The worlds most technologically advanced and most eco-friendly weldable webbing, thanks to our unique HiWELD™ technology.
WeldTECH™ is our premium quality ECO-friendly, 2nd generation weldable webbing, which has taken over 7 years of relentless development. This development process had us talk with our clients and industry leaders internationally to determine how to make the worlds most ECO-friendly, most advanced and strongest weldable webbing. Extensive research was undertaken seeking alternative compounds, materials and methods to reach this goal, during which time we constantly and repeatedly evaluated and re-evaluated the products performance to our goals. So now we can be sure that WeldTECH™ is the world’s ultimate and ECO-friendly weldable webbing.
We use a tightly woven webbing utilising extreme strength, high tenacity polyester yarn woven to exacting specifications on our own, state of the art, narrow fabric weaving looms. Our webbing has a tensile strength of over 23Kn, which meets the European standard for curtainsiders/Tautliners (BS-EN-12641-2-2006). Next we encapsulate the webbing with a layer of our proprietary polymer under intense pressure, utilising our own unique process called HiWELD™ technology, to create a superior laminate, ECO-friendly, weldable webbing. The HiWELD™ process delivers the industry leading polymer to webbing bond that also welds up to 7 times faster and delivers this with our ECO-friendly proprietary polymer that is non-toxic and classed as a food safe plastic. Our HiWELD™ technology gives so much better performance that it can produce double the bond strength in half the weld time over traditional weldable webbing
WeldTECH™ is New Zealand developed, but we have now moved our manufacturing to Thailand, in order to allow us to benefit from a cheaper cost to manufacture, whilst still maintaining our same high quality as before. This allows us to provide a much superior product to anything else available, but at the same cost as standard weldable webbing. Our manufacturing facility also includes in house tool manufacturing allowing us to provide quick, responsive solutions to meet our customer’s needs.
We manufacture our webbing on our own, state of the art, narrow fabric weaving looms, which allows us to maintain a very high quality webbing and retain a very attractive price for our customers.
We use a high density, tight weave that prevents either the warp or weft threads from being displaced when under load, particularly where the webbing is cut or punched. If the threads making up the weave are not held tightly in place and have room for movement, the overall strength of the webbing is compromised.
Yarn is delivered directly from our creel to our loom through a tension equaliser so that the finished weave is straight and each warp is of equal tension. This is very important as it ensures that any load applied to the weave is distributed equally among all warp yarn threads. This ensures that no individual filament gets overloaded, which could cause that filament to break prematurely, compromising the ultimate strength of the webbing.
We have adopted a very flat (non-textured) weave to reduce the webbing thickness without reducing the amount of yarn used and hence the strength remains very high. We can do this because our HiWELD™ technology is that good we don’t rely on weaving texture to key in to. Others need to employ methods like heavily textured weaves to achieve a bond that still falls well short. Heavily textured weave allows the plastisol coating to key into the webbing better and hence improve the bond strength, however this makes for more bulky webbing with more included air pockets within its structure. Often heavily textured weave is paired with very liquid (runny) plastisol, achieved by adding more plasticisers, so that it can travel further into the webbing structure during coating. Plastisol coating is done by passing the webbing through the plastisol when it is in it's liquid form without any added pressure. Unfortunately, by adding more plasticisers this dilutes the PVC content, but it is actually the PVC content that bonds during welding. Because we use extreme pressure to inject our polymer into the weave, we do not need to dilute our polymer in this way and so our polymer has 100% of it's active ingredients.
HiWELD™ is the technology we have pioneered that delivers the industry-leading polymer to webbing bond strength of upto 27Kg at 48mm width. We have achieved this without sacrificing any of the products flexibility or light weight. Not only does the HiWELD™ process deliver the industry leading polymer to webbing bond, but it also welds up to 7 times faster and delivers this with our ECO-friendly proprietary polymer. A polymer that took 7 years of constant development, which delivers the worlds strongest bond whilst also being non-toxic and classed as a food safe plastic.
