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      Print Decorating, Binding and Finishing

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        Folding / Gluing

        Folding Carton Production: Automation to the Rescue for Workflow Challenges

        September 15, 2022

        By Liz Stevens, writer, PostPress

        From the earliest days in the folding carton finishing sector, there has been a push for greater output quantity, higher product quality, increased speed and improved efficiency. Each time a goal in one of these areas is achieved, the honeymoon is short-lived because, in the blink of an eye, another new goal crops up. Folding carton finishers perpetually strive for ways to better serve their customers and improve their profitability. Finishing hardware and software manufacturers work equally hard to provide new technologies and automation solutions to meet the emerging needs and overcome the latest challenges.

        PostPress talked with printing and finishing equipment and automation leaders about the challenges they see arising for folding carton finishers, the automation and software solutions they offer for their customers, and the upcoming technology innovations they see on the horizon. PostPress is grateful to Bill Rice, product manager, postpress packaging at Heidelberg USA, Inc. (Kennesaw, Georgia); Doug Herr, director of sales, folding carton North America, Bobst North America, Inc. (Parsippany, New Jersey); Jeffrey Bates, national sales manager at W. H. Leary Co. (Tinley Park, Illinois); and Jan De Roeck, director industry relations & strategic marketing, Esko (Miamisburg, Ohio), for
        their insights.

        Challenges and solutions

        diecutting
        Bobst’s ToolLink is a chip embedded into the diecutting die when the tool is slid into the machine with job-specific information.

        The challenges facing folding carton finishers run the gamut. There is the chronic lack of available, trained workforce candidates, but automation and software capabilities may offer some solutions. There is the inherent mismatch between printing press speeds and finishing equipment speeds; here, software for overall plant/job scheduling and individual department scheduling may be helpful. The relatively consistent nature of printing workflows versus the wildly variable nature of finishing workflows produces plenty of challenge but here, again, computerized aids for managing jobs, presses and finishing equipment can help smooth out the rough transitions.

        The trend toward shorter runs, the demand for highest product quality, and the requirement to provide production data to customers – these certainly pose challenges. Technologies for streamlining makeready times, vision systems for ensuring superior product quality, and sensors and software for collecting and managing production run data can offer options for finishers. The rising price of energy, the still wobbly supply chain and the increasing costs of materials all add to a finisher’s list of items to address and manage, but good aids exist for finishers to run leaner and eliminate waste. And last but not least, a finisher’s aversion to updating or replacing equipment – and to spending the capital required – can be its own challenge. For this, the argument can be made that investing in equipment may give a company a competitive advantage and result in greater profitability.

        Common challenges

        Bill Rice, representing Heidelberg and its array of equipment and software solutions for the entire print-to-finish line, identified the challenge that exists in plants managing two systems – printing and finishing – which are sometimes viewed as a single job stream even though they have differing makeready tasks, makeready times and run rates. “The technology and software in our equipment can identify the best way to run a job through a particular machine,” said Rice, “but from one machine to the next, the job plan may not be consistent. A job schedule that might work well for the printing press is not necessarily the same order that would be ideal for running through the rest of the equipment.” Pushing a job through the plant based on the greatest efficiency for the printing press might lead to extended makeready times on the folder/gluer. Conversely, a great workflow for the folder/gluer (going from small and simple products gradually up to the larger products) would reduce the makeready times but that might disrupt the workflow coming out of the
        printing press.

        Esko’s ArtPro+ software provides print unit support and repeat layout creation.

        Rice offered two solutions: Heidelberg’s “Push to Stop” philosophy and the company’s Prinect software packages. “In dealing with the two sides of the printing-finishing line,” said Rice, “it ends up being a compromise. In the scheduling and planning of the production floor, it is important to get as much efficiency as possible through every process.” Heidelberg’s Prinect Workflow software offers management tools from web portals for communicating with customers to costing, job creation and planning, production management, and production and business reporting. “The other solution component is Heidelberg’s manufacturing philosophy: Push to Stop,” Rice said. “It is a way of working, using software and hardware, so that when the plant starts up for the day, everything is pre-organized based on efficiencies. The system starts the first job and then automatically goes from one job to the next, and human operators don’t get involved in changing that flow and schedule unless there is a problem.” Rice stressed that planning and scheduling are the foundation for getting a job through the whole plant as efficiently as possible. “We are seeing tremendous success in companies that are able to manipulate some of that,” he said. “We have seen the biggest success in plants that are able to look at the finishing side of things and manage that best because that is really the most labor-intensive part of the operation, whereas on the printing press side, there is so much technology built into the presses that it is possible to have very good makeready times even if some of the press’s efficiencies are disrupted.”

        At Bobst, which offers substrate processing, printing and converting equipment and services, Doug Herr said that longstanding challenges stem from several issues. “Run lengths are becoming shorter,” said Herr, “turnaround times for the client are becoming shorter, and margins are tight as always. So the efficiencies of the converting equipment are extremely important; they are critical to profitability. Our customers’ customers – the brand owners, for instance – expect a higher percentage rate of quality product; in other words, fewer defects are important. And more and more frequently, brand owners want production data and data relative to the number of imperfect products produced. In the pharmaceutical industry, for example, they need to closely track the production of the product, including the packaging, so that each item and each lot have a specific code which can be tracked back to the manufacturer.”

        Herr sees solutions that include upgrading or replacing hardware and adding software. “Older equipment,” Herr explained, “although it can still perform, often doesn’t include the software and capabilities which are built into new machinery to give customers information and quality assurance in an efficient way.” Herr used diecutting as an example. “Diecutting is an area where Bobst has made a number of improvements and introduced new equipment and related support products. We now offer a HMI 22″ (Human-Machine Interface) touchscreen; this is the control module, the brain of the equipment. We also offer Recipe Management, a program that can save up to 5,000 of our customers’ jobs and all of the parameters of those jobs.” Herr mentioned a third diecutting enhancement – TooLink, a chip which is embedded into the diecutting die so that when the tool is slid into the machine, job-specific information is transferred automatically to Recipe Management. “By the same token,” he said, “production information relative to a specific job, such as number of impressions, the number of times that job has been inserted into the machine, the number of times that job has been run utilizing that tool, are kept on the microchip embedded in the die.” Bobst now also offers a Digital Inspection Table, a standalone machine for checking the quality of a full sheet. “A quality assurance (QA) individual can inspect the print,” Herr explained, “to check the color or position, to check for missing copy or – with diecutting – to look for a poor score, an incorrect score or a missing score.” Bobst recently introduced Accucheck 2, a module positioned after the feeder’s blank alignment device on a folder/gluer, for example. Accucheck 2 has cameras which read the copy on each individual blank, check for incorrect color, missing color, missing type. The module can check creases, and can read imperfections in stamping, embossing and other embellishments.

        Jeff Bates, with W. H. Leary, a maker of quality assurance, glue application and mechanical solutions for the packaging industry, reported that the biggest challenge his company has seen for folding carton workflow is the continued lack of skilled or even unskilled labor, which has been made even worse by the COVID-19 pandemic. “I think the factories learned a lot from COVID,” said Bates. “It definitely affected a lot of factories; they now have to start looking more towards innovation and automation for the future.” According to Bates, a lot of plants have acknowledged that skilled workers do not exist and now are just looking for people who can run the lines and keep them going. “More or less,” Bates, said, “they just want someone who can push a start button and a stop button.”

        Leary has addressed the skilled workforce scarcity by building more features into its solutions. “Our software, Monet, is a pictorial system that we created 10 years ago, and we have improved it to change with the times,” said Bates. “With Monet, operators can just look at the graphics and understand whether they are shooting dots or shooting a line of glue, and they can see where the tolerances need to be from a quality standpoint.” The system also displays bar codes so that operators can verify that the code on the cartons matches the code on the computer screen.

