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Needle Perforation

Hot needle

Hot needle perforation involves passing super-heated needles through the substrate to both penetrate and melt it in a predictable fashion. This results in a hole consistent in both size and shape.

Our state-of-the-art hot-needle perforation features digital computer controls and servo drives for precise hole size. Potential pattern density can range from just one hole up to 1,000 per square inch. This makes hot-needle perforation the optimal approach for applications requiring many perforations throughout the entire material.

Hot-needle holes typically range from 100 microns up to 1,500 microns (1/16″) depending on the tooling and the substrate being perforated. Perforations can be made either across the full roll width or in defined lanes. Because we toll-perforate for many different applications, we maintain a library of patterns that likely includes a tool set that will work for you. If your application requires a pattern not in our stock, we can have a custom tool set manufactured just for you.

Mechanical “cold needle”

Mechanical (or “cold needle”) perforation is similar to hot-needle perforation but more appropriate for applications that do not require the high consistency and control made possible by heated needles. Mechanical perforation particularly suits industrial applications.

Mechanical perforation differs from hot-needle perforation in that with the absence of heat, the material is only pushed aside and not melted by the needle penetration. This generally results in the hole partially re-closing after perforation, which offers some advantages when trying to permit only one-way passage of a liquid or solid through the hole.

Common applications for needle perforation include:

  • Food packaging: Vent excess air in bulk packages of frozen foods or pet foods.
  • Fresh-cut produce and bakery: Allow undesirable surplus moisture and water to exit the package, resulting in shelf-life extension.
  • Envelopes for super-absorbent meat pads
  • Residential construction: Enable the passage of moisture but not liquid for radiant barriers and house wraps.
  • Perforated liners for weed block
  • Sound management: Permit passage of sound waves through an otherwise barrier material into a sound-absorbing core. This reduces excess sound and reverberation in applications such as automotive and truck interiors, heavy equipment and RVs.

Get started on your solution

Contact us at (630) 554-0010 today to discuss how our inventory of patterns may solve the barrier or permeation issue for your application.