WeldTECH™ produces a very strong weld with a high bond strength. When we talk about the bond strength we are talking about the connection between the PVC curtain and the polyester woven webbing inside WeldTECH™, as this is where all weldable webbing fails when it is delaminated. With a highly bonded weld, WeldTECH™ has been known to delaminate the PVC curtain, rather than itself.
HiWELD™ technology saves both time and energy, therefore saving you money
Welding at 7 times faster on our RF welder produces a weld that requires 12kg to delaminate compared to nearly 11kg for plastisol. If you slow the weld down, putting more heat into it, the bond strength starts improving. At 3 times faster than plastisol we get bond strengths resisting delamination of 19kg. Further increases in weld time can give results as high as 27kg depending on the environmental conditions and equipment. We have seen similar results on Hot Air and Hot Wedge machines.
Weld Time Comparison Chart
It can be seen that achieving a weld bond strength that is similar to plastisol coated webbing, we are able to achieve a weld speed that is 7x faster. By using progressively longer weld times we obtain better developed welds. At the same welding time as plastisol, the weld strength is more than doubled and can sometimes de-laminate PVC curtain fabric. Of course at this long weld time, webbing shrinkage becomes a real problem, so only short lengths can be welded. From this it can be seen a balance of bond strength and shrinkage needs to be achieved. If either end of a strap is welded hot and the majority of the centre of the strap welded much cooler, the best of both worlds can be achieved, a very strong bond at the ends, where it is needed most, with little overall shrinkage.
Look for the high initial resistance to delamination.
Plastisol is quite weak as far as plastics are concerned. Typically when you start to delaminate weldable webbing from PVC fabric, the plastisol snaps almost instantly and lets go of the polyester webbing it is bonded to. WeldTECH™ does something different. When you delaminate WeldTECH™, our polymer re-orientates and stretches its molecules, to resist the delamination from 2 directions, which is exactly how polypropylene packing tape or polyester yarn get there great strengths. Looking closely you will see our polymer form a peak lending strength to resist the delamination. This effect gives WeldTECH™ an even higher initial resistance to delamination. Once this initial resistance of the polymer succumbs to the load placed on it, the resistance to delamination figures seen above take over.
You no longer have to work with plastisol which may be detrimental to your health.
Plastisol used to make weldable webbing will almost certainly use industrial grade PVC. Although this is a lot safer than it used to be, thanks in large part to REACH regulations, these regulations still permit the use of SVHCs (Substances of Very High Concern). An SVHC chemical, of which many plasticisers are on that list, can make up 0.1% by weight of a product without any restriction. Whilst we cannot make any claims as to whether other manufacturers use plastisol containing any SVHCs, we can currently claim to be the only manufacturer that we know of which advertises a product with zero SVHC content. One of our goals was to create a product which is as safe as possible to both the environment and those working with it. The polymer used in our HiWELD™ technology contains zero SVHC chemicals and is so safe that it is classed as a food safe plastic, we could use it to make your lunch box.
Another health concern when working with plastisol coated webbing is the amount of heat required to weld it to a PVC curtain, which is applied to both the webbing and the curtain. The high heat required causes some of the plasticisers in both the plastisol and curtain to boil off and be released into the atmosphere. Because our polymer requires far less heat to achieve a much better bond, a lot less heat goes into the PVC curtain and so there is significantly less potentially toxic chemicals boiling off the curtain.