        “Operators can verify what they are running, guarantee that it is top quality and, at the end of the job, they can save the job info,” Bates explained. “All of the settings are saved now so it makes the makeready times shorter for repeat jobs and the quality specs are saved, too.” To further ensure quality, the Monet system includes password protection that prevents operators from making unauthorized quality spec changes. “Plants are taking product quality much more seriously these days,” said Bates. “Once a job’s quality specs are transferred to our system and password protected, no one other than a manager or somebody from the quality department can
        make changes.”

        Leary has added QA sensors to its hardware and the company’s Monet system has evolved to handle more quality assurance features. “Our QA focus used to be just looking for glue, looking for bar codes and scanning for missed copy,” Bates said, “but many companies now are starting QA all the way up at the feed. They are looking for doubles that are coming out of the feed, they are looking for skew and any bent flaps.” Leary’s system also now collects more production data and offers equipment troubleshooting features. “When there is a mechanical problem, the customers want us to guide an operator to a specific area on the machine to look for a problem and make a fix,” said Bates. “Helping customers pinpoint problems on the machinery is important since this can eliminate a lot of downtime.”

        diecutter
        Heidelberg’s Mastermatrix diecutter includes presets for things that are done automatically on the machine based on the data flowing into it.

        At Esko, which provides integrated software and hardware solutions for packaged goods, Jan De Roeck sees several challenges. “As the packaging industry continues to grow and adapt to the very real threats of today,” said De Roeck, “supply chain volatility, labor shortages and rising consumable and energy costs all underline that converters need to accelerate their search for increased efficiencies throughout the workflow.” De Roeck pointed to efficiency as the biggest benefit of a standardized workflow and identified standardization as being the necessary foundation of any successful automation. “Although the entire packaging sector faced unprecedented challenges in the last two years,” De Roeck said, “Esko has continued to focus on developing new technology, ensuring customers remain at the forefront of productivity, efficiency and innovation gains and are supported on their digital transformation journey.”

        Esko believes that successful digital transformation means more automation, more cloud computing and more integration between disparate systems. “In the face of the disruptive market trends in the industry, we continue to work closely with our customers,” De Roeck explained, “listening and developing innovations that respond to demands and deliver tangible benefits. That’s why we recently launched a series of innovations to empower businesses to improve ways of working, eradicate waste and optimize operational processes.” Esko Release 22.07 includes new features such as Cape Pack for cloud-based palletization and logistics optimization workflow, Automated Packshots for creating hyper-realistic packaging images, ArtPro+ for print unit support and repeat layout creation, and more.

        De Roeck also brought up the challenge for finishers of taking on capital investments. “Innovation and change are inherent in any packaging business but driving and implementing that innovation is a challenge that can sometimes be difficult to achieve,” said De Roeck. “Many businesses, in the face of challenging market conditions, insecurity and volatility, freeze investments in response. However, the opposite reaction is more appropriate. Investing in accelerating digital transformation maintains competitive advantage and efficiently deals with profitability pressures. We also know it is equally important that these innovations are integrated quickly and smoothly to ensure businesses achieve demonstrable improvements and a speedy return
        on investment.”

        Challenges created by shorter runs

        The increasing tendency of customers to request shorter runs of folded carton jobs is a challenge that all of the industry representatives recognized. “That is a challenge that everybody is facing,” said Heidelberg’s Bill Rice. “The way we respond to that is we try to build in as much technology into the equipment to reduce makeready times.” Rice pointed out that, as an example, splitting a previously routine run of 500,000 pieces into short runs of 50,000 pieces balloons one makeready time into 10 makeready times. “The estimating department now is having to add in those additional makeready times. We encourage folks to build those costs into their price because everybody is going to the much shorter runs.” This type of change also calls for input from equipment suppliers. “It is really a situation where OEMs, like Heidelberg, can work with production floor people to help them use the technology that they have properly and efficiently. In some cases, it means recommending that they buy additional software packages or workflow implementations that will help them operate better.”

        Leary’s Monet System settings are maintained with unique security features.

        Leary’s Jeff Bates offered an alternative solution to responding to the demand for shorter runs. “A lot of the plants that I have dealt with for years used to run maybe three or four days,” explained Bates, “and they would just put a card in on the machine – a side stream structure card – to eat up board.” But with board now being a hard-to-source commodity, some customers are looking at switching over to the upper end work – shorter runs but with cartons that are worth more money. “This might take them back into the pharmaceutical and the cosmetic lines,” Bates said, “but with board being as scarce as it is in the industry, that’s what a lot of these companies are looking for – the shorter runs, the more expensive cartons.” This, however, puts pressure on finishers to find the right opportunities for operators that can do these types of makereadies. “The automation with our equipment is really helping these companies turn short-run jobs into a profitable business model.”

        New technology solutions in the offing

        Though the future is unknowable, equipment manufacturers do their best to predict trends and design features for the next anticipated requirements. According to Doug Herr, Bobst will focus on increased automation, preventative maintenance and the flow of data between machines and software, among other priorities. “Bobst is automating more and more of our equipment so that the setups on the machine are more consistent and the length of setup times continues to fall,” said Herr. “Our PackMatic Plus, recently introduced, provides quicker changeover times and more automation to set up machines much faster, with less skill.”

        Bobst sees the demand for data driving future solutions. “Data is really key, whether it is downflow of data from machines or upflow of data to the equipment,” Herr said. “That is going to continue to be extremely important for upping productivity and for facilitating preventative maintenance.” Bobst’s Connect Essential, a subscription service, will help finishers maintain and troubleshoot their equipment. “If a customer has a problem where a machine overheats or stops or isn’t producing at the levels it should,” said Herr, “the customer can access remote diagnostics through the internet and communicate with a Bobst professional. We can possibly avoid sending a service person out by identifying problems which the customer can rectify. And if a repair part is required, we can order the part to be delivered a day or two later, versus sending a service person out to locate the problem and then order a part. There will be tremendous decreases in downtime with Connect Essential.”

        Heidelberg’s Bill Rice commented on the company’s plans for its finishing equipment and software. “What we have seen because of COVID-19, because the workforce is depleted and it is difficult to hire new employees whether skilled or unskilled, is a trend of more companies looking into automation,” said Rice. “We have a lot of existing automation in this area already, but a stumbling block for some customers has been the price point for added features such as collecting data and managing the production process with things like pre-sets. The newest diecutter in our fleet is the Mastermatrix; it has pre-sets for things that are done automatically on the machine based on the data flowing into it. On our folder/gluers, we have auto-set technology; at this point it is not tied into the Prinect workflow system but that is an upcoming development that Heidelberg will offer.” In today’s environment, Rice expects more customers to see the value of automating workflow as well as the value of data collection and information flow. “All equipment manufacturers are trying to make the technology much more affordable. We think that customers also will be more willing to spend money on these features to replace the (now unavailable) labor that was required to do things the manual way.”

        At Leary, Jeff Bates described his company’s future innovations. “For us, it will definitely be automation,” said Bates, “including being able to set jobs up and adding more integration with the OEM machines. We know the future is automation, and with automation comes an increase in demand for vision-based inspection systems.” Bates chalks up the future’s demand to a shrinking workforce. “It is no longer the case that facilities can count on having three or four people at the back of the lines, and two people at the front of the lines feeding the cartons. They just can’t get the headcount that they used to be able to rely on.”

        Bates offered his opinion on how the COVID-19 pandemic has spurred change in the industry that actually has been needed for some time. “I think the pandemic caused a lot of companies to pay more attention to tightening up productivity because so many people would get COVID-19 in one week,” he said. “Instead of having just onesies and twosies out sick, plants had half of an entire department out, to the point where it really stressed the ability to get production done. This definitely did wake up a lot of people.”

