By Jeff Wilcox, Independent Trainer, Finishing Industry

Fifty years ago, I started a journey into the field of the printing and converting industry. I found it fascinating to watch the machines that were folding paper cartons. The sound coming from those machines while in production was music to my ears. I decided that this was something that I would like to do. When I began my training to become a “machine setter” on a folder-gluer, I quickly learned that it was not as easy as it looked. I was not provided much training with my first job, and I was forced to “figure it out” on my own for setting up new folding/gluing jobs. I noticed that on any given folder-gluer machine, when a change of shift happened, a change of set-up often would follow. Each folder-gluer operator would have his or her own special tricks to get a job running more quickly. Sometimes the trick would work, and I would put it into my notebook for future use, and other times the operator spent time fixing something that was not broken.

I developed an interest in learning how to set the machines up as quickly as I could and how to run them as fast as possible. Once I established myself as a skilled folder-gluer operator, I had opportunities to gain experience on several different folder-gluer machines, from many different OEMs, over the years. I noted the separate ways to do the set-ups on each of them. The carton styles were the same, but the tooling used on the different machines looked different and the set-up procedure was different on each as well. I remember when I first started as an operator, I had to use a hand crank to move the machines carriers to various positions for the varying carton and box styles and sizes. Using a hand crank to move the carriers reminded me of an old “Model T“ car. This process was not entirely accurate. Set-ups could take a long time. I began to understand why my fellow operators told me to figure it out on my own. There was no established standard operating practice. Each job, even repeat jobs, could be a new and different set-up.

Today, folding/gluing machines have a much more advanced method of set-up and operation. The addition of motorized carriers, instead of hand cranks to position the carriers, has been a huge advancement that allows for far greater accuracy and job repeatability. Having the opportunity to use a digital scale that is built into the side of the machine at each carrier location as referenced when positioning each carrier was a significant improvement. This cut the time for set-up considerably. The elimination of the hand crank was well timed and very welcomed. Setting up a job on a folder-gluer with motorized carriers can be a straightforward process, and this process generally performs very well.

In addition to the use of motorized carriers, today’s folder-gluers are equipped with industrial computers to help with job set-up changes and establish standard set-up practices. An operator can enter the dimensions of a particular carton style and the folder-gluer will use those dimensions to automatically move the carriers for the set-up of the carton. This works great and saves an enormous amount of time during set-up, although, in many cases, the operator still must make slight changes to the carton style and then set-up the feed section and the delivery section for each carton style, among other refinements to the set-up. Having an experienced folder-gluer operator still is very important, even with automation and computer technology.

The advancements to folding/gluing machines today are incredible. The amount of production and running speeds are amazing. The folder-gluers now are capable of more inline processes, such as turning the carton blank 90 degrees like a “right angle machine” but doing it in a straight line through the machine; producing cartons with a front fold, such as an automatic lock-bottom style without the use of mechanical lifting devices; inline cellophane window application and label attachment systems that can be added to the folder-gluer and used as needed. In addition, glue application systems have evolved and now are multi-functional glue applications and inspection systems, that require a skill set of their own.

The newest folder-gluers on the market have even more advanced automation for set-up and production. The automation still requires the operator to enter the dimensions of the carton blank into the computer. However, this process now is more advanced and there are more carton styles to call up in the computer system, with added options to control or tie into the set-ups of the aforementioned ancillary processes.

With the added features and convenience of the new machines, the cost of the more advanced folder-gluers has risen. However, users must balance the savings in set-up times and increased production rates, which can offset a great deal of these costs. I recommend that those in the market for a new folder-gluer carefully assess the automation features and software and be sure to check with other users on how well it has performed. The folder-gluer should have the ability to store past set-ups, including special set-ups that can cause frustration for the operator. There are many OEMs in the marketplace today and it is important for companies to do their homework before purchasing a machine. It also is recommended to check the warranty periods of the machine. I have seen a fluctuation from different manufacturers with what warranties are being offered. There are machines on the market today where the tooling for the different carton styles stays on the machine and the carriers that the tooling attaches to are lifted and scuttled out of the way when they are not needed – so there are no worries the tooling will be damaged with making a changeover to a different style. I have found this extremely useful, especially for newer operators.

There are many new and inexperienced people becoming folder-gluer operators. It is far better to train a person on a new automated folder-gluer just by the mere fact that the machine does most of the set-up work and new operators do not have to figure it out on their own. If an investment in new folder-gluer machinery is called for, one should consider as much automation and computerization as possible. It will be well worth the investment.

Jeff Wilcox has over 50 years in the finishing industry and now is “semi-retired” but still in the industry working independently as an operator trainer. He can be reached by email at jsw7355@gmail.com.