Tag Archives: cold glue systems

Corrugated Glue Inspection SystemFor any corrugated manufacturer, the top points of concern usually come down to whether all glue joints are being glued properly and whether all boxes produced are accurately square. With those top-two priorities so easy to identify it is no shock that there are a ton of incredibly effective industrial machines designed to deliver exact boxes every time. In fact, it is likely that your manufacturing line rarely produces these types of errors already, but as you know there is almost no acceptance for even a single corrugated box fault. When you work in an industry where a common defect rate target is to have no more than 1 defect for every 3 million boxes produced, there is, in fact, no room for error at all. Just a few issues found in your manufacturer’s gap or a couple failed glue laps found in one of your shipments and your operation is in trouble.

As you know, when you ship a trailer full of 2 or 2.5 million good boxes, it is difficult not to be concerned that any customer that finds 2 faulty boxes could mean that they decide to ship the rest of the pallets back to your plant. If this occurs,  additional labor has to be hired to re-inspect the pallets of boxes. Such scenarios are the type of outcome that cost you money, time and customer trust in an incredibly competitive corrugated manufacturing industry. Even if they only have 1 defective box, it still may create troubles requiring you to reassure an angry customer who had a single faulty box cause an equipment jam that cost them thousands of dollars. Avoiding even small corrugated defect issues is important as every failure costs your operations money and customer trust. That is not counting the time you must spend to reassure valuable customers about the quality of your corrugated manufacturing operations. But when the difference between perfection is 0 defects in 3 million, acceptable but not amazing is 1 defect in 3 million, and totally unacceptable is 2 defective boxes out of 3 million corrugated boxes – what are you supposed to do?

Quality inspection and vision inspection systems can change a negative corrugated manufacturing reality. With the right quality inspection technology, you will never have to worry about your target defect rates being missed. A quality inspection system can identify every single fault in every single corrugated box that runs through your operational line during high-speed operations. You will never have two defective boxes shipped. Even if your equipment struggles during a run and produces five defective boxes, all five boxes can be identified and ejected before being shipped to any of your customers. No return shipments and no phone calls with your customers about jams that cost thousands of dollars.

There is a wide range of inspection equipment possibilities. Here are key capabilities that would likely assist your corrugated manufacturing operations:

  • Proper Glue on Manufacturer’s Seam – Vision inspection systems are available to check and ensure proper glue placement on every box produced while operating at high speeds.
  • Square Box Checking – Making sure each box you manufacture is perfectly square can be accomplished with a quality inspection system. Typically, measurements of each box are scanned to validate proper folds and adhesive glue or tape applications. Such inspection systems prevent your customers from experiencing automatic packing machine jams often caused by not accurately squared boxes.
  • Manufacturer’s Gap Inspections – This process will scan each box to verify proper manufacturer’s gaps. Sometimes these systems are combined or coordinated with square box checking systems mentioned above.
  • Print & Imagery Inspection Systems – These print inspection and print registration systems serve the important role of making sure the imagery and colors of every box are correct. This includes corrugated checks for hickies, missing prints, color density failures or misaligned imagery on folds.
  • Corrugated Box Score Validations – Such systems check that box scores are the proper depth and placed accurately to make sure they will all fold properly.
  • Board Layer Inspections – These are designed to visually inspect various corrugated board layers (face-layer, corrugated middle, bottom layer) and check for any signs of delam.
  • Label Scans – Similar to print inspection systems, but label scanning is focused solely on verifying UPC, barcodes, or similar labels for integrity. This can include labels printed actively being printed on the line as well as checking preprinted codes.

The product and system improvements available to corrugated box manufacturers through the types of quality inspection and vision inspection systems outlined above are substantial. Individual systems can be purchased for the most pressing concerns of each individual manufacturer and plant. While inspecting proper adhesive placement on each manufacturer’s seam and square box checking would apply to all corrugated operations, print and imagery inspection is more valuable for plants producing the attractive and appealing boxes found at the ends of grocery store aisles filled with products for sale.

The benefits of inspection systems are the total certainty your manufacturing plant can have regarding the quality of every single corrugated box that leaves your factory. The goal is no longer to have no more than 1 defect for every 3 million boxes produced. The reality is that you should not even have a single defective box in 30 million boxes. Think about what worries you most when a new shipment of corrugated boxes is sent to a customer. Which quality or a vision inspection system(s) could check to make sure that every 1 in a million defect is removed. Inspection systems will give you total confidence in your product, and they can help your bottom line as well. Stop hiring additional labor to re-inspect returned pallets of boxes. Get the right quality and/or visual inspection systems to take your operations to the next level. It will help with your operations, and will probably help you let go of some stress and concern wondering when your next customer will be calling about two faulty boxes.

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Learn about Valco Melton’s industry-leading quality and vision inspections systems:

Valco Melton’s ClearVision® Camera Inspection Systems offer an all-in-one quality assurance program that guarantees zero defect boxes. ClearVision® systems include:

  • GlueChek – inspects every glue pattern and ensures quality production.
  • FoldChek – inspects each manufacturer’s gap for width and skew defects.
  • BundleChek – automatically removes defective boxes.
  • BoxChek7 Inspection Software– collects complete information on production line performance.
  • ScoreChek – ensures the integrity of corrugator scorelines on your sheets.
  • PrintChek – is a full sheet inline print detection system used to inspect spots, registration (color-to-color and color to cut), stripes, scratches, color, missing print, smearing, double print/ghosting, drying, delta-e color density, and skew.
  • GapChek – measures the lead gaps, trail gaps, and skew for 100% of all boxes in a bundle.
  • RegChek – inspects print / graphic variation and quality.
  • InsertChek – inspection system for special labels on boxes.
  • CodeChek  – inspection system for barcodes.
  • MeasurementChek Remote Data Collection System – collect data from your production line to improve operations.