        The industry already had known it had a problem, but the pandemic got a lot more companies thinking and strategizing. “Companies realized that they had not invested much money into finishing; they had concentrated on investing money into printing,” Bates explained. “Now these companies are thinking that they must start investing more money in this last process that they have in their plants because where they used to have plenty of people, the workforce is just not there anymore and it’s not returning. Frankly, I don’t foresee it ever coming back.”

        For more information, visit www.bobst.com, www.esko.com, www.heidelberg.com and www.whleary.com.

        BOBST Improves ACCUCHECK

        September 9, 2021

        By Jewlissa Frickey, writer, PostPress

        BOBST has launched the new ACCUCHECK, which makes zero-fault packaging a reality. The new ACCUCHECK is an inline solution to inspect carton blanks for defects as they enter the BOBST folder-gluer. The solution is fully embedded into the folding/gluing line, allowing a seamless progression, with no additional quality-control step in the process required. As a result, production quality processes are improved while quality-check running costs are reduced. 

        The system detects a wide range of defects, including spots, missing prints, text errors or misregistration. Defective boxes then are filtered and ejected automatically, guaranteeing 100% quality-controlled production.

        Customers require zero-fault packaging while wanting to ensure perfect quality production and timely detection of any errors within the production chain. They need a system to identify issues and eliminate sources of errors, leading to quality consistency and client satisfaction.

        The new generation of ACCUCHECK answers those needs. It can inspect embossed surfaces with no additional quality-control step required in the process; consequently, not affecting the production speed. 

        The folding/gluing line inspection system also is easy to use. The integrated quality control system is equipped with the HMI SPHERE, which provides several operating modes for customized settings and easy operation. This feature is becoming standard on new BOBST machines. In addition, inspection parameters can be saved and recalled, with repeat orders set within seconds. Access rights can be set for different users.

        As with the first generation, the new ACCUCHECK carefully checks carton blanks for defects, but now at a faster speed – up to 500m per minute, or 140,000 boxes an hour. 

        BOBST also has introduced dedicated inspections for embossed, metallized and varnished surfaces, which are very useful features for producers of high-end luxury packaging. In example, the system can check for an absence and/or misregistration of embossing, as well as detect the lack and/or excess of varnish. 

        Other new features include advanced reporting, PDF functions and the new Smart Text Inspection feature, which ensures that even the smallest defects like non-compliant words or numbers are detected. 

        ACCUCHECK can be configured to suit all segments, with different speeds and inspection needs for industries such as pharma, cosmetic and food.

        Technical Details

        ACCUCHECK has a device length of 1.5 m and offers an inspection zone up to 400 x 400 mm, with an optional extension zone increase of 800 x 800 mm. It provides inspection speeds up to 350 m/min (or 500 m/min with high-speed option). 

        Inspection capabilities include stable and accurate color measurement; precise register control of print, embossing, foil cut patterns; and enhanced text inspection, regardless of text pose or color, as well as advanced control of finishes such as hot foil, embossing or varnish.

        The global control sensitivity can be adjusted within three pre-set quality levels. Moreover, the blank control areas can be customized according to the required defect type and adapt the control sensitivity adapted depending on the application’s needs.  

        Heidelberg’s Diana Go 85

        June 11, 2021

        By Chris Raney, vice president of product management, postpress commercial and packaging division, Heidelberg USA 

        Heidelberg, with US location in Kennesaw, Georgia, recently announced the addition of a new folder-gluer, Diana Go 85. It was developed on the basis of Heidelberg’s market requirements by the MK development team based in Neuss, Germany. It has a small footprint, but commercial and packaging printers will find it cost effective, flexible and productive. 

        The commercial print market seeks constant innovation as many of the products it manufactures are marketing driven, and the need for differentiation is high. Coupling this with the constant price pressure means that printers and finishers constantly are seeking new ways to improve their efficiency and to add new capabilities. The Diana Go offers a bridge between the more traditional table-type folding machines that predominantly use plough folding and a folding carton folder-gluer.

        Of particular importance is the robust construction and stable carrier design. This ensures that a makeready, once complete, remains set for the duration of the production run with no fine tuning required. This stability of setup, along with belt folding and longer machine sections, means that production speeds can be higher for greater output.

        The aligning section immediately after the feeder is a critical element to guarantee the best quality as it ensures that every item is registered before it enters the first folding section. Throughout the machine, the folding belt design ensures that all folds are made in a controlled way for the greatest accuracy. The open construction allows for the mounting of tipping units, bump and turn units and pocket folder devices, offering a wide range of capabilities. The compression section also allows the use of cold glue when appropriate. Cold glue is cheaper and easier to handle than hot melt and further improves the flexibility of job design.

        The Diana Go will enable a commercial printer or folding carton producer to improve the production output of most traditional products and offer a competitive production platform for short-run folding carton applications. Bridging that gap into folding cartons enables a commercial printer or packaging provider to expand its production capabilities and bring more business into the operation.

        The stable and robust design of the Diana Go provides a production platform that is unrivalled in this product class. Many machines of lighter construction require regular fine tuning to ensure initial settings are maintained. This leads to a variation in quality that is not a concern on a stable platform where nothing moves once set in position. In addition, the carrier design is simple and rigid for fast setup and easy handling for the operator. The belt speed, up to 1,000 ft/min., offers a production output that can improve competitiveness and allows growth into the folding carton market. Overall, the quality of the finished product will be consistent and at the highest level due to precise folding using belts throughout the machine.

        The interest in the Diana Go has been very positive. Customers appreciate the build quality and the wide range of capabilities the machine brings to the production floor. Operators have found the access to the different elements of the machine, due to the cutouts in the side frames, greatly enhances their ability to accurately set up the machine. The machine also carries the GS certificate of product safety, which is an independent certification of compliance.

        Technical details

        Maximum speed is 250 m/min with the option to make it 300 m/min. The minimum carton width is 75 mm (option of 45 mm) and the maximum is 850 mm. The maximum machine length is 9,840 mm with an optional alignment module. It weighs 4.3 tons.  

        Folding/Gluing: Working with Short-Run Cartons

        September 10, 2020

        By Kevin Koplin, managing director, and Shawn Rogers, training manager, American International Machinery

        Those in the industry know that print runs for most everything have become shorter, including many applications for  folding cartons. Today, carton runs have been affected by companies having the ability to digitally print short-run cartons as well – meaning carton runs for many applications are becoming shorter and shorter.

        No matter how short or long a run for a folding carton project is, in most cases, it must go on a folder-gluer before the final packaging of the product. The folding/gluing process can be meticulous and time consuming, so any type of pre-planning and preparation before the carton reaches the machine is extremely important. PostPress reached out to Kevin Koplin and Shawn Rogers from American International Machinery and asked them to share some tips for working with smaller carton runs, including how to keep makereadies and set-up times to a minimum.

        What recommendations would you make to the designer of a folding carton with a niche-market and shorter-run product?

        We would highly recommend that the designer discuss the project with the company that is doing the folding/gluing of the carton prior to production. Even better, if an experienced operator can be involved before the final design, on-press challenges can be avoided. Often, operators can determine what issues may arise and how to solve them before running the cartons, potentially saving set-up and running time, as well as decreasing product waste.

        From a carton design standpoint, what can help keep folder-gluer costs down when working with shorter runs?

        When designing the carton, it is important to use quality materials, such as paper stock and glue. Additionally, preventative maintenance performed at regular intervals on the folder-gluer and experienced or well-trained operators also are keys to success and keeping costs low. For example, if there is a glue issue on a carton, an experienced operator may explain that taking 1/32″ off the edge of the glue flap will eliminate the carton adhesion problem in the future.

        Another easy suggestion for times when a coating or varnish is being used is to ask the designer and printer to “knock out” the coating on the glue flap area, eliminating any potential problems where the glue might not adhere to the coated flap. Sometimes, simple adjustments to the design or final printing can save a great deal of time on the folder-gluer.

