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New India OfficeThe Valco Melton team is pleased to announce the expansion of its business operations in India with a move to a larger office space to accommodate future development plans.

The new office is located at #981, 1st floor of the Ideal Homes Township on Mysore Road in Bangalore.

While the team only recently moved into the space over the summer, they are already enjoying many of its new features including additional customer demonstration and trial areas, as well as increased inventory, and service and repair facilities.

The strategic decision to move offices will enable the company to increase sales and service support of all hot melt and cold glue products for its customers, and meet the demands from rapid business growth in India and surrounding territories.

Since January 2011, Valco Melton India (a wholly-owned subsidiary of our Cincinnati based corporation) has continued to build on its strong team of experienced managers and sales/service technicians. Bangalore will remain the main office in the area, with other regional offices located in Ahmedabad, Chennai, Mumbai, New Delhi and Pune.

Read more about Valco Melton India’s new office and presence at this year’s PackPlus trade show in Packaging South Asia magazine here.

On behalf of the entire Valco Melton India team, we look forward to working with you and welcoming you into our new office.

To speak with someone from Valco Melton India directly, please click here. Complete contact details for the new office can also be found below.

VALCO MELTON INDIANew India Office Location_Map

(Valco Melton Engg. India Pvt Ltd) #981, 1st floor, IDEAL Homes Town Ship, RR Nagar,Mysore Road Bangalore 560098

T: +91 80 28602821
F: +91 80 28606117

Assembling sheets and layers during the diaper manufacturing process involves several steps. The bond between each part must be flawless and any interference to the adhesive on the product kept to a minimum.

A common myth amongst manufacturers is that a strong, long-lasting bond means that it is necessary to use higher amounts of adhesive. This is false. By using specific patterns engineered to have higher adherence and locating the pattern in certain key spots, the use of adhesive can be decreased, while the strength of the bond increases. In other words, it’s not the amount of hot melt you use, but how you apply it.

Swirl Spray Technologies in the Nonwovens Industry
Swirl spray hot melt technologies.

Tests at diaper manufacturer facilities have proven that a 50% reduction of adhesive usage is possible by switching from standard spray hot melt dispensing applications to multi-spray adhesive patterns. During spray applications, the surface is covered from side to side with a swirl pattern. With the multi-spray option, the same surface is instead covered by 3 parallel mini-swirls. This application creates a pattern with a high number of adhesive swirl intersections to give additional strength using lower amounts of adhesive.

Aside from adhesive usage reduction, further savings can be attained by using hot melt modules with removable “insert nozzle” technology. This innovative concept permits easier cleaning and pattern configuration processes. The tip of the nozzle features 3 small inserts that provide a highly accurate mini-swirl pattern. A special air output design avoids nozzle clogging, while reducing costly downtime.

nonwovens BAT22 applicator head
PUR being applied onto a nonwoven material.

Additionally, inserts like Valco Melton’s NWV BAT22 Inserts can be easily extracted and replaced, facilitating and reducing the time spent on cleaning and maintenance operations. Inserts can be combined with blanks for additional pattern configurations with minimal spare parts investment and work-change times.

Spare parts inventory can also be reduced as an effect of this hot melt technology. If any malfunction occurs, there is no need to replace the whole nozzle, just the defective insert. By only replacing the inserts, some of the users of our multi-pattern modules with insert-nozzle technology have experienced proven savings of up to 40-60% in their spare parts expenditure.

If you are interested in a deeper technical analysis, here is a white paper detailing the savings a customer achieved at their facility by replacing their swirl spray hot melt systems with multi-spray hot melt technologies. Click here to download it now, or contact one of our experts for additional information.

Download Analysis Button

If you are in the market of clear-to-clear applications, master roll transparent labeling, or flexible packaging applications, you are well aware of how vital uniform and streak-free coating is to producing quality product. If you work with coating equipment, you also know that contaminants commonly trapped between the die and the substrate will cause damage to the coating surface.

Fortunately, rotating bar technology has been developed to specifically address this issue. By preventing even the smallest of contaminates from becoming trapped between the die and substrate, it virtually eliminates the risk of scratches to the coating surface. Coating equipment that integrates motorized bar technology is able to perform completely uniform, streak-free applications, no matter how small the adhesive grammage may be.

