Folder-gluer

A Viewpoint on Folder-Gluers – Yesterday and Today

September 16, 2024

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.

When It Comes to Folding/Gluing, Efficiency is Key

September 1, 2023

Compiled by Erin La Row, editor, PostPress

The automated folding/gluing process helps producers save time and money transforming flat, printed items into cartons and boxes. But as labor challenges continue across industries, finding skilled folding/gluing operators is tough for many companies.

PostPress talked with Kevin Koplin, director of operations with American International Machinery, Inc. (AIM)/Signature Folder Gluers, and Rick Pallante, president, Baumer hhs USA and Canada, about overcoming the challenges in today’s folding/gluing environment.

What recommended technologies, training and/or ancillary equipment can a company use with its folder-gluers to help decrease the learning curve and run folder-gluers more efficiently?

Koplin: The best way to economically find good gluer operators is to train them. Memory retention is one of the biggest challenges in today’s world. Use photos and videos. Select the most common and challenging jobs to create an in-house video. Supplement this with documentation, including pictures that mirror the videos that are produced. These will be enormously helpful to trainees and current operators.

Computerized makeready systems, both automatic and semi-automatic, can be a great addition to the standardization of the makeready process. An automatic makeready system allows operators to load the measurements of a job into the machine software where it will save the job. The software then calculates the measurements and moves its carriers to the measured location. Settings will be stored under the file name that is given to it. Operators can save their settings and then make minor adjustments with the push of a button. Subsequently, the file will be up to date for future runs. Semi-automatic makeready systems are similar to automatic ones, minus automation. Some systems allow the operator to set up the product and then save the product to the database. When the product is put on the machine again, the operator recalls the job to the screen and the computer loads the specifications. The information is sent to the machine’s dial indicators and then the operator moves the components to the stored location one at a time. The makeready still is done manually, but the machine is giving the operator the locations.

Automatic makeready systems can be a great addition to the standardization of the makeready process. Photo provided by American International Machinery, Inc.

Pallante: Folder-gluer operators are becoming a limited resource. The level of expertise of a folder-gluer operator has changed as well. Technicians are spending more time assisting operators with training for setting up the folder-gluer itself, in addition to their normal duties of installing the training on the gluing system. Machinery is becoming more complex as it is being asked to do many more things than it did in the past. Training is the most important thing an equipment company can provide. It’s done in-person at installation, but it has to be something that also is invested in after installation. Operator interfaces have changed so that they are more intuitive and less complex, even though they provide more capabilities than in the past. Many systems carry instructions in the Help section on the monitors. The more information operators can access easily and simply, the more it will help them in their responsibilities.

Finishers and folding carton manufacturers must run efficiently and have as little waste as possible to stay competitive and maintain margins. What are recommendations for a folder-gluer to help decrease waste and increase productivity?

Koplin: Sometimes it is impossible to avoid waste, but here are a few ways to keep it to a minimum. Setting up multiple jam switches in sensitive areas will avoid excessive product waste and decrease downtime and spoilage. Stopping the machine with the defective product will minimize damage to the cartons and the machine. Thus, operators will decrease downtime. Also, consider an inline carton ejector to remove bad products from the machine while it continues to run. This also takes the human factor out of the equation, meaning it ensures the waste will not be missed or packed in a case. Finally, preventative maintenance is very important. A properly functioning gluer that makes sure everything moves and works correctly is key to a strong successful setup. A preventative maintenance program to maintain the gluer is very important!

Pallante: Companies are is measuring their own key performance indicators and overall equipment effectiveness. Both of these can be dependent on having the system run as long as possible with the fewest stops and lowest amount of production waste. Quality control (QC) systems – whether moisture-based, UV- tracer-sensitive or camera-based – indicate to the operator how accurately the glue is being placed on the carton. With adhesive dispensing applicators that are reliable and repeatable, the tolerance on the glue pattern can be kept constant. If the pattern begins to move, there can be several factors that are causing this that can be addressed. These can be machine-related, such as a belt slipping or a worn encoder, or glue-related, such as a different glue or viscosity being introduced, or a change in the carton diecut. The determination between a good and a bad carton is measured in millimeters and milliseconds. The sooner it can be recognized, the sooner it can be corrected. Sometimes, operators will try and turn off the QC system rather than look for the cause. Most systems now have fail-safes that prevent that from happening, which will ensure quality produced cartons arrive at the customer.