        When working with shorter carton runs, how can operators decrease set-up times and decrease overall time on the folder-gluer?

        Backfolding-system
        Pre-planning and preparation is crutial when it comes to folding/gluing as the process can be time consuming.

        Decreasing makeready times can be approached in many ways. One is to “gang” together jobs that are using a common style of carton set-up. For instance, if there are several jobs of straight-line cartons, running those one right after another will cut down on changeover time because of the similar tooling. Second, it can be a time saver to keep much of the tooling on the machine during changeovers to avoid extra steps when in makeready.

        Third, and extremely important, is standardization. Standardizing a carton to the machine will decrease makeready times substantially. This means measuring carrier positions, tooling positions and any other movable/removable parts that are used in the makeready process. There are many different measuring methods for saving this information. Some machines have dial indicators for each carrier to allow the operator to log its location in a database or on a sheet of paper. If all of this information is computerized on the folder-gluer, then it is stored for the operator. Creating a job folder is great for repeat orders for the job history. Following the recorded measuring methods and information prior to producing the order could eliminate mistakes and certainly can save time on press, which is so important on short-run jobs. Also, photos and videos are good tools. Some operators need it to be visual, and a photo or video can help them remember how a job was set up in the past.

        When working with coatings or varnishes, what are some ways to decrease potential challenges on the folder-gluer, which in-turn can keep costs down for the project?

        Coating issues in the finishing department mostly are driven by press issues. If the coatings were not properly cured or dried, excess spray powder sometimes is used on the sheets. This can cause plenty of issues on the folder-gluers, such as skipping and other quality issues with the printed and coated sheet. Ensuring cartons are coming off the printing press in quality condition before folding/gluing will save time and product waste.

        When possible, coatings are needed to prevent downtime and other unforeseen issues during the gluing process. Many times, cartons will not feed or stack consistently, which will lead to high waste and customer complaints. So, if it is a short-run carton job, coatings are recommended. Many times, the problem can be with the sheets being UV-coated inline vs. offline because the ink doesn’t dry properly or the coating is not cured properly. Again, coating sheets on an off-line coater may be a better choice and help eliminate that problem.

        What other challenges do short runs create for the finisher or carton manufacturer when folding/gluing?

        The biggest challenge is the turnover time in between projects, with short runs often meaning multiple makereadies in a shift or day. Depending on the level of operator experience, this can either make or break a project in terms of profitability. Machine and job standardization is the key to being successful in high-volume throughput. Being proactive and not reactive will increase productivity and reduce waste and downtime.

        What future trends in the marketplace will affect the folding/gluing of cartons?

        The three main challenges are personnel, maintenance and training. Many companies are experiencing high turnover rates and an all-around operator shortage in the industry. Lack of qualified personnel can lead to production and process issues.

        Preventative maintenance often is put on the back burner as supply and demand are the focus and sometimes overshadow the health of the machine. Simple daily, weekly and monthly equipment checks can save hours or sometimes weeks of downtime should the equipment reach a failure point that could have been avoided. Having a machine go down for weeks while waiting on parts can be detrimental to a business.

        Operator training is a must and structured training programs, including refresher training courses, are key to achieving faster makeready times, improved run speeds and quality product – resulting in customer retention and higher profitability.

        American International Machinery (AIM) is a second-generation, family-owned business that provides a comprehensive line of products and support services for the paperboard and corrugated converting industry, including new, remanufactured and used equipment. AIM established the Signature Folder Gluers brand as one of the top converting equipment options in the industry, focusing on versatility and affordability for packaging companies. For more information, visit www.aim-inc.net/.


        Rotary Diecutting a Popular Option for Short-Run Cartons

        Folded-cartons-AIn addition to many changes being made with folding/gluing to accommodate short-run folding cartons, there also is a trend toward using rotary diecutting equipment for short-run work. Rotary diecutting utilizes two magnetic cylinders spinning inward toward one another using a thin flexible die(s) with a metal back to adhere to the cylinder(s) (certain machines use two dies, others just one). When the sheet of cartons travels between the two cylinders, downward pressure is applied via the machine and the cutting blades on the flexible die cuts the sheet on the other side after the rotation is complete.

        One of the biggest advantages of rotary diecutting is changeover time from one job to another. As with folding/gluing, this is extremely important for short-run work to create a suitable profit level on the job. A rotary machine can be changed from one job to the next in as little as 10 minutes, where a more conventional diecutting press can take as long as one hour. Another advantage of rotary diecutting is it provides the operator the ability to create more complex diecutting patterns because the die is CNC engraved vs. the bent steel used on a conventional steel rule die. In addition, flexible dies are much easier to store and can be housed in small filing cabinets, which can help finishers and folding carton manufacturers decrease  overall storage space for cutting dies.

        There are limitations that must be considered with rotary diecutting as well. The major limitation of the process is with the thickness of the stock/material being diecut. The flexible dies have overall limitations on how far they can cut into the material, where steel rule dies are conventionally two to three inches thick, allowing taller cutting blades to reach through thicker stocks and materials. So, it is important to check the thickness of the carton before considering rotary diecutting as an option.

        Folding carton production on rotary systems is ideal for short-runs given the ability to change from one carton skew to another in as little as 10 minutes, which enables companies to justify carton runs as small as 500 sheets. Those sort of runs are difficult to justify on a larger platen press where set-up can be 30 minutes to an hour to run the machine for five to 10 minutes for a 500 to 1,000 sheet job.

        This information was provided by Kevin Corwin, product manager for Rollem’s Insignia diecutting line. For more information, visit www.rollemusa.com.

        Quality Control Systems Key to Folder-Gluer Production Success

        June 5, 2020

        By Richard Pallante, president USA and Canada, Baumer hhs

        Quality control systems are not new to the folding/gluing and finishing industry, but there have been continued improvements in recent years, and the need for these types of systems is as important now as ever before. PostPress asked the experts at Baumer hhs for their input on the importance of quality control systems and what customers should look for when including quality control on new equipment or adding it to existing equipment.

        What benefits do advanced quality control systems provide folder-gluers?

        Verification systems might use sensors or cameras to process data for quality control.

        Suppliers that offer advanced quality control systems are providing a key competitive advantage to OEMs and their end customers. The ability to confirm to customers that their production runs have been checked for product accuracy and gluing accuracy reduces stress on all sides. With reduced access to trained labor, there are simply not as many experienced folding/gluing operators as in the past. Additionally, operators have many more responsibilities than just running the folder-gluer. A quality control system will catch issues that can arise from unintentional operator errors in set-up or operations and prevent incorrectly manufactured cartons from being shipped to a customer.

        quality-control-system
        A quality control system will catch issues that arise and prevent incorrectly manufactured cartons from being shipped to a customer.

        This is extremely important for the pharmaceutical industry where quality control validation is required as there can be severe legal and human ramifications if a product is mislabeled or improperly packaged. Additionally, manufacturing has changed. Long carton runs on the same machine no longer are the norm. Shorter runs with multiple set-ups per day are the new norm and can allow for more opportunities for possible errors. An advanced quality control system can provide that additional level of security to protect the operator, reduce waste and provide ultimate customer satisfaction. It truly becomes more economical to have a quality control system than not to have one, and consulting with a knowledgeable, experienced glue dispensing and verification system manufacturer can help customers find the best technology for their applications.

        What features should customers be looking for when installing a quality control system?

        It certainly is recommended that customers do their homework and talk to others in the industry who have purchased a QC system or have one that was included with their original folder-gluer. A reputation in the market is a good first cut on who to consider working with before purchasing a quality control solution. If the QC system is difficult to use, then end users are not going to get the full benefits from it and operators are going to try and bypass it instead of using it. Companies should be looking for ways that they can validate that the products are properly manufactured.