Valco Meltons ProClear Coating Station
Valco Melton’s ProClear Coating Station

The coating industry today, requires unique and customized adhesive application. As a manufacturer, it is vital to have the coating machinery necessary to meet your specific needs. Each project requires a different width. Whether you require a narrow web or wide web adhesive application, it is important that you have the option to provide various coating widths. This not only gives you ultimate control over your application, but also gives you the convenience to customize your coating application to your specific needs.

Valco Melton’s ProClear™ Coating Station can be configured to meet each user’s specific requirements and gives you a choice of three standard configurations. Even more, depending on each user’s specific needs, it can be constructed as a permanent fixture on an existing coating station or as a fully mobile cart to allow the existing line to be upgraded to include hot melt capabilities. With an extensive range of optional upgrade accessories, this type of Coating Station is adaptable to any project.

To learn more about how a coating station like the ProClear™ can help you achieve a streak-free, uniform coating today, or to learn more about which type of applicator configuration will best meet your specific requirements, click here.


adhesive dispensing equipment checklistAlthough the dispensing equipment you select is of the utmost importance to ensure a quality adhesive pattern is applied precisely and without error, box makers often overlook the importance of preventative maintenance. Let’s be honest, it’s usually an afterthought. We have seen time and time again, problems relating to adhesive dispensing equipment that could have been avoided if the box maker would have just followed a few simple steps, every so often, to make sure their glue machinery was running at 100% efficiency. To help you avoid this unwanted downtime and make sure your glue patterns are always at their best, here are seven preventative maintenance procedures for better box manufacturing.

1 – Overtime, particles and coagulated glue can build up on filter screens causing restricted adhesive flow and excessive stress on the adhesive. Cold glue filters should be checked once per week after installation or after a change in the type or brand of adhesive. Depending on the amount of build up, adjust the frequency to accommodate your dispensing equipment.Remember, opening the filter housing allows air into the system, so make sure you have the proper purge valve setup before you begin.

2 – Make sure glue pressure follows machine speeds. For box makers, the glue regulator is the most important adhesive delivery component in determining how much glue volume is applied at a given machine speed. If you experience too much glue on the joint when the machine slows down, or there is not enough glue when the machine speeds up, it could be the regulator. To test fluid regulators without an electronic pressure control, use the T-handle on old style regulators and the Auto/Manual switch on the new style regulators to manually check the function. If pressure does not increase or decrease, a simple repair is in order. Valco Melton regulator repair kits for corrugated box manufacturers provide a quick and inexpensive solution.

Quick disconnect fitting tips
A quick disconnect fitting tip.

3 – Applicator heads and nozzles must be kept clean. Buildup over long periods of time and a lack of cleaning after the machine is down can cause added downtime. Likewise, worn applicator heads can cause poor pattern quality (ticking at the end of the pattern, buildup on the leading edge or even missing glue lines). Applicator heads are wear items, subject to the abrasiveness of paper and are susceptible to some chemical corrosion after prolonged exposure. Quick-disconnect fittings are another critical component to achieving quality adhesive patterns. Loose applicator heads are prone to leaking. To avoid issues, inspect the fittings to verify that the applicator head is properly secured to the valve. Replace quick-disconnect fittings as required.

4 – Check to see if the Electronic Pressure Control (EPC) speed-tracking curve is accurately setup. Doing so will help you to achieve optimum pattern volume at all machine speeds. If the EPC is not working properly, you are relying 100% on operator skill to monitor adhesive output. This requires constant adjustments in order to maintain proper adhesive volume. Without a functioning EPC, the amount of wasted adhesive can quickly become a costly problem.

5 – A slipping encoder can cause intermittent pattern length variations, which can mean a troubleshooting nightmare for maintenance departments. Encoders should be regularly inspected for smooth rotation, good wheel or timing belt condition and secure mounting. Box makers should also pay close attention to common problem areas such as incorrect belt tension, damaged encoder cables or loose cable connections. By adding simple encoder maintenance to your schedule you can prevent extended downtime and hassle.

6 – Glue hose lines back to the regulator should be inspected for kinks and flushed periodically to check for clogged sections. An inexpensive section of tubing can become a costly problem for corrugated box manufacturers if it causes a flow restriction, as this results in poor glue volume at high machine speeds. Don’t overlook the pump suction line. A damaged suction line could cause air pockets to get into the glue line. This results in skips in the glue pattern or no glue pattern at all. Signs of leakage are not always obvious; plan now to avoid problems later.

an image of a tab scrap glue application problem
Example: tab scrap glue application problem.

