A Cosmos-Kabar RF welder converted to a 40-inch Packet Welding system — completed December 2020, Eagle Pass, TX. Production capacity increased from day one.
Conversion completed: December 2020 · Location: Eagle Pass, TX · Machine in production: 5+ years
Extra Packaging manufactures a broad range of industrial and specialty packaging products serving domestic and international markets. Their production operations require reliable, high-output sealing across demanding material specifications — including heavier-gauge scrim-supported materials where RF welding had previously been the standard approach.
Bryan Kramer contacted Novaseal® to explore whether an existing RF welder could be converted rather than replaced — and whether the converted system could handle the production volume and material range their operation required.
The existing Cosmos-Kabar RF welder represented a capital investment in press infrastructure — frame, actuation, operator workflow — that still had functional value. The constraint was the sealing physics, not the machine architecture. RF welding's dependence on dielectric material properties was limiting both the material range and the production throughput Extra Packaging needed.
RF welding requires polar, dielectric-compatible materials. As Extra Packaging's material requirements expanded, RF's dependence on material polarity became a direct production constraint.
Production volume requirements called for faster, more repeatable sealing cycles. RF cycle times and tuning complexity were limiting the sustained output the operation required.
Replacing the press entirely was unnecessary — the frame, actuation, and operator familiarity all had value. Conversion allowed Extra Packaging to retain that infrastructure while replacing the sealing physics.
As RF welding equipment ages, field containment can degrade. For Extra Packaging, this was a contributing factor in the decision to move away from the existing RF system — independent of its performance limitations. Conversion to Packet Welding removed RF field generation entirely, eliminating that category of concern.
The conversion replaced the RF heating and energy-delivery system with a Packet Welding sealing system engineered for packet-controlled thermal behavior. The press structure, actuation, and operator workflow remained unchanged.
Specific changes included:
After conversion, sealing behavior is governed by thermal absorption and diffusion rather than electric field response — removing dielectric dependence entirely.
RF generator and electrode assembly replaced by Packet Welding sealing system
In Their Own Words
"Nova Products did a great job converting our Kabar RF welder to Packet Welding — increased production capacity enables our company to serve our clients more efficiently."
Bryan Kramer
Extra Packaging — Eagle Pass, TX
After conversion, Extra Packaging's production behavior shifted from RF field-governed sealing to packet-controlled thermal delivery. Outcomes reported and documented from that conversion include:
Faster, more repeatable sealing cycles increased the throughput available from the same press. Production capacity grew without adding equipment or floor space.
The converted system sealed heavier-gauge scrim-supported materials as well as lighter-weight materials — material range no longer limited by dielectric compatibility.
The conversion accommodated a 40-inch Packet Welding sealing bar — 10 inches longer than the original RF bar — increasing usable sealing length without altering the press structure.
Converted in December 2020, the system has been in continuous production at Extra Packaging's Eagle Pass, TX facility for more than five years. The conversion has demonstrated the long-term durability and operating stability of packet-controlled thermal architecture in a demanding production environment.
The conversion was intentionally limited to thermal behavior — not mechanical architecture. Existing process knowledge carried forward. Improvements were realized through changes in heat-transfer behavior rather than changes in force, pressure, or motion.
After RF conversion, sealing is governed by packet-controlled heat delivery — not RF field dynamics. This changes the production profile in ways RF tuning cannot replicate:
Warranty coverage: Packet Welding components installed as part of the conversion are supported by a 5-year limited warranty — reflecting the durability of the sealing architecture and the long-term stability of packet-controlled heat delivery in production environments.
The Extra Packaging conversion demonstrates that RF welders can be converted to Packet Welding while preserving the press structure and expanding sealing capability. Novaseal® has documented this path and offers a conversion review process to assess feasibility based on your machine, materials, and production requirements.
Learn About the Conversion Path Request a Conversion ReviewSubmit your machine details and production requirements for a conversion feasibility review. No commitment required.
Request a Conversion Review Explore the Conversion PathOriginally documented December 2020. Page updated April 2026.