        The following are some key questions to ask before investing in a quality control system:

        • Who offers the most solutions (glue detection, code detection, camera-based detection)?
        • Can verification data be downloaded and shared
          with the customer?
        • Can the faulty product in the production process be traced?
        • Can the sensors differentiate between wet glue and
          cured glue?
        • Is the operator able to validate presence and placement of adhesive or a code?

        Customers need to know how the system works and how it processes the data. Just knowing that the product did not kick out does not always mean it is good. How the operator sets up the system and what parameters are being measured need to be understood. Verification systems only are beneficial if the user finds value in using them.

        Are different types of systems and sensors needed for hot melt glue vs. cold glue?

        Cold glue and hot melt both are adhesives but have different makeup and characteristics. Cold glue is an emulsion where the glue is carried in another medium, such as water. When detecting cold glue, quality control companies will try and detect the water medium or will add another ingredient, such as an ultraviolet (UV) tracer. So, for a cold glue system, the glue itself is not really being detected but rather the carrier or additives used for it. A cold glue QC system could use a moisture sensor to detect the amount of water. These are small sensors and widely used in the industry. Typically, the sensor shines a light into the glue bead and measures the spectrum of light that reflects back to the sensor that is not absorbed by the cold glue. It compares this absorption with the background. If the background is damp or wet, it can skew the readings, resulting in inaccurate verification results. Fortunately, wet or damp cartons are not the norm.

        UV tracers have their own challenges. With the increased use of UV inks and specialty UV coatings, the UV additives make the board indiscernible from the UV tracer in the glue, so the UV sensors cannot tell the difference between the two. This can create all types of challenges on the folder-gluer.

        Hot melt detection is done with a thermopile detector. The sensor is looking for the temperature difference between the paperboard and the glue and is typically placed close to where the hot melt is dispensed from the hot melt applicator to achieve the largest temperature difference possible. The sensors need to be kept at least 30 mm away from the heated hot melt gun in order not to affect the functionality of the hot melt sensor. Some hot melt sensors can limit the line speed of the folder-gluer machine as it can become saturated and no longer process the temperature difference. This limitation needs to be discussed before choosing a hot melt sensor.

        Besides cold glue and hot melt sensors, camera systems can be used as well. Cameras can take a digital picture of each product and compare it with a baseline picture where the patterns or codes have been verified. If a picture varies from the original picture, the product is identified as non-conforming and is marked or mechanically removed from the production line. Camera systems also have traceability capability, so if a product is found to be faulty after delivery to the customer, if marked or time coded, it can be traced back to time of production, the machine it was processed on and the operator involved. These additional capabilities bring a great deal of value, and, therefore, camera-based quality control systems are more expensive than standard sensor-based systems.

        When is adding a camera system on the glue line suggested? What added advantages does it offer?

        When choosing a camera vs. a sensor-based quality control solution, it comes down to the following issues:

        • Economics/number of glue lines – A beverage carrier can require 16 cold glue guns to glue the carrier. This means there are 16 separate lines of glue patterns that must be verified. In a sensor-based system, 16 individual sensors are required, where a single camera could provide the needed verification. So, in this scenario, a camera system can be determined to be a very feasible option for quality control. Considering the opposite scenario with a single gun, straight-line system only requiring a single sensor, a camera-based system could be an over-investment. Because of the wide variation in patterns, cartons, operator preference and set-ups, there unfortunately is not an easy way to say there is a general tipping point where the decision goes from sensor to camera. The decision is best discussed with a gluing and QC specialist.
        • Set-up time/makeready – Adhesive sensors are quick to set up. They usually are mounted directly to the dispensing guns and follow where they are mounted on the machine. They require a simple teaching function where they memorize the correct pattern and tolerances and monitor them through the run. A camera system will require proper lighting and mounting that allows it to see the entire pattern. If a new carton is run, a completely new set-up needs to be undertaken, adding time to the set-up. So, the length of the normal runs by the customer can have an impact on the decision between a camera system and using sensors. If a customer is changing over continuously, a camera system may not be very feasible. However, if a machine is running a particular job over and over, it may well be worth the investment.
        • Traceability – A camera system will store a picture of each carton and can allow the operator to trace a potential issue all the way back to the actual creation of that carton. A sensor system will not be able to provide a visual output of what was good or bad about the carton. If the customer received a series of bad cartons, a picture can show what the cause was while a sensor-based system will require the manufacturer to tear open the carton and play sleuth to figure out what happened.

        What projects or industries are best suited to take advantage of a quality control system?

        Almost all types of cartons or other folding/gluing work can benefit from a quality control system, but it really comes down to who is willing to pay for it. It is similar to buying insurance in that hopefully it never needs to be used, but it is good to have if something goes wrong. How much does it cost to get a semi-trailer full of pallets of cartons back because some of them were not glued? Doing this once may not equal the amount invested in a quality control system, but how much is the manufacturer’s name worth? Is it worth the risk of having the quality of the shop questioned?

        There are specific industries that benefit the most from a quality control system. Pharmaceutical, food processing, and health and beauty are good candidates. Each company could be critically impacted if a product were mixed, not sealed or incorrectly packaged. A mistake could prove fatal. While it is unlikely to happen, it is not worth the risk.

        Baumer hhs is a leading supplier of glue extrusion and quality control systems for the folding carton and print finishing industries. For more information, visit www.baumerhhs.com.

        Choosing the Right Folder-Gluer

        December 17, 2019

        By Jeff Wilcox
        PPC Technologies & Solutions, LLC

        folder-gluerThe search for a new folder-gluer can be very daunting. There are many folder-gluer OEMs out there and each have different models, features and sizes designed for a variety of applications. When a finisher or folding carton manufacturer is in the market for an upgraded or new folder-gluer, there are several questions to ask in order to find the best fit for the market they are involved in or attempting to enter.

        1. Do you run paperboard or corrugated?

        The paperboard market includes folding paper cartons – sometimes referred to as just folding cartons. The corrugated market produces folding boxes that often are referred to as cardboard boxes. The folding/gluing machines for these two distinctive markets may look similar, but the design and structure of the machines are quite different. There are folder-gluers that will produce products using both of these substrates, but on a limited basis. In other words, if you wish to produce corrugated C flute boxes, don’t expect the same folder-gluer machine to produce 12-point folding paper cartons – at least not efficiently.

        In addition, the paperboard folding carton market typically will have more variety to the carton styles (more folded panels) than the corrugated box market. Taking this into consideration, the folder-gluer for paperboard typically has to be more versatile in its design in order to produce a wider range of carton styles. However, a “specialty folder-gluer” for corrugated can be equipped to run some of the same styles as well and may need to run special folds for applications such as POP displays.

        2. What size and style of products are you running now or considering running in the future?

        Let’s take bottle carriers, for example. There are some OEMs that have designed a special section of the machine that will turn the product 90 degrees inline to the running direction. These sections are amazing to watch and can run at very high speeds. However, they are available at a considerable cost and add permanent length to the folder-gluer.

        If your product line has only a couple of designs that require turning, this additional section will need to be set-up to allow other products to pass through it when not turning. If you have large -volume products that need turning, this section may work very well for you. If not, you may want to consider looking at a machine that offers tooling instead of a turning section. Tooling can be placed on the folder-gluer to turn the product, will not increase the length of the machine and can be removed from the machine when not in use. Cost savings are great. Running speed can be an issue here as the tooling will not allow the machine to run some products as fast as the turning section will. Some OEMs offer a “Right-Angle” machine for those companies that have a lot of products or long runs that require 90-degree turning. A right-angle machine offers a simpler set-up and an increased running speed when compared to the tooling option.

        Other items to think about are the features and age of your current folder-gluer. Obviously, you wouldn’t be considering another folder-gluer if you haven’t examined the abilities and features of what you already have on your floor. Age can equate to repairs, and upgrade installations (if available) can lead to downtime and added cost. If you need a machine that can run 4-/6-corner products and your current folder-gluer is not equipped to run them, your options are limited.

