Methods | Spark Machinery's Camera Vision |
|---|---|---|
| Inspection Type | Manual / Random Sampling | 100% Inline Automated |
| Error Correction | Delayed (Post-production) | Real-time (Autocorrection) |
| Focus Adjustment | Manual, set by the operator | Automatic on 3D scanning (closed loop) |
| Material Waste | High (Whole batch rejection) | Near Zero |
Food & Breathable Packaging
Ensure maximum freshness and extended shelf-life for perishable goods. Our systems provide high-precision MAP (Modified Atmosphere Packaging) and EMAP solutions.
Best for: Fresh produce, salad bags, and bakery products.
Key Advantage: Precise CO₂ laser micro-perforation from 40µm to control gas exchange.
Medical & Pharmaceutical
Maintain strict hygiene standards with a contactless, sterile perforation process.
Function: Micro-perforation for sterilizable medical packaging.
Key Advantage: No mechanical contact means zero risk of tool contamination or material tearing.
Technical & Automotive Solutions
Engineered for high-performance membranes, filters, and ventilation systems. Our laser technology ensures perfectly uniform holes that optimize airflow and enhance component durability in the most demanding environments.
Best for: Airflow membranes, industrial filters, and automotive interiors.
Advantage: Maintains mechanical strength and consistency in technical textiles and composites.
Easy-Open & Convenience Features
Enhance user experience with high-precision laser scoring and easy-opening. Create precise "tear here" lines without compromising the barrier properties or the structural integrity of the packaging.
Function: Linear or shaped scoring for easy-tear pouches and bags.
Speed: Up to 380 m/min with the LO-S40 system.
Overview of our Laser Micro Perforators
Three machines on one platform: two perforate continuous lines along the web, one scans the beam across it to draw any pattern. Every model uses a CO₂ source and integrates into your existing converting line.
Machine direction · Entry level
LaserOne Line
Fixed beam, no scanner. The movement of the web itself draws continuous perforation lines, at the lowest investment in the range.
- Maximum speed
- 150 m/min
- Hole diameter
- Ø 50–200 µm
- Machine vision
- Optional
Machine direction · High output
LaserOne Track
A motorised single-axis galvo mirror follows the film during each pulse, so the holes stay perfectly round at full line speed.
- Maximum speed
- 380 m/min
- Hole diameter
- Ø 50–200 µm
- Machine vision
- Standard
Scanning · 2D and 3D
LaserScan 2D/3D
Galvo mirrors steer the beam anywhere inside the working field: continuous lines, custom shapes, cross pre-cuts and drawings, across the web as well as along it.
- Maximum speed
- 400 m/min (2D)
- Hole diameter
- From Ø 60 µm
- Working field
- Up to 1,800 mm
Compare the laser range
| Machine direction | Scanning | |||
|---|---|---|---|---|
| Feature | LaserOne Line | LaserOne Track | Scanning laser 2D | Scanning laser 3D |
| Beam delivery | Fixed head, fixed beam | Fixed head with motorised single-axis galvo | Galvo scan head, 2 axes (X, Y) | Galvo scan head, 3 axes (X, Y + Z focus) |
| Perforation direction | Machine direction | Machine direction | Cross web and machine direction | Cross web and machine direction |
| Patterns | Continuous lines | Continuous lines | Continuous lines, holes, custom shapes, drawings, cross pre-cuts | Continuous lines, holes, custom shapes, drawings, cross pre-cuts |
| Maximum speed | 150 m/min* | 380 m/min* | 400 m/min* | Depends on focus† |
| Hole diameter | Ø 50–200 µm* | Ø 50–200 µm*, perfectly round at full speed | From Ø 60 µm* on 50 × 50 mm, Ø 100 µm on 110 and 200 mm, Ø 120 µm on 300 mm | From Ø 150 µm* on 600 × 600 mm, Ø 250 µm on 1,800 × 1,800 mm |
| Working area | One line per head | One line per head | 50 × 50 to 300 × 300 mm | Up to 1,800 × 1,800 mm |
| Focus | Fixed, auto focus optional | Fixed, auto focus optional | Fixed, auto focus optional | Motorised Z axis, automatic with machine vision |
| Machine vision | Optional | Standard | Optional | Optional |
| Functions | Microperforation, cutting, pre-cutting, scoring | Microperforation, cutting, pre-cutting, scoring | Microperforation, cutting, pre-cutting, scoring | Microperforation, cutting, pre-cutting, scoring |
| Laser source | CO₂, 80–1,000 W* | CO₂, 80–1,000 W* | CO₂, 80–1,000 W* | CO₂, 80–1,000 W* |
| Ideal for | Entry-level laser perforation on standard-speed lines | High-output lines that need round holes at speed | Precise custom patterns at high speed | Large-format patterns and wide webs |
* This value depends on the type of material, application and machine configuration.
† On the scanning laser 3D, the maximum speed depends on the focus travel the requested job needs: the more the beam has to refocus across the field, the lower the speed.
Get a free quote for your perforation project
Tell us your film, your line speed and what the pack has to do. We come back with a machine configuration and a price, and we can perforate a sample of your own material in our lab first.
- Free and without obligation
- Answer within two working days
- Sample test on your material
Fill in the form below, or write to info@sparkmachinery.com.