Quiet Progress in Folder/Gluers

Folding and gluing equipment manufacturers don't run the loudest marketing campaigns for their products, but there's plenty of innovation in the marketplace to shout about.

FOLDER/GLUERS DON'T attract the attention that new presses and prepress software do. But that's not to say manufacturers of this finishing equipment don't have a reason to brag.

According to Craig Jasper, sales director for converting equipment and product packaging at Roberts PolyPro, in the past five years, significant advancements have been made in the safety, quality, and value-added areas of folding and gluing equipment. With safety a top priority for every converter, some companies have taken such measures as building rooms and screens around their gluing technology to increase safety, Jasper said.

Chris Raney, vice president of folding carton products for Bobst Group, acknowledged there was a period in the late 1980s and early 1990s in which there was stagnation in folder/gluer equipment development. This changed when Bobst introduced the Alpina line in 1998.

According to Raney, Alpina introduced many innovative features such as a built-in blank aligning module, 4- and 6-corner hooks on a mobile frame using one hook design, a flipper ejector, and in-line ejection of non-conforming boxes. He especially highlights the Gyrobox module.

"The ability to turn a box through 90 degrees on a machine of straight-line configuration eliminated the need for slow and space-inefficient right-angle machines," says Raney. "Alpina with Gyrobox opened the door for designers to create more complex and unique designs."

As for quality, today's folder/gluers face a growing challenge—having the capabilities to keep up with the ever-increasing demands of new-and-improved folding carton designs and innovations. "All around you're seeing improvements in quality," Jasper said. "The printing technology is much improved and you have high-quality coatings now that require gluers that can handle them without scuffing and harming the package. Gluers had to change to accommodate this improved quality, especially in tobacco, pharmaceutical, and cosmetics industries, where the demand for quality is the highest."

In addition, as more companies merge, and either acquire or consolidate with other companies, these larger companies have to be able to make themselves stand out among the competition. Jasper said, "Now more than ever, these companies have to differentiate themselves from each other. You're seeing them pump a lot of money into new technologies to do things the competition can't do. This niche-market separation approach, I believe, is the future in our industry."

Another important improvement in folding and gluing equipment comes by way of adaptability. According to Elizabeth Jordan, senior program manager at Nordson Corp., the main area of progress is changeovers. "It used to be a lot of work to change jobs," she said. "But the ability of equipment to be adapted for different jobs has greatly improved. Changeovers can be done quickly now, compared to past years."

Most of the focus has been on bettering yesterday's technology without completely overhauling the original system. One example of this is the emergence of servo technology to folding and gluing equipment, said Steve Leibin, sales manager of Matik North America.

"Particularly the use of servos to replace older timed clutch systems for 4- and 6-corner beer trays," Leibin said. "Servo systems have become even more capable in recent times with elaborate internal programming allowing for high rear-folding speeds. Today's high-memory CPUs produce rear-folding capabilities that were unachievable only a few years ago."

For more on today's equipment offerings in folder/gluers, packagePRINTING has provided a review of the latest products:

Open frame gluer means flexibility

ADI/PDM Trade Group

www.arcdoyle.com

The Onepass semi-automatic gluer has a unique open-frame feature, which allows the machine to be offered in modular units. It can initially be purchased as a single-joint or one-piece gluer, and later retrofitted as a dual-joint or two-piece gluer. At that point, it would become three machines in one. All functioning components can be operated as one or independently, this would include the infeed lifts, compression transport units, glue systems, and downstackers. With this versatility, this machine can be used for processing two-piece boxes in one pass; processing one order, one-piece boxes; and processing two separate orders, one-piece boxes simultaneously.

Folder/gluer with blank aligning module

Bobst Group USA Inc.

www.bobstgroup.com

Available in 31˝ or 44˝ widths, the Mistral offers many of the features of the higher-end Alpina, but at a lower investment cost. Each version of the Mistral is available in straightline version (A-1) or crashlock version (A-2), either with or without 4- and 6-corner capability. The key features of the machine are the blank aligning module to ensure accurate feeding of each blank into the machine, high production speed (maximum belt speed of 1,300 fpm), 4- and 6-corner production at up to 25,000 boxes per hour, and a new design structure that ensures optimum stability and near elimination of vibration through the machine. A new drive belt design system also dramatically reduces the noise levels of the machine when in production, improving the working environment.