        On a side note, one also must consider the folder-gluer operator. Good operators are getting hard to find these days. Having one who can understand (or has experience) on the new mechanical and electronic systems is a real plus. Having an operator who has confidence in his ability to make the transition from the old methods to the newer ones also is a plus. Either way, the operator should be included in this process in order to give an opinion and feedback. The operator can get some questions answered from the OEM during the demonstration as well. Even operators who have many years of experience can feel challenged if the company they work for decides to enter into a different market. Now the operator must learn how to run the different carton styles that the new market presents and a new folder-gluer as well.

        3. What does your budget allow? What can you afford?

        The price range for a new folder-gluer can run from around $200,000 for a small, simple machine designed to do simple-style products to well over a million dollars for a machine that can do large, complex styles. The price should be reflective of the technology that went into the design. However, this is not always the case. It is important to analyze all the different folder-gluers on the market, the features available and how those features meet the type of cartons you will be running. Look for extended-length parts warranties that are included in the base price. Extra operator training also can be included, in many cases, as incentive for purchase.

        When comparing different folder-gluers and looking at the technology included, you have options.

        Option 1. Option 1 is a model that is automated with a system that can record and store the job names, carrier locations and all systems settings, with the ability to recall them, accurately place the carriers and energize the different systems for future repeated runs. These types of folder-gluers find a good home in companies that have a lot of repeat jobs or small runs that can come up during another run. That means the operator must pull the current job off of the machine and set-up the new order. That can lead to excessive waste. An automated folder-gluer that can set itself up on repeat jobs can reduce these potential inefficiencies and can save money in the process.

        Of course, folder-gluers with the automation option will be at the higher end of the price tag, but can offer cost savings in the form of reduced waste, quicker set-up times, increased accuracy for set-ups and, in turn, a higher quality product that may eventually pay for itself.

        Another benefit of the automated folder-gluer is that your jobs are stored in the memory program of the machine. In the situation where an operator is out for vacation or sick, a job that is stored in the memory program can be recalled by another operator. Look for automated set-up processes that not only set-up the entire folder-gluer but also will include automation for adjusting individual carriers and individual sections of the machine.

        Option 2. This is a model without automation, but with motorized carriers. This option can save on the initial cost outlay for a new folder-gluer. Even though there isn’t a memory bank of jobs to recall from when repeating jobs, motorized carriers still can save a lot of time during the set-up. Motorized carriers often will allow the operator to look over a specific area of the machine while moving the carrier(s). Folder-gluer machines that offer a numerical carrier position indicator also will help the operator place the carrier. Although these indicators are not usually very accurate compared to the automated method, the operator still can write down the numerical position of each carrier and refer to this for future set-ups.

        Option 3. Option 3 is a model without automation or motorized carriers. The operator uses a hand crank to move and adjust each carrier position. This is even less costly and is old school for sure. But, it can fit into the overall budget better and the set-up methods of the seasoned operator. Numerical carrier position indicators should be a must have for repeat jobs; however, most seasoned operators won’t use them. This is okay as long as the job is set-up in good time and the waste is low. Experienced operators generally know what they are doing on a folder-gluer but would be well-served using the new technology to increase their knowledge and productivity.

        A final consideration is the method of packing the cases with cartons or banding the bundles of boxes. You may have made improvements to your finishing department to make it more efficient with an upgrade to your folder-gluer, but how you handle the product as it exits the folder-gluer also should be considered. This will be discussed in a future article on automating the feeding, exiting and packing of the cartons.

        PPCTS is a supplier/designer/distributor and manufacturer’s representative of quality products and equipment for the packaging, printing and converting industries. This includes the PPCTS-DGM Smartfold series of folding carton folder-gluers and IMPACK folder-gluer packing systems. For further details, visit www.ppcts.com.

        Proper Design Key for Successful Folding/Gluing

        June 12, 2018

        by Jeff Peterson, editor-in-chief, PostPress

        With the multitude of paper stocks, coatings, inks and other finishes available today, it has become more important than ever to have communication up front on any job that will be moving through folding/gluing equipment to finish the project.

        Whether it is a folding carton, direct mail piece or presentation folder, specific areas need to be addressed prior to the folding/gluing process and before the piece is printed, coated, decorated and/or diecut.

        “It is surprising to hear that in many cases the folding/gluing process isn’t even considered at the design stage,” said Chris Leary, director of sales at W.H. Leary Co. “Unlike printing and diecutting, the finishing process is three-dimensional and the structure of the carton is critical to successful finishing.”

        Coatings and metallic finishes

        Many of the pieces, especially folding cartons, are typically coated in some way before they are folded and glued. This is important to do, in many cases, to help protect the print and prevent scuffing. However, it is always important that this coating is not applied to the glue flaps where the glue from the folder-gluer is applied. Even an aqueous coating can prevent the glue from properly penetrating the paper stock and creating the right fiber tear.

        “UV coatings or any type of coatings should be avoided on the glue flap,” said Bobst North America Product Support Manager for Specialty Folder Gluers Yvan Magni. Magni pointed out that there are now technologies available, such as plasma surface treatment, that allow operators to treat the coating surface to get the glue to properly penetrate. However, even plasma treating the stock is based on having the coating applied properly, so it isn’t always 100 percent efficient.

        Leary added that if the stock being used includes a metallic surface (hot or cold foil, or a metallic board), “glue assist” perforations may need to be added during the diecutting process in the gluing area on the carton. This will allow for cold glue to penetrate the metallic surface and create a proper bond.

        “Another idea when working with a metalized surface is to use a combination of both hot melt and cold glue,” explained Leary. “The hot melt system can apply a couple of dots to hold the carton together while the cold glue sets.””

        If the carton or other printed piece is not coated, it is important the ink dries completely before putting it through the folder-gluer.

        “If you dare to run pieces that aren’t coated, at least wait until the ink is completely dry before running them through the folder-gluer,” explained Chris Pett, engineering manager for Brandtjen & Kluge. “Wet ink can wreak havoc. It can easily scuff and can offset from tracking on the machine and then transferring ink back onto the pieces.””

        Paper stock/carton board

        This is an example of a metalized board with glue assist perforations that can be performed in the diecutting process.

        As with any type of process, the quality of the paper stock can have a huge impact on the folding/gluing process. The better quality of stock, the more likely it will run smoothly through the machine and decrease rejects. The challenge is in the end user balancing the cost of the paper stock. For larger runs, the paper or board can have a huge impact on the final cost of the job. So this must all be considered. (See side bar on carton boards.)

        Pett pointed out that glue flaps on heavier board will fold more easily and lie flatter if they are scored in the same direction as the paper grain. And with lighter stock, ranging from 4 to 8 point, the paper may fold better when it’s turned over and scored from the opposite side (reverse scored).

        “It is best to be proactive and get the folder-gluer operator(s) involved to validate the best way to score the stock being used,” said Pett. “We have seen some 4-point stocks have perfs in place of scores. In these instances, we noticed that the folds followed along the perfs better than the scores.””

        Pett also recommended following the diemakers’ suggestions on scoring the piece. The diemaker should have a comprehensive chart that will match up the correct matrix and scoring rule thickness with the material thickness to help ensure optimal scores for excellent fold quality.

        Although scoring is mostly done during the diecutting process, there is folding/gluing equipment available where a blank aligning module and creasing section adapted with creasing rollers can be used and potentially eliminate the need of an additional process through the diecutter.

        “This type of creasing process can help with precise and straight guiding of the folding and allows the paper fibers to be re-molded after the printing and the coating process,” explained Magni. “This allows the paper fibers to bend in the newly created scoring channel instead of breaking, and essentially will help avoid cracking.”

        Avoiding scuff

        The best way to avoid scuffing of the printed piece through a folder-gluer is to be sure it is coated. This can be either a cured UV or aqueous coating that can be applied inline or offline. Either way, as discussed earlier, it is best to keep the coating off the flaps or other areas that will be glued.

