Our Technology

Our proprietary heat sealing technology results from continuous research and development, giving us peak flexibility in the way we approach the design of film-based products and allowing us to achieve the high-quality, accurate seals critical to their success.


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Trlby Heat Sealing Elements are some of the most technologically sophisticated components in the industry - setting our equipment apart from off-the-shelf machines. We use advanced analytical tools such as Finite Element Analysis (FEA) to design every element.

Our technology is ideal for products with air cells, bladders, curved shapes & surfaces, cut seals, fittings, ports & valves, inflatable bladders, and electrode bagging.

We heat seal all thermoplastics including nonwovens, polyesters, polyethylene, polypropylene, polyurethane, polyvinyl (PVC), laminates, and battery separator membranes such as Celgard™.

The Trlby Advantage:

❯❯ Faster Process Speeds 

  • Perfect seals in a fraction of the time other sealing technologies require.

  • Heat cycles are as short as 0.1 seconds and total seals in less than 1 second, including cooling time.

  • Process speeds can be significantly accelerated by integrating cooling lines in the sealing system.

  • Ideal for high-speed in-line applications.

❯❯ Customizable & Versatile 

  • Cost-effective for prototypes and pilot runs.

  • Elements are designed to match profiles precisely, not bent to conform.

  • We don't use drawn ribbon or wire elements; our elements are custom-designed for specific applications.

❯❯ Advanced Process & Equipment 

  • Full system automation with temperature controllers and PLCs.

  • Our PLCs are programmed with exact parameters, so there is no need for tuning, warm-up, burn-in, or other start-up adjustments.

  • Multiple programs can be saved for various materials or products, minimizing changeover times.

  • Consumes 78% less energy than radio-frequency welding processes.

  • Material webs control results in better registration from station to station.

  • We use Finite Element Analysis (FEA) to design precise elements that heat uniformly and eliminate hot or cold spots.

  • Allows for validatable seals to ensure ENO and ISO adherence (EN 868-5, ISO 11607) to standards requiring the sealer to monitor and record the temperature, the force applied, and the time cycle of the sealing process.

❯❯ Stronger Seals

  • Our seals are stronger than film components.

  • No sacrificial layers, buffers, or special coatings.

  • Thinner seals that are stronger than the thick seals produced by other processes.

  • Techniques to balance seal strength with peelability.

  • Our seals are stronger than their surrounding material, unlike RF welded seals.

  • Our seals can be flush with the material surface without compromising strength, and no need for additional buffer material.

  • Our elements are embedded to create flat seals. Flat seals prevent fatigue at seal edges and degaussing of polymers through the seal cross-section.

  • Materials can be cut (true cut, not tear) and sealed in a single operation with no reduction in integrity.

❯❯ Unique Applications 

  • Complex and intricate shapes (curved, around ports, fittings, valves, radii, etc.)

  • Cut seals

  • Seals around ports, tubes, and fitments.

  • Multiple, simultaneous seals.

  • Maximized seal area (for strong seals required in confined spaces).

  • Seals in minimal areas - within fractions of a millimeter.

  • Seal multiple layers.

  • Sealed folds and pleats

  • Thin to thick materials.

  • Peel seals

  • Long seals that are >10'.

  • A unique baffle system that makes quilted-type pattern seals obsolete.