What new challenges have been seen in recent months with customers that have folding/gluing operations (paper stocks, printing inks, glues, etc.)? And what recommendations can be made for these challenges?

Koplin: The biggest challenge is the lack of personnel. This last generation of retirees is not replaceable – we have to build operators. This is why automation is so critical. The labor pool simply isn’t there. Fluctuations are seen in substrates. Paper mills look for cost reductions on their end, and more additives are found in the boards. And special applications such as security tags, labels, tape, inserts and imprinting, cause challenges. For these reasons, AIM/Signature had additional lengths added to the gluer to support any future ancillary equipment.

Supply chain challenges continue to be an issue with unpredictable lead times and material shortages worldwide. Standard items, such as electronics, paper, belts, etc., that were once a few days out now are taking weeks or longer. Unfortunately, this is out of manufacturers’ control, so being proactive and having extra parts on hand before the machine goes down is one recommendation.

Pallante: Thankfully, these are becoming less as the supply chain starts to catch up to demand. Customers were trying to run different adhesives due to availability. This can start a glue pattern late or increase tailing at the end of the pattern. Having the best dispensing technology with a strong, robust coil and fast closing can better manage these changing viscosities. On the carton front, more cartons are being made from recycled content. This content typically contains UV from printing, as well as UV tracers used in the adhesives. QC systems that are dependent on UV tracers for glue detection can become “blind” as they can no longer detect the difference between the UV tracers in the glue and the UV now in the carton fibers. Customers are having to move to moisture- or camera-based technologies to combat this situation.

Run lengths for folding cartons and other products continue to decrease. What type of ancillary or other equipment accessories should a folder-gluer have to help with quick set-up and makeready?

Koplin: Once again, computerized makeready systems truly make set-ups go faster, thus allowing for more makereadies in less time.

Having enough tooling to make fixtures, such as lock-bottom assemblies that can be mounted to the machine instead of having to put individual parts together each time, cuts down on time considerably. There should be no reason that all parts are taken apart each time and reassembled for the following job. With additional tooling, operators also can put together special components while another job is running. Pre-manufactured parts, such as Z-Fold attachments, are available to eliminate having to do any assembly.

Pallante: From the gluing side, operators want to be able to easily access a program from the controller that saves the information so if a job is run again, the parameters can be pulled up easily and quickly. They also can do a “copy and paste” using one program to quickly create another. For the applicator, having an applicator that closes securely matters. Operators need to be able to leave it for an extended period of time and not have to worry about covering the nozzle tip every time. They need to be able to start the system up and glue that first carton. A quality applicator will provide that.

What new technologies are on the horizon that will help with the efficiency and productivity of folder-gluer equipment and/or ancillary equipment?

Koplin: Adding detection (glue, doubles, window, bar code, etc.) works well to remove waste from the machine without disrupting production. Detection also takes the human factor out of having to sort through cartons prior to packing to find bad products, which then allows them to pack more efficiently and accurately. Print detection also is becoming more common and is required by some customers, especially pharmaceuticals. Print inspection – both words and color – guarantees the wrong product or misprinted product will not be sent through the machine. This also can be tied to the inline ejector to remove prior to packing.

Pallante: Artificial intelligence (AI) is going to change things, maybe not as quickly as end users would hope, but I think it will come into play with preventive maintenance calculations. Being able to gather the data and allow it to be manipulated by customers for use by their systems will be the next big thing for this industry. Getting the data will be a challenge. It’s going to be more than counting strokes. It’s going to be asking how this stroke compared to the last stroke. Is there a trend? Can it be changed internally, or should the operator be notified that maintenance is imminent? It’s going to be very interesting to see what lies just over the horizon.

PostPress magazine would like to thank Kevin Koplin, director of operations with American International Machinery, Inc. (AIM)/Signature Folder Gluers –
www.signaturefoldergluers.com and Rick Pallante, president, Baumer hhs USA and Canada – www.baumerhhs.com for their assistance with this article.

Buying a Folder-Gluer: Top Three Factors to Consider

December 13, 2022

By Hani Hallal, Impack Packaging

Looking to buy a folder-gluer machine? Because of the role a folder-gluer machine plays in the production of carton and corrugated boxes, the demand for folder-gluers is growing rapidly.