7 – Ensure there are no false triggers from tab scrap. Corrugated box manufacturers operating with tab-side installations are often plagued by flying tabs from the slotter. False triggers from tab scrap can be the result of broken or dull knives. Replacing worn out knives along with routine maintenance is recommended to combat false triggers from tab scrap. Additionally, a dual scanner setup using two photo eyes, along with control settings can help block false triggers.

watch the choice all-electric system in action
Watch the choice all-electric system in action.

We have been selling and manufacturing adhesive dispensing equipment and cold glue or hot melt systems of all kinds since 1952. Through careful testing and repeated implementation around the world, we have experienced firsthand, why various systems outperform others.  In our lastest post, we concluded that up to 75% of adhesive can be saved by implementing an all-electric hot melt glue system. Just to get the point across, this week we have uncovered 7 additional ways that an all electric hot melt glue system is reshaping the packaging machinery, folding carton, and print finishing industries.

#1 – Fewer Plugged Nozzles:

Did you know that by using an all electric system, you can use lower pressures to administer the adhesive from the hot melt glue gun? Well you can! This means that the nozzle diameter can be increased. The larger the nozzle, the lower there is a chance for clogging. Maintenance requirements and any risk of downtime are virtually eliminated.

#2 – Safer Operation:

As you probably know, the high pressure required to operate a pneumatic system along with the high temperatures of the hot melt adhesive, is a potential safety hazard. Fortunately, there is a better way… Because an all-electric system utilizes a gear pump, they are able to provide operators with a safer dispensing application and work environment.

picture of seals
seals

#3 – Less Chances of Failure:

Electric gear pumps and electric valves utilize almost 90% less seals and additional parts required to run pneumatic pumps and valves. This practically eliminates the chance of failure caused by worn out or imperfect seals.

#4 – Any Pattern Configuration:

Electric hot melt glue systems can be easily configured to work on stitch mode through a pattern control to produce any pattern larger than 1/8” in length (3mm), with exact start and stop placement and virtually without stringing. Pattern size is not affected by pumping rate limitations as often occurs with pneumatic systems.

#5 – Longer Valve Life:

By using electric hot melt glue guns, the lifespan of a valve module can reach up to 300 million cycles with slight variations, depending on the type of adhesive used. What that means for the user is easy savings and less hassle.

#6 – Reduced Maintenance:

The most frequent downtime on packaging machinery involves changing failed pneumatic glue modules, plugged nozzles and solenoids. Switching to electric guns eliminates the need for gun solenoids and modules that can be soiled and worn with a dirty, wet, and sometimes inconsistent air supply. In result, maintenance requirements are reduced to a minimum level.

dollar sign icon#7 – Minimal Spare Parts Stock:

With fewer moving parts virtually eliminating the chances of failure, the spare parts stock is reduced to a minimum, resulting in lower investment, storage costs and downtime associated with the replacement of parts.

To better understand how these 7 aspects affect your overall revenue and other key factors, we have put together a visual example with an intuitive diagram. You can get this complimentary download instantly here.

As an alternative, learn more by speaking with a packaging expert today here.

If you are a packing list envelope maker, you know that adding envelopes to corrugated boxes can use a lot of adhesive, consequently costing your company a great deal of money. If you could only decrease adhesive usage, you could not only decrease your production costs, but also significantly improve your company’s efforts to work a little more eco-consciously. By adding an immediate competitive advantage, not to mention giving your brand something positive to talk about, this little “leg-up” can mean big stuff for your marketing and sales group and add big value to your brand. Unfortunately, most people don’t know how to decrease their adhesive usage. Being that this is what we have been doing for the last 61 years, we have some information that can really help you out.

 

diagram of window frame pattern application
window frame pattern application

Generally speaking, the usual choice for adhesive dispensing onto the back of an envelope is to cover the entire surface. Naturally, it seems fail proof; so what more could you ask for? A lot actually. What most printing machinery, envelope makers, and coating manufacturers don’t know is that although this may seem like the right thing to do, it is unnecessary. Of course, this approach works and produces a reliable bond, but there is a better way; an approach that provides a bond equal in strength, but that uses a fraction of the amount of adhesive. This approach is called window-frame pattern application.

diagram of high speed intermittent application versus a continuous application
High speed intermittent application versus continuous application.

