High-Frequency Welding vs. Other Welding Techniques

high-frequency welding

In industrial manufacturing, choosing the right welding method can significantly impact efficiency, product quality, and costs. One of the most advanced and widely adopted technologies is High-Frequency (HF) Welding, especially in the production of conveyor belts and synthetic material processing. In this article, we’ll compare high frequency welding with more traditional welding methods.

What is high-frequency welding?

High-frequency (HF) welding uses electromagnetic waves to generate internal heat within thermoplastic materials, fusing them from the inside out. This technique is particularly effective for materials like PVC, TPU, PET, and other films with dielectric properties.

Advantages of high-frequency welding

  1. High Precision and Uniformity. HF welding ensures seamless, consistent bonds—even on thin or intricate surfaces—offering excellent aesthetics and superior mechanical resistance.
  2. Strong and Durable Seals. Thanks to internal material fusion, HF welding creates a molecular-level bond, ideal for products subject to mechanical stress and long-term use.
  3. Fast Production Cycles. HF welding has significantly faster cycle times compared to other techniques, boosting productivity and reducing overall lead times.
  4. No Direct Contact with Heat Sources. With no direct heat elements, material degradation is minimized, eliminating burns, scorching, or deformation.
  5. Easy Automation. HF welding integrates smoothly into automated systems like those developed by REG Galbiati S.r.l., maximizing efficiency and quality control.

Comparing HF Welding to Other Techniques

When we compare high-frequency welding with hot welding, we immediately notice that the latter, although more affordable and widespread, does not guarantee the same level of joint quality. Processing times are longer, and process control is less precise, which can result in lower aesthetic and functional performance.

Ultrasonic welding, on the other hand, is suitable for certain types of rigid plastics and offers good speed. However, it requires highly specialized equipment and tends to be less versatile than HF technology.

Another alternative is impulse welding. In this case as well, the joint quality and ease of automation are not comparable to those achievable with high-frequency welding.

HF welding stands out as the most high-performing solution for those seeking speed, consistency, and seamless integration into automated industrial processes.

Why Choose REG Galbiati S.r.l. for High-Frequency Welding?

With over 50 years of experience in designing and manufacturing machinery for conveyor belts and synthetic material welding, REG Galbiati S.r.l. is your ideal partner for implementing custom HF solutions.

Our systems are engineered to provide:

  • Maximum energy efficiency
  • Accurate process control
  • Long-term reliability
  • Compliance with CE safety standards

Discover our full range of high-frequency welding machines and contact us for tailored guidance.

How REG Galbiati machines improve product quality in the conveyor belt industry

How REG Galbiati Machines Improve Product Quality in the Conveyor Belt Industry

In the competitive world of industrial automation, production efficiency and final product quality are two essential pillars. In this context, REG Galbiati S.r.l. stands out as a leader in designing and manufacturing custom machinery for the conveyor belt sector, playing a key role in enhancing the performance, durability, and reliability of industrial systems.

Innovation and precision of REG Galbiati’s machines

The machines developed by REG Galbiati S.r.l. are engerneered using advanced technologies and high-quality materials, aiming to optimize every stage of rubber and PVC conveyor belt processing. The company offers tailor-made solutions for operations such as:

  • Precision cutting of conveyor belts
  • Automatic edge trimming and finishing
  • Lamination and bonding of technical materials
  • Controlled calendering and pressing

Each machine is designed to ensure repeatability, millimetric precision, and high productivity, while reducing waste and downtime.

How does it improve the final product quality?

Using REG Galbiati solutions has a direct impact on the quality of industrial conveyor belts. Thanks to precise tolerance control and consistent processing, the final products are more durable, reliable, and resistant, even under the most demanding conditions.

Specifically:

  • Structural defects and cutting imperfections are minimized
  • Adhesion between material layers is significantly improved
  • Dimensional consistency is enhanced, which is crucial for in-line efficiency

Fields of Application

REG Galbiati machines are used across a wide range of industrial sectors, including:

  • Material handling and logistics
  • Food and pharmaceutical
  • Packaging and wrapping
  • Recycling and waste treatment
  • Automotive and metallurgical

In each of these fields, the quality of conveyor belts is a critical factor and REG Galbiati’s solutions serve as a strategic partner for companies striving for excellence.

