Macro Perforation Machines by Spark Machinery

Macro perforation systems are built to punch holes of varying diameters and shapes through flexible materials in motion. These holes confer crucial functional properties—such as permeability, drainage, and controlled airflow—so that films, foils, or nonwoven webs can breathe, release moisture, or equalize pressure without compromising structural integrity. Particularly in packaging, food, agricultural, and industrial contexts, the controlled apertures help maintain product quality, reduce waste, and enhance usability.

The versatility of Spark’ Machinery’s macro perforators finds use across numerous industries. In food and produce packaging, macro holes help maintain freshness by allowing gas exchange. In agricultural films and mulching, they support moisture control and plant health. In the manufacture of bags, pouches, and packaging films, they are used for handles, valve holes, euro-slots, or other shaped openings. Because the machines can process a wide range of flexible substrates (PE, PP, BOPP, nonwovens, even composite films), they serve clients ranging from packaging converters to agricultural product manufacturers.

Spark Machinery offers side-unit and bridge (PU series) designs that integrate directly into moving film lines. The bridge systems are engineered for high speed and stability—operating at up to 250 m/min under optimal conditions. Side units arecompact and ideal for punching along film edges, making them easy to integrate into existing lines. The actual perforation is achieved via punch-and-die mechanisms — pneumatically actuated — with a choice of dies to produce circles, euro-slots, handles, or custom shapes. Control systems employing encoders, photocells or electronic logic ensure precise registration, consistent spacing, and synchronization with printed films.

Side units are space-saving punching units designed to punch macroholes of various diameters and shapes on the moving film edge by means of die and punch driven by an electronic control system. This choice is the most advantageous and economical for those who need to make a few lines of holes on materials up to 600mm wide.

Reduced Dimension: The side units are designed with a reduced dimensions to maximize available space in existing production lines, allowing easy integration and ensuring high efficiency.

Versatility: These units can punch macroholes of various diameters and shapes, offering a versatile solution for a wide range of industrial applications.

Easy Integration: Because of their compact design, the side units can be easily integrated into existing equipment such as extruders, welding machines, slitters, bag machines, printing machines, and into all moving film processing lines.

These space-saving macro perforation punching units are widely used in the packaging industry and in plastic film production lines, providing an efficient and reliable solution for punching macro holes on edges of the moving film.

Bridge macro perforation units provide a dependable and flexible solution for creating large holes of different shapes and diameters in moving materials—particularly in neutral or printed plastic films. These systems are specifically designed to operate as integrated modules within continuous film processing lines.

Speed and Precision:
Bridge macro perforators ensure fast, stable, and accurate operation, delivering precise perforations even at high production speeds. Depending on the film type and the desired perforation pattern, these machines can reach working speeds of up to 250 m/min.

Versatility:
This technology is highly adaptable and suitable for a broad range of applications. It is frequently used for fruit and vegetable packaging, agricultural film perforation, and many other processes requiring holes of various shapes and sizes in flexible materials. Thanks to the Industry 4.0 software, the perforation pattern can be easily modified to meet specific production needs, while punching recipes can be saved and recalled at any time for future use. This feature greatly enhances flexibility and production efficiency.

Seamless Integration:
These punching modules can be easily incorporated into existing production lines such as slitters, extruders, printers, welding machines, and rewinders. This allows for smooth integration, increased efficiency, and exceptional adaptability in diverse manufacturing environments.

The macro-punching units are also widely employed in industries such as food packaging, shopping bags, garbage bags, mulching films, packaging films, and more.

Spark Machinery's PU2 macro perforation units are engineered to efficiently create holes of various shapes and diameters in moving flexible materials, such as plastic films. Such models are designed for integration into continuous film processing lines, offering high-speed and stable performance.

The PU20 is a compact and efficient punching unit that delivers precise perforations at speeds up to 200 meters per minute. It operates with a maximum frequency of 45 Hz, allowing for rapid processing of materials. The unit is equipped with an intuitive electronic control system (QCSM1) that enables power and position control for each individual punching tool, as well as the management of punching recipes, including insertion, storage, and recall.

The PU22 enhances the capabilities of the PU20 by incorporating two perforation bridges, effectively doubling the punching frequency. This design allows for higher throughput and greater flexibility in production lines, making it suitable for applications requiring increased perforation density or faster processing speeds. Like the PU20, the PU22 is equipped with an advanced electronic control system for precise operation and efficient recipe management

The PU40 and PU42 are specialized macro perforation units designed for creating large-diameter holes in moving plastic films, particularly for agricultural mulching purposes. These units are engineered to be seamlessly integrated into continuous film processing lines, such as extruders, slitters, and printing or welding machines.

The PU40 is a robust and efficient punching unit, ideal for applications requiring precise perforations at high speeds. It features an advanced electronic control system that allows:

• Individual control of each punching tool

• Management and storage of punching recipes

The unit can operate at speeds of up to 200 m/min with punching frequencies up to 45 Hz, depending on material and perforation pattern. The PU40 is designed to create holes ranging from 1 mm to 100 mm in diameter, accommodating various hole shapes such as circulars, valve, euroslots, handle and custom holes

The PU42 builds on the PU40 by incorporating two perforation bridges, effectively doubling the punching frequency to 90 Hz. This makes it ideal for applications requiring higher perforation density or faster production speeds. Like the PU40, the PU42 offers:

• Advanced electronic control system

• Ability to create holes ranging from 1 mm to 100 mm in diameter

• Compatibility with various hole shapes including circular, valve, euroslot, handle, and custom designs

The PU42 is designed for high-speed operation, with a maximum speed of 200 m/min, depending on material and perforation pattern.

The PU50 is a compact and cost-effective macro perforation unit designed specifically for creating large-diameter holes (50–100 mm) in moving plastic films, primarily for agricultural mulching applications. Its streamlined design makes it ideal for operations with limited space, offering a practical solution without compromising on performance.

• Compact Design: Optimized for installations where space is at a premium, making it suitable for smaller production lines.

• High-Speed Operation: Achieves speeds up to 200 m/min, with a punching frequency of 35 Hz, depending on material composition and hole spacing.

• Versatile Hole Sizes: Capable of producing holes ranging from 50 mm to 100 mm in diameter, accommodating various agricultural needs.

• Pneumatic Punching System: Utilizes a punch and die system driven by pneumatic movement, ensuring clean and efficient hole creation.

• User-Friendly Electronics: Features the QCSM1 control system, allowing for independent management of each punching tool, recipe storage, and remote operation via PC or tablet.

• Seamless Integration: Designed to be integrated as a host unit in film transport lines such as slitters, extruders, printing presses, or welding machines.