UltraThinSeal

What UltraThinSeal does

UltraThinSeal is a privately held affiliate of EWI, an engineering and technology organization, headquartered in Columbus, Ohio. The company develops and commercializes a patented, single-sonotrode ultrasonic sealing system for thermoplastic film packaging. Unlike traditional heat sealing, which requires multiple sonotrodes and heated jaws, UltraThinSeal's system uses high-frequency vibration from a single sonotrode to generate localized molecular-level friction, producing hermetic seals as narrow as 1 millimeter versus the industry-standard 13 millimeter thermal seal.

The technology is deployed through two primary channels: as a retrofit module on existing vertical form-fill-seal (VFFS) and horizontal form-fill-seal (HFFS) packaging machines (rotary or reciprocal-style), and as an integrated component in new high-speed rotary ultrasonic bagmakers. Documented customer outcomes include 8–12% material reduction (up to 25% when paired with smaller bag dimensions), a 40% reduction in scrap rate, a leaker rate improvement from 1.5% to 0.87%, and shelf life extension of more than 30% (up to four weeks). The technology is also validated on bio-polymers, PLA, and recyclable films, positioning it for sustainability-driven packaging applications.

UltraThinSeal sells to consumer packaged goods companies, OEMs of VFFS/HFFS equipment, retailers, and film/resin suppliers on a quote-based, multi-year contract model. Revenue is generated through one-time hardware sales (retrofits and new bagmakers) and professional services (consultation and sealing trials conducted at the company's facility using customer-specific film). Go-to-market is enterprise-led, with an inside-sales phone channel supplemented by a senior field-sales team whose leadership came directly from PepsiCo and Del Monte. The company's value proposition has been validated against more than 5 million packages in live customer production, and its underlying technology was developed by EWI engineers in partnership with a global food manufacturer.

Name

UltraThinSeal

Legal name

EWI UltraThinSeal

Website

https://ultrathinseal.com

Company type

Private

Operating status

Operating

Short description

UltraThinSeal is a private EWI affiliate that commercializes a patented single-sonotrode ultrasonic sealing system for thermoplastic packaging, serving consumer packaged goods companies, packaging OEMs, and retailers with retrofit modules and new rotary bagmakers.

Ownership category

akta.pro rank

Product category

Industrial Packaging Equipment

NAICS

Gasket, Packing, and Sealing Device Manufacturing (339991)

SIC

Gaskets, Packg & Sealg Devices & Rubber & Plastics Hose (3050)

akta.pro primary industry

Capping, Closing & Sealing Equipment (Capper, Induction, Heat Seal) (IMALAOAC)

akta.pro secondary industry

Form-Fill-Seal (Vertical & Horizontal) Machines (IMALAOAA)

Keywords

• Ultrasonic packaging sealing
• Form fill seal equipment
• Packaging machinery retrofit
• Consumer packaged goods packaging
• Sustainable packaging films

Headquarters

HQ city

Columbus

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Technology or R&D, Personnel, Marketing or Sales, Supply Chain, Operations

Revenue model

1. Equipment Retrofit Services: Retrofitting existing VFFS and HFFS packaging equipment with UltraThinSeal ultrasonic sealing system. System can be mounted on rotary or reciprocal-style machines.
2. New Equipment Sales: Sale of new high-speed rotary ultrasonic bagmakers with integrated UltraThinSeal technology for packaging operations.
3. Consultation and Sealing Trials: Consultant assessment of existing packaging equipment and economics of conversion. Sealing trials conducted at company facility using customer's specific packaging film.

Pricing tiers

Go-to-market motion2 records

Distribution channels4 records

Marketing channels4 records

Core offering

UltraThinSeal develops and commercializes a patented ultrasonic package sealing technology that uses a single sonotrode and high-frequency vibration to create hermetic, contaminant-tolerant seals as narrow as 1 millimeter on thermoplastic films. The system can be retrofitted onto existing VFFS and HFFS packaging machines or integrated into new high-speed rotary ultrasonic bagmakers, eliminating the need for heated seal jaws and enabling sealing of bio-polymers, PLA, and recyclable materials. The company delivers its offering through hardware sales, equipment retrofit services, and consultation plus sealing trials to consumer packaged goods companies, OEMs, and retailers.

Product overview

UltraThinSeal is a single-product company offering the UltraThinSeal System, a patented ultrasonic packaging sealing technology. The technology is designed as a compact, single-sonotrode system that can be retrofitted onto existing vertical form-fill seal (VFFS) or horizontal form-fill seal (HFFS) packaging equipment (rotary or reciprocal-style machines), or integrated into new high-speed rotary ultrasonic bagmakers. The product enables 8-12% material reduction, extends shelf life by up to 30%, and produces seals as narrow as 1 millimeter without heated elements.