Chosing REG Galbiati machines means investing in high performance, reliable technology that enhances product quality and boosts the efficiency of the entire production process. In a market increasingly focused on precision and sustainability, relying on these solutions is the key to standing out.

Please feel free to contact us!

High-frequency technology for solid and durable packaging

High-frequency technology for solid and durable packaging

High-frequency technology has become a key pillar in the production of solid and durable packaging, thanks to its ability to fulfill the ever-increasing demands of the industry. REG Galbiati S.r.l., a world leader in the design and manufacture of high-frequency sealing machines, plays a crucial role in this context, offering tailor-made solutions for various industrial applications.

How high-frequency welding works

High-frequency welding uses a magnetic field to generate heat within the material being welded, allowing for precise and rapid fusion. This process is particularly suitable for materials such as polymers and synthetic fabrics. REG Galbiati’s machines are designed to ensure efficient and precise welding while maintaining the mechanical and aesthetic characteristics of the materials used.

Applications in packaging manufacturing

The packaging industry has grown in scope and interest over the years. REG’s high frequency blister welding machines are the best solution to meet all the requirements of an increasingly demanding industry, which requires strong, attractive, lightweight and tamper-proof containers for its thousands of products.

Why use high frequency blister welding machines?

It’s easy to see how HF blister welders can easily satisfy all the requirements pur forward by the packaging industry:

  • Robustness. The packaging is extremely stress-resistant and virtually impossible to open accidentally.
  • Attractiveness. High frequency blister welders operate at low temperatures, which prevents warping of layers and preformed shells and results in crisply welded, perfectly shaped packages.
  • Protection. Once joined by high-frequency welding, the two halves of a blister require scissors or a knife to be separated, severely hampering any theft attempts.

We built and sell high frequency press from 6 to 25 kw, standard or customizable by the client, to product solid and blister packaging and flexible packs for the no-food sector, textile sector and luxury sector. With high frequency techonolgy you will always have pratical and safe products.

Please feel free to contact us!

Automation of production processes: the role of REG Galbiati

Applicazioni per le saldatrici ad alta frequenza

Automation of production processes is a key pillar for modern manufacturing companies. In this context, REG Galbiati Srl emerges as a key player in the industry, specializing in the design and manufacture of customized high-frequency welding machines applied in strategic areas such as automotive, conveyor belts and packaging.

Why is production automation essential?

Production automation is now essential to ensure efficiency, quality and competitiveness. One of the main benefits is increased production efficiency: machines, such as industrial welders, enable faster processes by reducing the margin of error. This allows companies to produce more units in less time while maintaining high quality standards. Another relevant aspect is cost reduction: although the initial investment in advanced technology can be significant, in the long run there are savings through reduced labor, more efficient use of materials and energy, and reduced waste.

Automation also contributes to improved product quality. Modern technologies, such as high-frequency welding, ensure consistent and accurate production, which is essential in industries where reliability is crucial, such as medical and automotive. Finally, adopting automated solutions strengthens market competitiveness. Companies become more flexible and responsive to changes in demand, can introduce innovations faster and respond more accurately to customer needs. Thus, investing in automation means not only optimizing internal processes, but also consolidating one’s position in an increasingly dynamic market.

Why invest in automation now?

Adopting automated solutions means gaining a concrete competitive advantage:

  • Faster deliveries: optimized processes to dramatically reduce production time.
  • Reduced costs: fewer errors, less waste, maximum efficiency.
  • Better, more durable products: consistent quality guaranteed by advanced technologies.
  • Real sustainability: lower energy consumption and waste reduction for a greener future.

How can REG Galbiati Srl help automate your production?

REG Galbiati Srl offers advanced solutions for industrial automation through high-frequency welding machines custom-designed for specific sectors.

In the automotive industry, their technologies enable automatic quilting of synthetic fabrics for seat covers, ensuring precision and reducing dielectric losses. For conveyor belts, the welders optimize the strength and safety of assemblies while maintaining robust characteristics required by the industry. In packaging, they automate the production of durable, anti-theft packages, combining reliability with aesthetic appeal.

For more information about our solutions and services, please feel free to contact us.

PVC conveyor belts

PVC conveyor belts

PVC conveyor belts are widely used across industries for efficient material handling. Known for their durability and flexibility, these belts cater to a variety of applications, particularly in food processing, manufacturing, and logistics.