By eliminating the need to cover the entire surface of the envelope with hot melt adhesive, and instead applying the adhesive in window-frame patterns, you save up to 70% of your adhesive instantly. Coating equipment like Valco Melton’s FlexCoat™ applies adhesive intermittently using independent dosage from two separate channels. This ensures a constant and homogeneous grammage or coat-weight across the entire frame’s pattern. channel 1 dispenses a continuous and longitudinal application, while channel 2 dispenses an intermittent and perpendicular application.

 

envelope closing configuration
Envelope Closing Configuration

Valco Melton’s FlexCoat coating equipment is the best option for high-speed intermittent coating. The integrated against-roll mount assembly ensures that the coating head is accurately and consistently presented against its chromed back-up roller. After the backside of the envelope has been coated, the packing list envelope is sealed using a second system that applies a layer of adhesive onto the folded tab that will close and secure the envelope.

If you are looking to decrease adhesive usage and achieve instant adhesive savings of up to 70%, finding a coating station that can apply window-frame patterns is a great next step. If you would like to learn more about our coating equipment in particular, you can read more here.

image of corrugated boxes in bundlesThe corrugated box manufacturing industry has long been focused on reducing waste as one of the key drivers of efficiencies. Like most box makers, you are probably focused on reducing waste in your facility. However, most people fail to realize the complex interdependent relationships that exist between quality, waste, product price, cost and production volume. What if “increasing” waste built value for your customers or increased your revenue and “decreasing” waste actually increased the cost of the box or even lowered sales? With so much at stake, it pays to take some time to more closely examine the tipping point between quality and waste.

What is Waste Anyway?

image of corrugated box waste
corrugated box waste

There are actually two separate types of waste – internal and external. Internal waste is typically what the corrugated box industry refers to as “waste.” Internal waste represents any defective sheet or box that is produced and not shipped to the customer. However, if you don’t catch the defective product and it ends up in the hands of the customer, it is considered external waste. External waste is rarely, if ever, discussed unless brought up by the customer. The cost is only accounted for in the form of credits for defects returned. Some customers do not return many defective or problem products to the corrugated box maker, resulting in an inefficient and distorted feedback loop.

Misleading Numbers

Through our investigations, we have found that the costs tracked for external waste are more often larger than the internal waste figures. Furthermore, customer complaints, credits and feedback are a minority of the actual rate of defective product that customers are receiving. What this means is that some customers are bearing much of the direct costs (downtime, lost productivity, wasted products) associated with external scrap rates, while box makers are bearing much of the direct costs associated with internal scrap rates.

image of unsatisfied option check-markedIf customer complaints were, in fact, true indicators of the external scrap rates, this model would be useful for making operational decisions. However, discussions with end-users have shown that customers are not complaining about the vast majority of problems. Similarly, many box plants don’t complain about every hiccup in their machines or every minor issue with their paper – that’s the norm and they are used to it. Because this feedback loop is broken, many corrugated box makers have a warped view (literally) of how much scrap they’re actually sending their customers.

Options

Two clear options are available to box makers for handling waste. First, do a better job of finding all defects before shipment and remove them from the production stream, increasing internal scrap rate and improving quality. Alternatively, send defects to customers in an effort to reduce internal waste, but increasing external scrap rates and decreasing quality. What are box makers expected to do? Is sacrificing quality worth the savings of reducing internal waste? What impact will this have on your business?

Possible Solution

The secret to improving both internal and external waste is not only to identify the defective products and remove them from the production stream, but also to identify the root causes of the scrap production and address them. Investment in quality assurance systems for box inspection, operator training, as well as PM discipline and keeping equipment current can both identify scrap and reduce its root causes. If management is committed to solving problems on the floor that are causing waste, not only will less defective product be produced internally (internal waste) but also less defective product will be shipped to customers (external waste). In addition, profits will improve and customer retention will increase, which directly improves the bottom line. Finding the problem quickly through quality assurance devices and not having them occur from the other improvement measures will decrease internal and external scrap rates and improve the ROI performance of the business.

End Result

If investment in quality assurance systems, operator training, improvement in preventative maintenance programs and an upgrade program for production machinery can reduce the internal scrap rate, then the external scrap rate will be significantly reduced. Box makers will improve profits and keep happy customers who shouldn’t need to complain about the products they receive.