        Even if the carton or other printed piece has been coated, it is still best to avoid contact with any static tooling (bars, guides, deflectors, etc.). However, the belts on the folder-gluer also can create challenges with scuffing, particularly the feeder section where a carton will go from zero speed to over 2,000 feet per minute in a matter of seconds, which can create a burn-out effect on the printed side of the carton.

        “The belt manufacturers have done an incredible job in the past few years to create rubbers that can sustain those high speeds without putting too much stress on the printed surface,” explained Magni. Magni went on to say that the operator also has a part to play in this process; a good setup allowing for a larger surface of these belts to contact the carton also will lower the burn-out effect.

        Ultimately, the use of a good quality coating, a quality folder-gluer machine, and fresh and clean belts with a good setup should all help combat any type of scuffing. “In the worst case scenario, the production speed may need to be reduced slightly to avoid any scuffing,” continued Magni.

        Conclusion

        The design of the piece and the consideration of areas such as the coating used and the quality of paper/board are important to achieving a quality outcome on the folder-gluer. Pett recommended communication from the end-user, printer and the final folder-gluer operator as an important step in determining final quality.

        “When creating designs, get the folder-gluer operators involved early,” said Pett. “They have a vast amount of experience. Show them the drawings and ask them to show you how it would run through the machine.”

        “Every step along the way will affect the next one, and the more mistakes or wrong choices that are made during this process will not only affect the time needed to produce the job, but most of all, will increase the cost of manufacturing which will affect the profit of the job,” concluded Magni. “This is why I always emphasize the fact that a well-conceived job starts by the design team’s knowledge of the products and equipment that will be used during the manufacturing process.”

        Installation and Training are Key with Folding/Gluing Equipment

        December 18, 2017

        Jeff Peterson, editor-in-chief, PostPress
        The selection of a quality extrusion glue system is the first step in ensuring quality carton production.

        In the purchasing of folding/gluing equipment, especially with more complex folding carton gluers, the training, set-up and installation are very important portions of the purchase decision. Everything from pre-planning, location of the folder-gluer and knowing where air and electrical connections will be made to allowing proper time for operator training will make for a smoother transition.

        “New folder-gluers have many advancements that make them more versatile,” stated Jeff Wilcox, PPCTS’ product manager for DGM folder-gluers and Impack case packer design, Waukesha, Wisconsin. “Along with this added versatility comes added complexity, and it takes time to learn the new ways of doing things.”

        Importance of training

        The amount of training needed on a folder-gluer depends on the experience of the operator(s) and the experience level on the specific machine that is purchased. If the customer is purchasing an additional folder-gluer from the same manufacturer/supplier, training will be much easier and shorter. In any case, experts agree combined installation and operator training should take at least one to two weeks.

        “It is important that the operator has a full understanding of the machine,” said Kevin Koplin, managing director at American International Machinery, Oak Creek, Wisconsin. “Trainer-assisted set-ups with a wide range of work/blanks that will be running on the machine is very important.” Koplin further explained that everything should be gone over in detail, from the jogging of the blanks through the machine to the pinch points, belt tension, transfer points, folding options and all other parts needed to complete the task.

        Other important training points to include are how to change and adjust the amount of pressure being applied over the lower carriers by the upper carriers, as well as how to assemble tooling and where it is attached on the machine.

        “The person training the operator should explain all of the tooling options available and when it may be necessary to use different tooling or alternative methods of setting up the machine,” continued Wilcox. Operators must be trained on different stocks and coatings, compressed air adjustments and, most importantly, how to set up the machine for all the different carton styles that will be running on the folder-gluer.

        Besides training for running different types of cartons and jobs on the folder-gluer, it also is very important to go over maintenance procedures for the machine. Such things as how to clean and adjust internal components on the glue pot, how to change and adjust carrier belt tension and tracking, and how to change bearings on the machine are key maintenance items to review.

        “An overall maintenance program should be put in place to keep the machine moving and performing at its optimal level,” stated Koplin. It is important to have the ability to complete much of the maintenance of the folder-gluer in-house, saving costs and downtime.

        Auxiliary equipment

        In today’s production environment, there are many different types of auxiliary equipment available for folder-gluers, including sophisticated glue systems, quality-control barcode and camera systems, and automated and semi-automated case packing and feeding systems at the front and back of the folder-gluer line.

        The selection of a quality extrusion glue system is the first step in ensuring that consistent cartons are produced. “The implementation of quality control on the folder-gluer has become very common and usually starts with a system that includes glue scanning and code reading,” stated Chris Raney, president of Baumer hhs, with US headquarters in Dayton, Ohio. “Scanning the glue lines that are laid down by the extrusion guns, or glue wheel, ensures that enough glue is applied every time for a quality bond that meets specification.”

        Including code reading with the glue system is the best way to ensure there is no mixing of cartons of identical profile but a different SKU. Whether cartons from the diecutter are separated manually or automatically, scanning the barcode in the gluer will ensure there is no mixing of the finished product. It also is possible to scan the UPC code both for product type and to check readability for future use in the store or elsewhere.

        The controller of the extrusion glue system also can be used to drive other devices, such as a timed air blast to fold a specific panel or, for example, to drive a tape head. As customers seek to combine many processes into one to complete the production process, it is possible to lay down either one- or two-sided tape onto a carton to provide a sealing feature. When using a single silicon tape, it will typically be combined with a coating head, driven by the same controller, laying down a wider line of fugitive glue.

        It also is possible to tip on different security devices, such as sensomatic or RFID tags for high-value items. To control the application of these, operators can use camera technology to control the position and presence of these devices. “Camera technology can be applied to control quality in a wide variety of ways,” stated Raney. “Cameras can be used to control the position and presence of other items, such as labels, cards, etc., as well as to detect the presence of printing, alignment, etc.”

        Any type of quality-control function should be interfaced with some type of ejection system to ensure that the defective carton does not reach the final customer. There are different systems available on the market, from those integrated into the machine itself to add-on devices that can remove a specific carton from the line. The specific type of applications that the folder-gluer will be running will help determine if these types of features are necessary with the initial installation of the folder-gluer.

        Today, carton folder-gluers can run well over 100,000 cartons per hour. Although this looks from the outside to be a huge rate of production, if the operation does not have the automatic ability to feed and pack the cartons at high speeds, it may not be feasible to reach this type of output. Thought must be given to the addition of automatic or semiautomatic feeding and case packing systems if the folder-gluer is going to run at these high speeds.

        Wilcox pointed out that the customer should be aware that not all case packing systems are the same. “Some carton packers cannot pack certain types of carton styles because the carton batches must be alternated during case packing. Automatic lock-bottom cartons are one style where the carton batches must be alternated because the folded and glued carton will have a thicker bottom end than the top, due to the additional folds on the bottom of the carton,” he said.

        Koplin also pointed out that those looking at folder-gluer options should consider a carton aligner to ensure all blanks are straight through the folding/gluing process. Also, consider any type of job-specific attachments (such as a Z-fold attachment) that will help reduce set-up and makeready time on the folder-gluer.

        Conclusion

        The experts agree that the specifics on installation and training should be included in writing before the final purchase of the folder-gluer is made. Prior to delivery, the purchaser should be sure to confirm if the shipping costs are – or are not – included in the price of the machine. Also, it is recommended to confirm who is responsible for any rigging costs to move the various pieces of the machine off the delivery truck and to the installation area on the plant floor. Finally, it is recommended to ask questions about what needs to be prepared for installation on the plant floor, such as air and the proper electricity set-up.

        The bottom line: Be very thorough when purchasing any type of finishing or bindery equipment. Finding the right machine is step one, but step two is making sure everything is in place to receive a quality installation and the proper training on the machine.