Maintain Gluing Efficiency Even as Temperatures Drop

Cold Glue Systems in Cold Weather

December 22 might mark the first official day of winter, but chances are you’re already experiencing those colder temperatures, and so is your production area. Just a few degrees drop in ambient temperature at the machine can cause major problems with the viscosity of water-based, cold glue adhesives.

Luckily, warming hose kits offer a pretty simple fix for maintaining constant adhesive viscosity, helping ensure your cold glue systems are functioning properly when the mercury falls.

Here’s How It Works:

All cold glue systems are temperature sensitive. In fact, standard cold glues can change in viscosity by up to 2% for every 2° F (approximately 1° C) temperature change, or in some cases, even more. Such changes in viscosity result in an inconsistent adhesive flow, and in turn, can lead to lost production and poor product quality.

Specifically in the winter as temperatures drop, adhesive viscosity increases and can reach a point where the system cannot function properly, or in a worst-case scenario, quit working altogether.

To combat this, cold glue warming hose kits are used to maintain the adhesive at the correct operating temperature, ensuring constant adhesive viscosity for proper system operation. No matter how cold the plant gets, the adhesive temperature and viscosity remain stable.

Benefits of Cold Glue Warming Hose Kits

The benefits of using heated hoses for cold glue application include:

  • Allows for very stable adhesive viscosity year around
  • Fully operational glue valves
  • Reduces product waste due to improper adhesive volume
  • Uses less energy than needed to heat the area around the machine
  • Easily adapts to nearly any existing installation/application

Maintain Consistent Cold Glue Adhesive Viscosity

If you’re operating in factory conditions where ambient temperatures can fall below what is recommended for adhesive application, these warming hose kits offer an efficient and cost-effective method to help guarantee your cold glue systems are operating at full capacity this winter.

If you’d like to learn more, speak with one of our product specialists today by clicking here.

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 new facility 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.

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

Today, the corrugated box industry is very competitive.  Not only do you need to deliver corrugated boxes in record times at unbeatable prices, but with the various technologies available, the standard requirements for corrugated box manufacturers have been set extremely high.  You are now expected to deliver 100% defect-free boxes. In an effort to help you manufacture boxes at the highest possible level, we have gathered together a few important points, learned from over 60 years in the industry.

  1. Keep it clean! I’m sure many of you are tired of hearing those three words. But, as many others will tell you, it wouldn’t need to be said, if everyone made sure to do it. If you are working with an older glue pot and wheels, you know they tend to generate a little glue slinging. This can affect the quality of the glue joint and create stickers where boxes in the bundle will stick together. Gluepot and wheels can also create adhesive contamination with dust and debris. Additionally, the metered amount of adhesive is hard to maintain to ensure a proper bond. As for adhesive applicators, although they are the cleanest choice, it is important to check them regularly to avoid possible nozzle or applicator clogging.
  2. Minimize any possibility of human error. This may seem impossible to some, but it can be done. When working with different sized board panels and speed requirements in the corrugated box industry, it is necessary for the operator to constantly adjust the pattern length and placement in order to keep a consistent and high-quality adhesive application. This necessity is a time-consuming task– Any distraction can cause the wrong adjustment that will result in product loss. It is now possible to upgrade your adhesive application system to a gluing station with automated pattern changes or auto-glue, which ensures a proper glue-lap joint regardless of the length of the tab or panel.
  3. Ensure that the board has been glued, folded and printed properly. These days this is possible by incorporating a quality assurance vision inspection system into your process. Quality assurance has 3 components: identify the non-conforming product, remove it from the production line, and monitor the lines’ statistics to hold plant operations accountable. All 3 are possible in ways not imagined five years ago in the corrugated box manufacturing industry, with vision-based quality assurance. Snapshots of defective products are saved and cataloged. Machine performance can be monitored remotely and statistically analyzed. The same statistics enable managers to be aware of developments on converting lines as they occur and to take corrective action in a timely fashion.
  4. Scrap can blotch your reputation. For a flawless result, incorporate a scrap or tab removal system to prevent hanging scrap that has not been properly cut after being folded into the box.
  5. Get rid of defective boxes before they make it onto your delivery truck. Bundle ejection systems are used in conjunction with a quality assurance system to guarantee that the defective boards are removed from manufacturing and not shipped to the customer. As the second major component of a Quality Assurance System in paper converting, removing defective product from the line automatically is unparalleled in regards to effectiveness. All other options rely on operators to sort product or catch errors and take them out of the stream. Automatic ejection takes care of the removal without interrupting production.

By implementing these tips into your manufacturing process today, you will begin seeing its direct impact on the quality of your corrugated boxes. If you are interested in hearing more about any of these topics, please let me know!

For additional information or to speak directly with one of our leading gluing and quality assurance experts, contact us here

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