Plastic welding offers a stronger, more durable and more reliable connection than traditional adhesive techniques. This technique makes customised packaging more robust, consistent and resistant to demanding industrial conditions. Faes is taking a new step forward in quality and production stability with this technique.
Summary of this article
In recent years, Faes has taken major steps to improve and modernise its production processes. One of the most important developments is the introduction of plastic welding and laminating as an alternative to traditional adhesive bonds. This step did not come out of nowhere: customers were increasingly asking for plastic packaging, which required new techniques and new skills on the shop floor.
The demand for plastic packaging has clearly increased in recent years. This forced Faes to invest in new production methods. The technique of plastic welding — similar to metal welding — makes it possible to connect plastic parts more strongly and sustainably.
The advantage is immediately noticeable: a welded joint is often stronger than the base material itself, while adhesives can be sensitive to factors such as temperature changes. It is precisely this sensitivity that has caused problems in the past, for example when adhesive layers came loose in the field. Plastic welding offers a robust and reliable alternative here.
In addition to plastic welding, laminating is also being used more and more. This is basically a form of welding foam parts, using heat and extra material to join parts together.
The advantages:
This approach almost completely solves the previous problem of adhesive bonds coming loose.
Although automation in the factory is increasing, plastic welding remains a manual skill for the time being. This is mainly due to the wide variation in piece production — many orders consist of a few pieces, which makes full automation unprofitable or unfeasible.
Welding is therefore done ‘by hand, but according to fixed standards’. Where possible, parts are prepared automatically, but the actual welding process still requires craftsmanship.
The same applies to lamination: partly automated, partly manual. In both cases, the combination of technology and craftsmanship is essential for quality.
The introduction of plastic welding was not just a technical change. It also meant that employees had to be educated, trained and certified to ensure that the work was consistent and of a high standard.
Faes therefore invested in courses and official welding certificates to ensure that the skills matched the quality requirements of customers and the complexity of the products.
The switch from gluing to welding/laminating has had a major impact on quality assurance. Whereas adhesive bonds were sensitive to variable factors (pressure, temperature, processing speed), welding delivers consistent results.
What’s more
For a welded plastic packaging solution, reliability is not determined by the welding equipment alone. The biggest risks often arise much earlier. They can result from selecting incompatible materials, providing insufficient weld surface, introducing sharp transitions or designing a construction that deforms during welding. That is why, at Faes, we treat the weld as a functional part of the packaging from the very beginning of the design process.
We determine where the joint will be subjected to mechanical loads, whether it will remain accessible for welding and inspection, and how much process variation is acceptable without compromising quality. For critical applications, this may involve producing test samples, defining the welding parameters and validating the joint through tensile or leak testing. The results are then used to optimise both the design and the welding process.
This approach helps prevent situations where a packaging solution appears sound after assembly but develops weak points during transport, cleaning or long-term use. For Faes, the value of plastic welding is therefore not simply in joining two components. It lies in controlling the entire process, from engineering and material selection to a robust, repeatable and validated welded connection.
The development of plastic welding does not stand alone. It is part of a broader movement towards vertical integration and greater control over the company’s own production chain. Think of splitting and laminating foam yourself, milling panels yourself and bringing steps that were previously outsourced back in-house.
Plastic welding makes it possible to work faster, more flexibly and more consistently — exactly what is needed in customised production where there is a lot of variation.
Tim van de Puttelaar is the Engineering Manager at Faes and specializes in packaging engineering and custom solutions. In his articles, he shares insights on optimization, testing, and engineering projects that contribute to more efficient and sustainable packaging solutions within complex supply chains.
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