        References

        American International Machinery (Signature Folder Gluers), www.signaturefoldergluers.com

        Baumer hhs, www.baumerhhs.com

        PPCTS Technologies & Solutions, www.ppcts.com

        Q&A: What is Protein Glue?

        May 19, 2016

        by L.D. Davis Industries
        Soft gel netting is what’s left over from the production of vitamin E and nutrition gel capsules.

        Protein glues, also called jelly or cake glues, are used in many everyday applications like bookbinding, game board manufacturing, packaging, woodworking and more. The main ingredient in protein glue is recycled scrap gelatin from pharmaceutical netting. Gelatin is derived from collagen, hence the name “protein” glue.

        Pharmaceutical and nutritional encapsulating companies normally dispose of their excess netting. Instead of this material going to waste, L.D. Davis is able to utilize it by recycling the gelatin for use in its adhesive products.

        There are a number of high-quality sources of recycled pharmaceutical and nutritional gelatin, which can come in the form of soft gel netting or ground hard cap. Soft gel netting is what’s left from the production of vitamin E and nutrition gel capsules. Ground hard cap comes from excess pharmaceutical capsules.

        Besides gelatin, other raw materials used in the manufacturing process of protein glue are sugars, Epsom salt, water and glycerin. Since all raw materials are 100 percent natural, protein glues are biodegradable.

        What bookbinding equipment commonly is used with protein glues?

        • Crathern and S&S
        • Horauf Universal
        • Perfect Binder Machines
        • Pot Devin Machines
        • Sheridan Roll Feed Case Maker
        • Stahl Case Maker
        • Kolbus Case Maker

        What are the benefits of using protein glues in bookbinding?

        • Open time, tack level and viscosity easily adjusted to different running parameters
        • Easy cleanup with water
        • Eco-friendly, biodegradable, recyclable and repulpable
        • Water-soluble
        • Forms a strong, long-lasting bond
        • Useful in “green” applications
        • Application issues can be corrected by operators with temperature, dilution and application levels
        Ground hard cap is from excess pharmaceutical capsules.

        Protein glue is one of the most effective adhesive solution for casemaking, however it is not feasible to use a hot glue system in a very low volume operation. In short-run casemaking applications, PVA (Polyvinyl acetates) glues work very well. PVA glues are water-based and are applied at room temperature.

        For 90 years, L.D. Davis Industries has been manufacturing industrial and commercial adhesive solutions. They specialize in protein, hide and liquid glues. All adhesives manufactured by L.D. Davis Industries are eco-friendly and biodegradable. L.D. Davis Industries also is an established distributor for hot melt and PUR adhesives. For more information, visit www.lddavis.com.

        Avoiding the Insanity of Gluing Poly-Coated Substrates

        March 11, 2016

        by Technical Service Department, Capital Adhesives
        There are six key questions to consider when developing a strategy for improvement and to avoid the pitfall of insanity when it comes to the gluing of poly-coated stock or window film.

        Einstein once wrote that the definition of insanity is to do the same thing over and over while having an expectation of a different result. One such area of manufacturing where insanity seems to preside is in the process used to produce cartons that are poly-coated and/or cartons that require a window film; more specifically, the insanity of gluing poly-coated substrates. In both instances, whether it be a poly-coated board stock or a window film to board, the surface is considered poly and as such poly (or plastic surfaces, for ease of understanding) is not easily glued, and can, in fact, appear to be glued only to have bond failure sometime after the process is complete. Below are six key questions to consider when developing a strategy for improvement and to avoid the pitfall of insanity when it comes to the gluing of poly-coated stock or window film. This is not meant to be an exhaustive review, but instead a general overview of some critical steps in making a good first step toward gaining greater returns.

        The term “dyne” often is used for poly surface substrates. What does “dyne” mean?

        Dyne is not something you do when you eat, but it is something that will eat profit, eat time, eat productivity and minimize success if it is not properly managed. Dyne is simply a mathematical term used to measure surface tension. All surfaces have a surface tension, but for a poly-coated surface to respond well to gluing, it is important that the surface tension or dyne level of a poly board or film be equal to or greater than 38 at the time of gluing, noting that the higher the dyne number, the better the treatment. For incoming film or material that has poly-coating, the minimum dyne should be 44 since you will lose treatment during the normal use and processing of the material.

        Why is dyne important?

        The dyne level of a poly surface is critical to successful gluing and must be managed if the process is to be consistent, efficient and sustainable. The primary reasons dyne level is important are simple: profits and customer relations. Success in business is directly proportional to making money and keeping good customers. Having control of the process, such as that you know what the dyne level is at time of gluing, will change the game in production of poly-type materials. Poly surfaces are not receptive to gluing without treatment, and the measurement of that treatment is critical to the process – if being more efficient, less wasteful and increased profits are important.

        What is a good process to manage dyne?

        Five components should be managed to monitor dyne treatments of a poly material: 1. Purchase properly treated material with a specification as to the dyne level. As a reminder, the incoming treatment of a poly surface board or film should be 44 or greater. 2. Check dyne level and record results at time of receipt of the material. Sometimes a shipment will not meet the specification you have requested, but without the quality check upon receipt there is no way to be certain. Also, capturing the data will help identify reliable sources and the ability to track the degradation of the treatment in-house as all treated surface will lose treatment over time. 3. Check dyne level throughout storage of material to avoid printing, cutting and gluing of low dyne materials; or at the least, to help prepare the manufacturing process for dealing with materials that have less than desired treatment levels. 4. Check dyne level at time of gluing as material will lose surface treatment within the process and storage. As previously mentioned, the dyne level at point of gluing is to be greater than or equal to 38 for more consistent results. As a note, there are special solutions and markers available for testing dyne levels. Dyne solutions are the best measuring tool and give more accurate results. 5. Work closely with an adhesive professional to identify test methods for measuring dyne levels properly and to identify the best adhesive product for bonding the poly surface material being used.

        Does the dyne level of a poly surface, once treated, stay the same?

        Absolutely not. As stated previously, treatment levels dissipate from the moment they are treated. The average life span of a treated surface for gluing purpose is approximately 12 months. Aged poly-treated material is a high-risk glue-able surface. The more aged a poly surface, is the more difficult it becomes to glue.

        What can be done to help ensure glue-ability of a poorly treated, low dyne level poly material?

        In some applications, skiving the material provides a solution to a poorly treated poly surface, but skiving creates dust and often time is inconsistent. A more reliable and cleaner process is to use inline plasma or corona treatment systems. These systems can be expensive, and proper use is essential to increase the consistency in gluing. Whatever the issue, having a knowledgeable resource that understands these challenging applications is essential.

        Does it matter what adhesive is used to bond poly substrate?

        Emphatically yes. Too often the wrong glue is proposed or used for gluing poly surface. Unfortunately, there are some adhesive producers that are not aware of the differences for gluing poly, and in many cases the one gluing the poly substrate is not aware of the potential issues. The reality is that using the wrong glue will create more cost than any factor related to the price of the adhesive. Be cost-effective more than simply price-conscious. Choosing the right adhesive supply will make you money and retain better customer relationships. Selecting the wrong or cheaper glue may cost you in profit with slower run speed, inconsistent gluing and wasted product, resulting in a strained customer relationship.

        As with any process, many factors contribute to success. The dyne level is not the only factor to consider when gluing a poly surface, but it is a critical component. Understanding and managing the “dyne factor” will promote a better first step in the process. And as we know, a good first step makes way for better things to happen. Avoid the insanity of doing the same thing over and over expecting a different result. Review your process, control the dyne and enjoy the benefits of fewer complaints, better customer relations and increased profits.

        PostPress would like to thank the Technical Service Department of Capital Adhesives, Mooresville, Indiana, for its assistance with this article. Capital Adhesives provides a full line of adhesives and glues for all types of finishing and bindery applications. For more details, visit www.capitaladhesives.com.

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