- has a breaking load exceeding 23kN (approx 2400kg)
- welds on RF, Hot Wedge, Hot Air
- gives welding speeds up to 7 times faster
- gives a tunable bond strength up to 27kg
- contains zero PVC or Phalates
- is considered a food safe product
- delivers reduced energy requirements
- offers reduced noise for hot air welding
- exhibits a very high initial resistance to delamination
- releases far fewer volatiles and toxins during welding
- causes far less toxins to boil off the PVC curtain
- complies with BS EN 12641-2-2006 European standard
- is easy to rework. It can be re-welded to it’s original bond strength
- has less webbing shrinkage or creep due to less overall heat induced in to the weld
- can be removed completely from a PVC curtain, by a skilled technician, without damaging the curtain
- is less effected by hot and cold conditions compared to standard weldable webbings
- is a New Zealand designed product you can trust
All these added benefits at the same price that you pay now.
Welding tips for WeldTECH™ weldable webbing.
Our unique polymer coating tends to be applied thicker than with traditional plastisol (PVC) coated webbing, also it absorbs heat very quickly. For these reasons our polymer coating allows the transfer of large amounts of heat into the underlying polyster webbing, which can cause excessive shrinkage if the application of heat is not controlled. It is therefore important to understand that WeldTECH™ needs to be welded a little bit differently than standard weldable webbing. If you were to weld WeldTECH™ in the same way as standard webbing, too much heat would be taken in and cause the excess shrinkage to the webbing. However, due to the much superior bonding of our HiWELD™ technology, a far greater bond is achieved with the application of much less heat. When following our welding tips below, it is possible to achieve greater bond stengths, whilst seeing less shrinkage of the webbing, when using WeldTECH™.
Like all polyester and nylon webbing and sheet products, shrinkage will occur with sufficient heat, remember that the total heat absorbed is a factor of the amount of time heat is supplied and the temperature that is applied. When welding with WeldTECH™ it is necessary to reduce either the time, the temperature (power in the case of RF welding) or a combination of both. Our customers have found that WeldTECH™ welded at higher speeds has the least shrinkage they have seen.
Be aware that our polymer we use in our HiWELD™ technology melts at approx. 50°C less than plastisol, therefore, especially when aiming for the strongest bonds, you may find that WeldTECH™ remains in a 'workable' state for longer after welding. If you try and fold or roll the curtain too soon, you may casue WeldTECH™ webbing to bond to itself or finish solidifying whilst rolled, causing it to 'set' to the curved shaped. Therefore it is best to keep everything as flat as possible until you are confident that the polymer coating has cooled sufficiently to completely solidify again. When aiming for a similar bond strength to standard plastisol coated webbing, then the time needed to be able to safely move the curtain, after welding, should be similiar to that of standard webbing.
Using a crawler hot air welder
Keep the temperature set to your normal setting, but set the speed to its maximum. Start performing a number of test runs, reducing the temperature in equal steps, performing delamination tests after each run. Once the weld delaminates too easily for your needs, adopt the temperature that was one step back in the test run as your minimum operating temperature. If you feel that the maximum speed runs too fast to get good results, then move the speed down to where you are comfortable with and repeat the testing to obtain the minimum temperature at the new speed. From here you can adjust the speed and temperature to balance speed and bond strength with minimal shrinkage to best meet your needs.
Using a framed hot air welder
Start at the maximum temperature you are comfortable with and 12,000mm / minute traverse speed. Start performing a number of test runs, increasing the traverse speed in equal steps, performing delamination tests after each run. Once the weld delaminates too easily for your needs, adopt the traverse speed that was one step back in the test run as your maximum traverse speed.The quality of your heat source is very important, a heat source that can deliver large volumes of high temperature air, evenly over a long section of the webbing and over the full width is ideal, also adding shields to either side of the webbing to retain the side spilled hot air, if possible. Testing in-house and in conjuction with our customers we have seen weld traverse speeds of 34,000mm / minute, whilst still giving better bond strength than standard weldable webbing. From here you can adjust the speed and temperature to balance speed and bond strength with minimal shrinkage to best meet your needs.
One method of balancing strength with speed is to weld either end of the run at slower speeds to gain the maximum bond strength, then weld the bulk of the weld between the ends at a faster speed. In this manner you can obtain extremely strong anchors at either end of the weld, whilst still maintaining a stronger bond than standard webbing throughout the rest of the run.