Differentiator

Problem solved

Functional benefit

Products and services

• UltraThinSeal Ultrasonic Sealing System Patented single-sonotrode ultrasonic sealing system for packaging equipment that uses high-frequency vibration to create narrow, high-quality hermetic seals (as narrow as 1 millimeter) on thermoplastic film packages, eliminating the need for heat sealing. Designed for consumer packaged goods companies, OEMs, and retailers running VFFS or HFFS packaging lines.
• Equipment Retrofit Services Retrofit of existing vertical form-fill seal (VFFS) and horizontal form-fill seal (HFFS) packaging equipment with the UltraThinSeal ultrasonic sealing system. Compatible with both rotary and reciprocal-style machines; no heat-up time required. Targets CPG manufacturers and packaging operations seeking to upgrade without replacing equipment.
• High-Speed Rotary Ultrasonic Bagmakers New high-speed rotary ultrasonic bagmakers with integrated UltraThinSeal ultrasonic sealing technology, offered as the next-generation alternative to retrofitted legacy form-fill-seal lines. Targeted at CPG manufacturers and OEMs seeking advanced packaging equipment.
• Consultation and Sealing Trials Consultative assessment of a prospect's existing packaging equipment and economics of conversion, plus sealing trials conducted at the UltraThinSeal facility using the customer's specific packaging film. Aimed at CPGs, OEMs, and retailers evaluating the technology before purchase.

Quantifiable outcome

• 8-12% material reduction without reducing package size
• +6 more outcomes

Segments5 records

Ideal customer profiles3 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature5 records

Partnerships

One partnership is on record.

• EWIcoreStrategic or Co-development PartnerEWI is the parent organization and leading engineering and technology organization that developed the UltraThinSeal technology. UltraThinSeal is an affiliate/spinout of EWI created to commercialize the ultrasonic sealing technology for packaging-industry players worldwide.

Scale indicators10 records

Recent moves6 records

Expansion highlights5 records

Direct peers

• Telsonic Ultrasonics: Telsonic supplies ultrasonic welding and cutting/sealing systems used in food, medical, and consumer packaging. Directly comparable as an alternative ultrasonic sealing vendor for VFFS/HFFS-style packaging lines.
• Dukane Intelligent Assembly Solutions: Dukane (now part of Aurizon) is an established ultrasonic welding and sealing equipment supplier serving medical, packaging, and industrial assembly. Comparable to UltraThinSeal as an alternative ultrasonic packaging sealing technology provider.
• Herrmann Ultrasonics: Herrmann Ultrasonics is a leading global manufacturer of ultrasonic welding and sealing equipment for plastics packaging. It is the most direct competitor to UltraThinSeal, supplying ultrasonic sealing modules used on VFFS/HFFS-style packaging lines across food, medical, and consumer-goods end markets.
• Rinco Ultrasonics: Rinco Ultrasonics specializes in ultrasonic welding machines and components for plastics packaging, including tube sealing and pouch applications. Direct competitor to UltraThinSeal in the narrow band of ultrasonic thermoplastic-film sealing for consumer packaging.
• Sonics & Materials: Sonics & Materials is a US-based ultrasonic welding and sealing equipment manufacturer serving packaging, plastics, and assembly applications. Comparable to UltraThinSeal as a competing ultrasonic sealing technology supplier for thermoplastic film packaging.

Broad incumbents

• Sealed Air: Sealed Air is a major packaging solutions company whose Cryovac and food-packaging businesses serve the same CPG customers UltraThinSeal targets. While Sealed Air is primarily a materials and packaging producer, it is an adjacent incumbent whose sustainability and shelf-life claims overlap UltraThinSeal's value proposition.
• ProMach: ProMach is a large diversified packaging machinery integrator that supplies VFFS/HFFS bagmakers and integrates various sealing technologies. It is a relevant channel and ecosystem peer: UltraThinSeal's OEM strategy depends on getting embedded into machines like those ProMach builds and integrates.
• Bosch Packaging Technology: Bosch Packaging Technology is a global incumbent supplier of VFFS/HFFS packaging machines and integrated sealing systems for food and pharma. Comparable as a large OEM into which UltraThinSeal's technology could be embedded or against which it competes on sealing module performance.

Emerging players

• Sonobond Ultrasonics: Sonobond Ultrasonics manufactures ultrasonic bonding and sealing equipment for textiles, films, and nonwovens, including packaging applications. Comparable as a smaller specialty ultrasonic sealing vendor competing for similar thermoplastic-film packaging applications.
• MS Ultrasonic Technology: MS Ultrasonic Technology is a German manufacturer of ultrasonic welding and sealing machines used in plastics and packaging. Comparable niche competitor to UltraThinSeal in ultrasonic packaging sealing, with overlapping target customers in food and consumer goods.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat4 records

Key risks7 records

Key highlights7 records

Customer concentration

Revenue estimate

Valuation estimate

Number of profiles

Profiles2 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about UltraThinSeal