That means choosing the right folder-gluer that fits a company’s needs and budget is critical. Failing to do so will not only cost the price of the folder-gluer, but also major long-term productivity and output losses.

For the last two years, I’ve researched and interviewed some of the most experienced folder-gluer experts. Recently, I met with Mario Persechino, a folder-gluer expert and instructor with more than 40 years of experience in the industry, to talk about the most important factors to consider before buying a folder-gluer.

This guide covers the top three factors Persechino said must be considered before buying a folder-gluer.

Top three factors to consider

Choosing the right folder-gluer depends on a multitude of factors that vary from company to company. However, there are three critical questions every folder-gluer owner needs to ask before buying a new folder-gluer:

What are the company’s production needs?
How will space be organized for the new folder-gluer?
What post-purchase services are important to the company?

1. What are the company’s production needs?

A company’s needs always will be the biggest deciding factor influencing the right choice of folder-gluer model.

Although all folder-gluers can produce the 300 different box formats that exist on the market, not all folder-gluers will be able to produce at the output, speed and budget a company requires.

That is, every company’s needs are different and the choice of a folder-gluer rests on the knowledge of that.

Most company needs can be broken down into two types: volume-based needs and format-based needs.

Volume-based needs
If a company’s primary focus is to produce the same types of boxes consistently every day, that would classify the company’s needs as volume-based.

In this situation, it is recommended that companies choose more than one fully automatic folder-gluer machine and have each dedicated to a specific box material. This allows companies to produce a high volume of different box materials at the same time without having to stop or pause folder-gluer production.

Format-based needs
If a company’s projects are such that different box materials are produced for each project and it’s not likely the company will be producing a high volume of boxes for each project, the company’s needs would be classified as format-based.

In this situation, choosing a semi-automatic folder-gluer is recommended since it is more versatile and flexible, allowing companies to meet customers’ requests for different box formats.

Now that it is known what the production needs are, the second most important factor to consider is: How much space is available?

2. How will space be organized for the new folder-gluer?

Knowing that the company needs a new folder-gluer is important, but just as important is knowing how this new machine will fit on the production floor.

It’s no secret that finding good operators these days is hard, and labor shortages have become a serious problem affecting the packaging industry. Thus, if the company’s needs are volume-based, then more than one operator will be needed. In addition, packing staff (or packers) also may be needed to pack the boxes into cases after they come off the folder-gluer delivery belt.

Most companies needs for a folder-gluer can be broken down into two types: volume-based needs and format-based needs.

This is all to say that if a company is thinking about buying a new folder-gluer, consider the space on the production floor and how operators and packing staff will be moving around workstations, with respect to the folder-gluer.

I know, it sounds like a lot to consider, but the good news is that companies do not need to personally calculate all of those factors. A folder-gluer supplier should help with these considerations before companies buy. Hence, make sure a reliable folder-gluer supplier is found with whom a solid long-term partnership can be formed for after-sale needs, which this article will get to next.

Ask Impack for recommendations on folder-gluer suppliers, if in doubt. We work with small companies, medium-sized companies and some of the biggest names in the packaging industry. We know what folder-gluer brands are on the floors of the least to the most successful box manufacturers.

3. What post-purchase services are important to the company?

When evaluating different options of folder-gluers, ask suppliers about past problems they have experienced with that specific model, but, more importantly, what after-sales services they offer. The answers will speak volumes about the only thing that truly matters in those types of relationships: reliability.

The biggest cost a company will incur is not the cost of the new folder-gluer but rather the productivity loss that will be incurred as a result of the machine breaking down, failing or not being utilized to its maximum capacity.

Find a folder-gluer supplier that truly cares about the service it offers after the sale. Make sure to consider everything, from the maintenance of the folder-gluer to the installment, training and delivery services.

After all, every single machine eventually will break down, fail or come across some sort of issue. It is what a company can do to fix it and maintain it that truly matters.

Ready to buy? Choose the right one.

As can be seen, there are a lot of factors to consider when buying a new folder-gluer; and it is impossible to think of everything before making the investment.

Reading this article can help those trying to make an informed and educated decision. After all, buying a folder-gluer machine is a big decision, and companies certainly
do not want to regret their purchase a few months down the line.

Hani Hallal is the marketing manager at IMPACK. To get answers to the most common folder-gluer problems, visit www.Impack.ca.