Tag Archives: sealing systems
If you’re in the market of using pressure sensitive adhesive with a deferred use seal machine for corrugated box products, folding cartons or envelopes with conventional paper converting machinery, it’s important to consider production speeds and volume when making the decision between a double sided transfer tape applicator system or a system that applies pressure sensitive adhesive followed by a covering release liner. Both double-sided transfer tape and pressure sensitive adhesive sealing systems with release liner get the job done, but which method completes the task most efficiently, while giving the highest quality product and the most cost-effective solution? I’d say it depends largely on a few things.
The pressure sensitive adhesive applied in ribbon, bead, or spray form during the converting process on the converting machine is deposited evenly onto the substrate surface. This process produces a much stronger bond than adhesive transfer tape systems. The release liner overlay can be customized for length and width coverage to off set the adhesive pattern thus providing the easy peel and seal feature that is not possible with transfer tape.
By eliminating the need for excessive transfer tape roll changes, production significantly increases, while simultaneously decreasing down time and reducing material costs by 40% or more. The cost of buying bulk adhesive and bulk silicone paper is far less than the cost of transfer tape and is easier to inventory and store.
If you are looking for a more efficient process, a stronger bond, to reduce material cost, increase production, and decrease downtime, I’d suggest using the Valco Melton SealTak® deferred-use sealing equipment method. Just do the math and decide what makes the most sense for your company.
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 flawless, 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.
- 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. Glue pot 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.
- 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 is a time consuming task; any distraction can cause a mis-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.
- 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 catalogued. 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.
- 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!
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What I’ve found through my research is that few companies can boast the knowledge and expertise that Valco Melton has acquired by working on special engineered projects with market leading companies in the coating and converting industries over the past number of years. When speaking with one of our Label, Coating & Converting Division Sales Experts, Bob Taylor, he explained that our sales & engineering groups have a skilled understanding of our customer’s requirements and can offer expert guidance on hot melt and cold glue adhesive coating on numerous substrates including paper, foil, film, foam, and release liner to the Label and converting industries. From standard coating equipment to “turn-key” engineered solutions that can integrate into customers’ existing equipment or solve a specific problem, Valco Melton systems are proven to perform to the desired exact specifications.
Our Engineered Products Group designs and manufactures complete stations to be incorporated into both existing production lines including retro-fittings into most label presses or new OEM supplied lines. These stations often include web control, tension control devices, nip roll configurations and integration into existing control systems as required.
Our ability to customise and design solutions to customer requirements combined with our standard fluid handling systems, including melt tank options from 10–600kg capacity and new high output drum unloaders and customized control systems, provides the perfect solution for single sourcing the customer’s complete adhesive application requirements.
Valco Melton slot-die coating systems can be configured to apply coatings with zero scrap caused by unglued web following reel changeover or production stops. Their unique re-circulating systems can be presented as an option to improve temperature stability for accuracy to existing Gravure coating systems.
Our systems also coat at the highest precision with a wide range of adhesives such as PSA, UV hot melt, heat-seal adhesives, barrier adhesives or water based acrylic emulsions.
And last, but certainly not least, our adhesive applicators feature diverse configuration options to meet and exceed each user’s specific needs with customised coating widths, removable blade-sets for bi-directional coating and fast width / pattern changes along with manual or motorised width regulation and options for integrated motorised bar for ultra-thin, streak free adhesive coatings are all available.
Valco Melton supports its customers from over 70 countries worldwide through a network of direct sales and distributorships. It has been a leader in providing the most innovative gluing application and quality inspection systems since 1952. For questions, or to watch more about this now, click here.