Automatic folder/gluer with increased capabilities, reduced set-up time

Brandtjen & Kluge, Inc.

www.kluge.biz

The Kluge OmniFold Automatic Folder/Gluer is designed to maximize converting capabilities while minimizing set-up time. It includes features that bring productivity and reliability to a whole new level of expectation. The feeder area includes a multiple sheet detector, vacuum manifold position adjustment, and dual vacuum wheels. The vacuum feeder features a rack and pinion elevator drive, exclusive to Kluge. This low-maintenance system allows for smooth and accurate feeding with no chains or sprockets. The OmniFold's greater-sized converting area has patent-sealed bearing bed drives, with right and/or left hand sheet registration—another Kluge exclusive—that minimizes friction and allow for the use of longer top drive belts. This gives the operator greater sheet control and decreases the makeready time. In addition, the buckle fold area comes equipped with a vertical buckle fold plate, designed to eliminate crow's feet or wrinkling on heavy stock, and allows for a second-up fold such as used in a double CD wallet. A total of three buckle folders can be set up in a single machine configuration for a range of applications.

Folder/gluer with flexibility and speed

Brausse Group

www.brausse.com

BRAUSSE Combo series folder/gluer has all the necessary features to produce what most folding carton manufacturers require. Sizes range from 18˝ to 43˝ wide and the BRAUSSE Combo series folder/gluer has a maximum belt speed of 1,350 fpm. Beside regular straight line boxes and auto-bottom boxes, if properly equipped, it can also produce 4- and 6-corner boxes, CD jackets, pocket folders, and more.

Versatile and flexible folder/gluer

Matik North America

www.matik.com

Vesta is a well-engineered, well-built, easy-to-operate folder/gluer designed to handle 4- and 6-corner, straight-line, lock-bottom, interior partition, tapered, CD envelopes, miniature cartons, and pocket folders at high speed. Vesta folder/gluers are capable of a maximum belt speed of 1,268 fpm in four sizes—23.6˝ to 43.3˝ working widths—and they handle stock up to E-flute corrugated. The touch-screen panel operates speed, the counter, the kicker, and all functions. Standard equipment includes digital rail indicators for quick set ups; a retracting overhead control unit to allow operators to run the entire system; and a new kick design, which adjusts kick (riming) and duration for each carton length. New features include reduced changeover times, reduced waste, and improved efficiency, which reduces overall costs.

Pumps for consistent adhesive delivery

Nordson Corp.

www.nordson.com

LA 300 dual-acting piston pumps offer flexibility and consistent high-flow rates of liquid adhesives in folding carton, and bag and sack manufacturing. A rotating manifold allows independent orientation of the filter and air motor sections for installation adaptability. A 7:1 air-to-fluid ratio delivers precise application when paired with LA 380 pressure regulators. High flow rates allow use of lower pressure, reducing risk of adhesive shearing and the need to use multiple pumps in high-flow applications. LA 300 pumps accommodate 20-, 30-, and 200-liter containers. They also use no Teflon® seals or parts and the lubricating oil is U.S. Food and Drug Administration approved, making the pumps acceptable for use in food and tobacco industries.

New multiple bead cold glue applicator

Robatech AG

www.robatech.com

Thanks to new cold glue applicator head technology and glue station design, the multiple bead CTE applicator head helps avoid nozzle clogging and skewing of the boards. The new design of the multiple bead heads guarantees precise pattern placement following the geometry of the glue flaps on 4-corner boxes and corrugated box flaps. This design minimizes the risk of inside gluing. In addition, the new modern operating terminals are precisely designed for the specific application and characterized through an easy-to-operate control philosophy, which reduces operators' involvement.

Folder/gluer with vacuum system

Roberts PolyPro

www.robertspolypro.com

The SuperGluer® Folder/Gluer offers exceptional line speeds, fast set up, operator safety, and ease of maintenance. The SuperGluer can perform consistently at very high speeds with much less maintenance and downtime than conventional gluers. Cartons are secured and controlled throughout the folding and gluing sections by an innovative, low-pressure vacuum system. This vacuum bed eliminates the overhead carrier belt and all its inherent disadvantages, and reduces moving parts by approximately 80 percent. The vacuum carrier also offers significant safety benefits to an operator. Motorized adjustments, digital controls, and a tooling bar make set up simple and extremely fast. The Supergluer is modular and is readily adaptable to practically any application. The Roberts PolyPro Triple Compression Module can also be mounted at the SuperGluer exit to apply adequate pressure on carton blanks to evenly set the adhesive and complete the cartons before the casing operation.

By Kate Sharon

Associate Editor