Features and advantages

PVC conveyor belts are made with a synthetic fiber core coated with PVC plastic. This construction provides high tensile strength, minimal stretching and outstanding resistance to wear and tear.

Notable advantages include:

  • Robustness: designed for light to medium loads, offering resistance against abrasion and impacts.
  • Chemical resistance: can endure exposure to hot water, steam and certain chemicals.
  • Temperature tolerance: Functions effectively at temperatures reaching up to 60°C.
  • Antistatic Properties: prevents static electricity buildup during operation.
  • Custom Design: available in different widths and thicknesses to suit various applications.

Applications of PVC conveyor belts

PVC conveyor belts are versatile and find applications across multiple industries:

  • Food sector: ideal for bakery production, dairy processing, meat and fish handling, as well as fruit and vegetable transportation due to their hygienic properties.
  • Manufacturing: suitable for moving raw materials, packaged goods, and lightweight items in production facilities.
  • Logistics and warehousing: facilitates the efficient movement of packaged goods within distribution centers.
  • Textile industry: used in machines such as blow room equipment and other textile processing systems.

REG welders for conveyor belts

Industry and automation heavily rely on the production of PVC conveyor belts; and often, the surfaces of such conveyor belts need to be equipped with specific accessories, such as sidewalls and cleats, according to specific application needs, in order to comply with industry requirements.

High-frequency transmission-based welding, such as is used in REG’s machines, proves ideal for such work because of its strength and precision. Besides this, it offers the huge advantage of being executed at low temperatures, which ensures absence of any undesired warping on projects and applications of any size and shape.

We build and sell high frequency welding machine from 3.5 to 20 kw, standard or custom to weld profile sidewall, splicing and all other application where high frequency technology is necessary. All our press respect the highest safety standard and electromagnetic field emission.

For more information about our solutions and services, please feel free to contact us.

Conveyor Belts: types and applications

Conveyor Belts types and applications

Conveyor belts play a crucial role in optimizing operations, improving efficiency, and streamlining the flow of goods. They provide a reliable and efficient method for moving items across various distances and configurations.

Types of Conveyor Belts

There are various types of conveyor belts, each designed for specific industrial applications:

  • PVC and PU Conveyor Belts: Primarily used in the food and pharmaceutical industries for their resistance to oils, fats, and chemicals. They are easy to clean and maintain high hygienic standards.
  • Roller Conveyors: Composed of a series of rollers on which the material moves. Suitable for transporting items with a rigid base and often used in sorting centers and warehouses.
  • Modular Conveyor Belts: Made up of plastic modular segments, they offer flexibility in configuration and are ideal for applications requiring curves or inclines.

Applications of Conveyor Belts

Conveyor belts are employed in a wide range of industrial applications:

  • Food Industry: For the hygienic transport of food products along production lines.
  • Logistics and Warehousing: For the efficient handling of packages and materials in distribution centers.
  • Manufacturing Industry: For the assembly and transport of components along production lines.

Innovation in High-Frequency Welding for Conveyor Belts

REG Galbiati srl is a world leader in the production of high-frequency welding machines designed to apply details, sidewalls, and cleats on PVC, PU, and polyester conveyor belts.

REG’s high-frequency welding machines ensure precision and robustness in applications, offering numerous advantages:

  • High precision. High-frequency technology ensures precise welds, essential for applications requiring high quality.
  • Robustness and durability. The resulting welds are extremely strong, ensuring a long lifespan for conveyor belts.
  • Application versatility. REG machines are designed to apply a variety of accessories and details on conveyor belts, adapting to the specific needs of each production sector.

For more information about our solutions and services, please feel free to contact us.

Car mats production

REG Galbiati Srl Car mats production

The production of car mats is a process that combine design, material selection and advanced manufacturing techniques. Car mats serve not only as protective accessories for vehicle interiors but also contribute to aesthetics and comfort. The manufacturing process typically involves several key stages, including design, cutting, welding, and finishing.

Material selection

Car mats are made from various materials, including rubber, PVC (Polyvinyl Chloride), and PU (Polyurethane). These materials are chosen for their durability, ease of cleaning, and ability to withstand wear and tear from foot traffic and environmental factors. The choice of material also influences the manufacturing techniques employed.

The role of high frequency welding machine

High frequency welding machines play a pivotal role in the production of car mats, particularly in creating strong, seamless joints between different components. This technology utilizes electromagnetic waves to generate heat within thermoplastic materials, allowing them to be fused together without external heat sources.