Using an RF welder
Start at the maximum power you are comfortable with and half the time you would usually weld for. Start performing a number of test runs, reducing the time in equal steps (1 or 2 seconds), performing delamination tests after each run. Once the weld delaminates too easily for your needs, adopt the time that was one step back in the test run as your minimum time for that power setting. From here you can adjust the weld time and power to balance speed and bond strength with minimal shrinkage to best meet your needs.
Using our in house RF welder we found that we could reduce the weld time to one seventh of what we would use for plastisol coated webbing. Your results will be much better than plastisol, but may not reach one seventh the weld time, the performance improvement is very much dependant on environmental conditions, your machine and bar length you use.
Most people do not believe how fast this product can weld. Go all out and run it as fast as your machines will make a good weld. Not only will you save time, but less toxin will be liberated from the PVC sheet, and you will achieve the smallest shrinkage results.
This is not a problem, our polymer will reactivate with heat and the residual polymer left on both the PVC fabric and webbing will create a new bond. The bond strength will more than likely now be higher than it originally was. You weld the side that now has no polymer on it to the polymer that is left behind on the PVC fabric. With hot air, just reheat the polymer on the PVC fabric, taking care to not direct too much heat on the exposed polyester webbing, and roll the webbing back into position. Provided the webbing and polymer are clean and dry, this can be done several times.
In a factory situation just re-weld the delamination, bearing in mind that it can take up to 10 minutes for a weld to cool. So if you weld twice in quick succession you may introduce too much heat and cause shrinkage, either allow sufficient time between welds or reduce your settings.
Just rip it off the PVC fabric and re-weld it again following the instruction above, in the faq - “The webbing has delaminated, what can be done?” - above. If there was too much shrinkage in the first weld, it may be better to weld a new piece of WeldTECH™ over the residual polymer left on the PVC fabric, because excessive shrinkage can have an affect on the certified load capacity of the WeldTECH™ webbing.
This too can be fixed, all though it is quite time consuming and does require skill. The polymer used in WeldTECH™ melts at about 50ºC less than PVC. First delaminate the WeldTECH™ webbing from the PVC fabric, then gently heat the remaining polymer on the PVC fabric with a heat gun and scrap it off.
WeldTECH™ welds perfectly to itself. We have also seen it welded, with great results, to plastisol netting. Of course it welds to PVC fabric, which is exactly what we designed it to do.
With a slow weld it can achieve a weak weld to canvas and jute, however the results for polyethylene and polypropylene are unsatisfactory.
We would expect it to weld to a number of other natural and synthetic fabrics. Just give it a go, we would love to hear your findings.
This will be because the total heat absorbed by the WeldTECH™ is too much - the total heat absorbed is a product of time and temperature. Either increase the traverse speed or decrease the hot air temperature. For RF welders decrease either the weld time or the power used.
WeldTECH™ can take up to 10 minutes to cool properly. The more heat you put into Weldtech, the longer it takes to cool again. Ideally, you should be welding as fast as you can with the least heat possible to meet your objectives in the weld. If you still have a problem, you will have to leave the welded area laying flat until the WeldTECH™ has cooled sufficiently.
This is most likely caused by too much heat absorbed by the WeldTECH™ webbing. WeldTECH™ can take up to 10 minutes to cool properly. The more heat you put into Weldtech, the longer it takes to cool again. Ideally, you should be welding as fast as you can with the least heat possible to meet your objectives in the weld. If you still have a problem, you will have to leave the welded area laying flat until the WeldTECH™ has cooled sufficiently.
Because of the the structure of our webbing weave and how we apply our polymer coating under extreme pressure, the polymer coating is taken up slightly more on one side than the other. The side marked with the sticker welds with up to about a 30% stronger bond than the other side, however both sides create a stronger weld than standard plastisol coated webbing.