Sonobond Equipment Assembles EvoOrganic's Eco-Fabrics

Assembler of Innovative Eco-Friendly Landscape and Garden Fabrics Looks to Sonobond Ultrasonics for Practical, Cost-Effective Bonding Solutions

EvoOrganic in Lexington, Kentucky Finds Sonobond's SeamMaster(TM) Modules to be the Ideal Choice for Fast, Reliable Assembly of Its "Greener Lifestyle" Products

WEST CHESTER, Pennsylvania, August 25, 2010-When Rick Baker, President and CEO of EvoOrganic was looking for a fast, cost-effective way to assemble his company's Rainweave(TM) fabrics, he turned to Sonobond Ultrasonics. "We wanted to find a reliable machine on which to base our entire line of garden fabrics," he says. "This was a big project with a relatively short time line. Our application necessitated critical tolerances and precise controls. We also needed to have confidence that whatever equipment we ordered would be delivered on time.

"For two years, I traveled all over the United States looking at quilting machines and other fabric bonding techniques. We even tried sewing fabrics together. But when I learned about Sonobond's ultrasonic bonding technology and the potential advantages this process offered, I contacted the company for more information. They responded promptly. Melissa Alleman from Sonobond, along with her associates Dan Busse and Jim Manowski, came to see me. I was impressed by how prepared, thorough, and capable they were.

"After carefully assessing our needs, they recommended SeamMaster(TM) Modules as the bonding units that were best suited to provide the fast, coordinated production capabilities we required. They then took the time and effort to develop a customized solution. Everything was thoroughly tested to be certain the Sonobond equipment met our tough requirements. We eventually acquired 12 SeamMaster(TM) Modules and began production in December 2009.

"I see the dependability and consistency of the bond as the primary advantage of using Sonobond's technology. I've been very pleased with the results. We plan to add at least one machine to our U.S. operation and expect to be using SeamMaster(TM) Modules as we expand production overseas."

Assembling "Green Lifestyle" Products

EvoOrganic, founded in 2006, is a "green lifestyle" company that provides organic garden products to homeowners, farmers, and businesses. It offers "the world's first garden and landscape fabrics with built-in irrigation." Central to the company's product line are its Rainweave(TM) fabrics, designed to reduce water usage by up to 80% over conventional methods and to encourage improved plant growth.

Rainweave(TM) consists of a top and bottom fabric (both made of polypropylene) with drip irrigation tape sandwiched between. Sonobond's SeamMaster(TM) Modules are used for sealing and slitting the fabric during the assembly process. Some units seal around the drip irrigation tape and bond the two layers of fabric together. Others slit the fabric into whatever widths are desired.

According to Mr. Baker, "EvoOrganic is leading the way for water-saving fabrics in the farm, garden, and landscape arena. Sonobond is helping us do this. In addition to providing quality equipment, they stand behind us with the kind of service and support so critical to manufacturing operations like ours."

Sonobond Ultrasonics Technology Speeds the Assembly Process

In discussing the EvoOrganic installation, Sonobond's Vice President, Melissa Alleman, says, "When Rick Baker contacted us, we quickly realized that our ultrasonic bonding technology would be a good fit for EvoOrganic. The SeamMaster(TM) Modules eventually selected by EvoOrganic are a cost-effective way for assemblers to incorporate sealing and slitting into one continuous operation without the need for thread, glue, or other consumables. This system is ideal for special-purpose textile applications like those at EvoOrganic. Of course, I think Rick was also very pleased that our bonding method is environmentally-friendly, as well as efficient and dependable."

Ideal for OEM Applications

Manufacturers (OEMs) across a wide spectrum of industries are using Sonobond's SeamMaster(TM) Modules to cost-effectively integrate seaming, slitting, and trimming capabilities into special-purpose bonding machines and production lines. These modules use a motor-driven rotary system in conjunction with a rotary pattern wheel to deliver continuous, problem-free operation. High quality results are produced in just one pass without thread, glue, or other consumables. Fraying or unraveling of bonded edges and seams is virtually eliminated. Assemblers can choose from a variety of stitch patterns to perfectly fuse and seal seams.

Ultrasonic bonding with Sonobond equipment is more efficient than sewing, heat sealing, adhesive machines, or stationary sonic operations. SeamMaster(TM) Modules are also faster than conventional sewing machines and adhesive methods. Single, dual, or multi-head arrangements are available, as well as a variety of easy-to-change stitch and slit pattern wheels. Like all Sonobond equipment, these modules can be operated easily with only minimal training.

Materials most suited for use with the SeamMaster(TM) are either 100 percent synthetic or blends with up to 40 percent natural fibers. These include lycra spandex, tricot, polyester, nylon, acrylics, polypropylene, PVC, and thermosplastic urethane that are constructed as wovens, nonwovens, knits, films, laminates, and coatings. Product applications include filters, medical apparel, safety products, draperies, blankets, oil-absorbent pads, floor mats, carpet backing, banners, flags, and netting.

Advantages of Ultrasonic Assembly

Ultrasonic bonding does not use needles, thread, or glue. Instead, nonwoven materials are fused by means of ultrasonic vibrations. As a result, manufacturers and assemblers can eliminate problems related to stitch holes or glue gaps. This makes ultrasonic bonding especially suitable for assembling medical apparel. Seams created in this way are capable of satisfying the tough regulatory requirements designed to help protect medical personnel from hazardous fluids. Sonobond ultrasonic bonding is also reliable, cost-effective, and safe for the environment.

Leaders in Ultrasonic Bonding Technology

Sonobond Ultrasonics has been a worldwide leader in the application of ultrasonic bonding and welding equipment for 50 years. Over this period, the company has earned an outstanding reputation for its pioneering work and quality-engineered products. Sonobond manufactures a complete line of bonding and welding equipment for a wide variety of customers in the apparel, ballistics, filtration, medical, automotive, appliance, electrical, solar, and aerospace industries.

According to Sonobond Vice President, Melissa Alleman, "Our success as a company has been built on our record of innovation, on the quality and performance of our equipment, and on our commitment to providing the very best in customer service and technical support. We welcome inquiries from manufacturers and assemblers who are looking for reliable, practical, and cost-effective solutions to their particular bonding or welding requirements."

Additional Information

To learn more about Sonobond products-or for information about the company's free, no-obligation Ultrasonic Bonding Viability Test for specific applications-visit the website at or call toll free 1-800-323-1269. Melissa Alleman can be reached directly at For more information about EvoOrganic and its organic garden products, visit the website or call toll free 1-800-731-6461.

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