High frequency welding enables manufacturers to join large sections of material seamlessly. This is particularly important in high-volume production settings where consistent quality and efficiency are paramount. The technique ensures that weld seams are as strong as or stronger than the surrounding material, which is essential for durability in automotive applications.

Efficiency Improvements

The use of high frequency welding machines significantly streamlines production processes by reducing cycle times and minimizing downtime. This translates to higher output rates and lower operational costs, giving manufacturers a competitive edge in the market. The ability to control temperature and pressure during the welding process also ensures consistent quality across batches.

Contact us!

We build and sell high frequency press custom on the customers need from 9 to 60 kw to embossing automotive textile, carpet floor welding, sun visor and all other application where high frequency technology is necessary or asked. We specialize in tissue welding.

High frequency welding machine what problems does it solve?

High frequency welding machine

High frequency welding machine what problems does it solve?

A high-frequency (HF) welding machine addresses specific welding issues related to precision, speed, and joint quality by using high-frequency electromagnetic waves to melt materials. This technology is mainly used for welding thermoplastic materials (such as PVC and polyurethane) and some thin metals, making it highly efficient for creating strong, uniform joints.

Problems Solved by a High-Frequency Welding Machine

  1. Uniformity and Strength of Joints: High frequency enables homogeneous melting of materials, eliminating typical defects in traditional welding like bubbles, weak points, and irregularities.

  2. Reduction of Thermal Distortion: HF welders focus heat precisely on the joint area, minimizing deformation in surrounding materials—an advantage for objects that require dimensional accuracy.

  3. Speed of Execution: HF welding is generally faster than other methods due to the rapid generation and application of heat, which makes the process more efficient and allows for faster production cycles.

  4. Welding of Difficult Materials: This method is particularly suited for materials that do not weld well with traditional methods, such as PVC, polyurethane, and other plastics, as well as certain thin conductive metals.

  5. Temperature Control: HF welders offer precise heat control, reducing the risk of overheating or damaging delicate materials.

  6. Reduction of Waste: The precision and uniformity of the process reduce the risk of discarding defective pieces, improving overall efficiency.

 

High frequency welding machine what problems does it solve?

High frequency welding machine what problems does it solve

Sectors and Activities that Can Benefit from High-Frequency Welders

  1. Textile and Technical Apparel Industry: HF welders are widely used in the production of waterproof garments, such as jackets and work suits, bags, and accessories, where seamless joints are essential for ensuring water and air resistance.

  2. Medical Sector: HF technology is ideal for the production of PVC medical items, such as transfusion bags, tubes, mattresses, and other products that require high hygiene standards and airtightness.

  3. Production of Tents and Outdoor Structures: In the manufacture of tents, tarps, and PVC covers (for trucks or outdoor events), HF welding ensures joints that are resistant to water and weather, essential for durability and effectiveness.

  4. Automotive Industry: High-frequency welders are used for producing car interiors, particularly for sealing fabrics, foams, and PVC or faux leather linings, ensuring an aesthetically pleasing and durable finish.

  5. Packaging Sector: For products packaged in sealed bags, such as food items, first-aid supplies, and pharmaceuticals, HF technology provides a secure, durable closure.

  6. Inflatable Products Manufacturing: Inflatable products (mattresses, pools, water toys) require leak-proof welding, which HF welders can guarantee thanks to the precise heat application.

  7. Electronics Industry: In some cases, HF welding is also used for electromagnetic shielding and assembling electronic components, taking advantage of its ability to concentrate heat in very small areas.

In summary, high-frequency welding machines are used in industries where high-quality, durable joints are essential, with a fast and precise process.

High frequency welding machine what problems does it solve?

As we have seen, high frequency welding is suitable for an incredible range of applications

How REG become what’s now?

 

Over seventy years have passed by since the brothers Angelo and Luciano Galbiati founded “RADIO ELETTRONICA GALBIATI” in 1948, building and selling the first high frequency welders with the “REG” brand. This has been possible thanks to the theoretical knowledge of the first radar systems developed during wartime and to the work experience accrued in the post-war period in the field of inductive and capacitive heating of materials (first high frequency PVC welding systems). 

High frequency welding machine what problems does it solve?

It is an original article from REG.IT