Packet Welding Upgrade

Upgrade your existing Novaseal® bar sealer to the latest Packet Welding technology — performed entirely on-site while your machine remains installed and operational. Experience faster cycles, stronger seals, and less maintenance, all while extending the life of your current equipment.

  • ✔ Performed at your facility — no shipping required
  • ✔ Installation completed in one day
  • ✔ Training & Q&A the next morning (approx. 90 minutes)
  • ✔ Works with your existing Novaseal® frame, power system, and automation

➜ Read the Castle Case History »

Upgrade Options

Configuration WPI (Watts per Inch) Ideal Materials Typical Applications
75 WPI Mid-range power Mid-weight vinyls, polyester blends Windows, awnings, banners
100 WPI Higher power Heavy vinyls, vinyl alternatives, nylon Inflatables, tents, canopies
Custom / Switchable (75 / 100 WPI) Adjustable Wide range of fabrics Multi-material operations

Why it matters: Selecting the correct WPI optimizes energy density and control. Higher WPI values handle thicker or more absorptive materials, while lower WPI offers efficiency for lighter fabrics—all through Packet Welding’s precise micro-bursts of heat.

What’s Involved in the Upgrade

  • Transformer Installation: Added or upgraded to achieve your target WPI
  • Safety Switch Replacement: Ensures safe operation at higher power levels
  • PLC + HMI Upgrade: Controls timing and absorptive energy precision
  • Complementary Enhancements: Wiring, relays, calibration, and energy filters
  • Performance Verification: Full testing and validation before completion
  • Operator Training + Q&A: Conducted the following morning
  • Complimentary Maintenance Check: Unless time constraints prevent, we’ll perform a free inspection to ensure all systems function properly

Key Benefits

  • Less Maintenance: No heating elements or Teflon tape replacements
  • Faster Production: Up to 4× faster cycle times than RF or Impulse sealing
  • Lower Operating Costs: Reduced wear, downtime, and energy usage
  • More Material Flexibility: Works with vinyl, nylon, polyester, and sustainable alternatives
  • Improved Seal Strength: Consistent micro-burst heating for cleaner seams
  • Extended Equipment Life: Upgrade your current system instead of replacing it
  • 5-Year Warranty + Forever Support: Backed by Novaseal® reliability