Why pay the price of the traditional corrugated box manufacturing industry’s approach for quality, counting pennies and losing dollars.

Download or request a free infographic depicting the difference in cost and value from decreasing scrap versus increasing quality here.

 

transparent labeling machinery in action
transparent labeling

Businesses have been using labels to identify and ship their product since the late 1800’s. Label making has advanced from the art of lithography to being able to print self-adhesive labels in the comfort of one’s own home. Today, the demand for label stock is higher than ever and many label converters do not own a coating station. Instead, they are buying their label stock pre-coated. What those people have not yet discovered is that there are three significant advantages to having their own coating station for label converting worth looking into.

The first and most important advantage is savings. Switching from pre-coated label stock to a coating station is much more cost-effective. The converter can mount the coating station to their press,coat their own pressure-sensitive label stock in-line, and now have control over the cost of their raw materials. This allows the converter to increase their margins on existing products.

The second advantage of a coating station is that it gives the user the optionto perform multiple adhesive applications. Various coating widths and patterns are available with easily adjustable coating heads and interchangeable blades. A coating station offers an extensive range of accessories providing flexibility to the project.

Last but certainly not least, the third advantage of a coating station is reliability and consistency.  When the converter is in control of the coating process on their label stock, they can breath easy knowing that the coating station will provide continuous and reliable adhesive application for each project. Whether you are using hot melt adhesive application or cold glue, coating stations ensure consistency with each application.
Aside from bringing significant advantages to your production process, coating stations are easy to install and fully compatible with existing machinery. 
Learn more about what type of coating station might best fit your needs today by clicking here.

Learn more about coating stations

The ClearVision Gluechek Monitor
The ClearVision Gluechek Monitor

Check out this new case-study published by PaperBoard Packaging on Minnesota Corrugated Box after they implemented ValcoMelton’s ClearVision GlueChek System: Eliminating Glue Issues to Create Perfect Boxes. Minnesota Paper Box is mentioned by PaperBoard as having over 250,000 square ft of space in its state-of-the-art facility.

This is one of many positive stories that I have received about box companies that have added camera inspection systems to their corrugated production lines. If you’d like to find out more about Valco Melton’s ClearVision GlueChek System and what it can do for you, let me know here.

More and more, manufacturers within the industry are realizing the benefits of providing perfect boxes to their customers… improved client trust and retention, fewer instances of damaged product due to defective boxes, increased volume, and a higher price per box.  We noticed this change as it was happening years ago and started quickly working on new technology to meet the required need to innovate the old standard.

Well, a young, dynamic company named ClearVision Technologies, Inc. out of Vancouver, Canada, started by a group of talented entrepeneurs, beat everyone to the punch.  With a devote focus to solve the industry’s issue by creating the best camera inspection technology, and to do it first, they were recognized by the very strongest companies as the solution that could actually guarantee a perfect box for its customers. Their expertise built from years of research and working one on one with customers to discover an innovative A few clearvision team members and valco melton.vision inspection solution, produced thousands of real examples showing exactly how they could now do this.  After successful installation at one of the largest integrators, the product went to market.  As a result, it wasn’t hard for others to realize the decision to invest in ClearVision™.

Valco Melton quickly recognized that ClearVision™ had become the corrugated industry standard. As the leading adhesive dispensing company in the industry for almost 40 years, we wanted to make sure that the camera inspection experts joined our team.  The synergies of the two companies were perfect, and so ClearVision™ was added to Valco Melton’s umbrella of solutions for adhesive dispensing and vision inspection.

With the added knowledge and experience from Valco Melton’s adhesive application division, ClearVision™ has continued to show the industry how it can also find peace in The Perfect Box™.  To date, more than 284 box plants worldwide have discovered the gains and additional cost benefits with ClearVision™ box inspection and bundle ejection systems:

  • Detection systems only spray bad boxes.
  • Operators cannot be relied upon to remove bad boxes.
  • Research shows fewer than 10% of sprayed boxes are removed.
  • You cannot promise your customers 100% quality unless you are certain of removing non-conforming product.

To learn more about how ClearVision’s patented camera technology is changing the way box makers do business, and how you too can take advantage of this opportunity to deliver more value to your customers click here.


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