Extrusion gluing is the most advanced adhesive application method for folding carton production. Many plants are still learning the value of converting from glue pots and wheels to extrusion gluing. A perceived learning curve and the cost investment may seem like inhibitors when replacing glue pots, but the immediate payoffs from a Leary Sempre-i glue valve with CleanStart include consistent quality, time savings, and reliability.
The Sempre-i cold glue valve, delivers a complete, hands-off gluing solution. Precise application in a controlled and accurate extrusion method removes glue sling and stickers caused by glue wheel systems. Glue wheels require frequent cleanup, regular maintenance and even then, result in cartons sticking together. Without this, operators can focus more on production and less on downtime.
The Sempre-i allows precise start/stop control in glue application, allowing edge-to-edge gluing, eliminating unwanted tabbing while reducing glue consumption by as much as 50% compared to glue wheels—especially when utilizing spot or stitch patterns. Real-world case studies show that replacing glue wheels with Sempre-i extrusion valves reduces downtime by up to one hour per day, allows increases to run speeds of 20% and eliminates internal stickers.
The CleanStart feature of the Sempre-i eliminates the need for operators to wipe glue nozzles before restarting. It automatically seals the nozzle during the stop, preventing glue drying and ensuring the machine is ready to resume production. This results in the first carton through the machine after a stop being glued correctly; reduced waste, improved uptime, and enhanced operator safety by keeping hands out of the machine. From a performance standpoint, the Sempre-i valves operate at speeds over 700 m/min, removing limitations to machine throughput. With a 1 billion cycle lifespan, wide glue viscosity range, and unmatched end-to-end precision, Sempre-i extrusion gluing with CleanStart delivers efficiency for short or long production runs.
Maintaining quality and reducing waste delivers cost savings to plants and improves overall efficiency. Quality inspection is available for hot and cold gluing, 1D and 2D code reading, cameras for print inspection, Braille, codes and also LearyVIEW Flex; a flexible camera system for inspection of glue, flaps, skew, and cellophane windows.
The combination of Sempre-i, CleanStart and LearyVIEW Flex offers a fully integrated solution covering everything from side-seam gluing on the 4th panel to complex carton involving twenty or more glue valves, such as 6-pack bottle carriers.
The LearyVIEW Flex camera solution delivers maximum inspection with minimal setup. Thanks to high-speed capabilities of 700 m/min, the LearyVIEW Flex system keeps pace with today’s fastest production lines, guaranteeing quality.
A significant advantage of LearyVIEW Flex is its wider Field of View (FOV) compared to traditional sensors. This enables the system to detect both glue presence in the correct locations and unwanted glue specks anywhere on the product. If utilizing fixed camera locations, operators can also be required to align the glue to the pre-approved boundaries, standardizing quality and minimizing the chances of human error.
The Flex system also reduces the need for multiple sensors by using a single camera to detect glue, skew, flaps, folds, and handles. Plants no longer have to setup individual sensors for each application as one camera is used for multiple applications. Set-ups are fast and intuitive with up to (4) Flex cameras making this suitable for even the most complex jobs. With auto-learn capabilities, operators simply run a few cartons through the machine, and the camera auto-calibrates by applying predefined tolerances. This streamlines job changeovers and reduces training needs.
Visual imaging of each carton confirms accurate inspection, visible on the Monet operating screen. Advanced features like dynamic edge finding further enhance accuracy by checking alignment of glue with the actual position of the carton, not just the camera’s view.
For cartons that do not meet intended quality standards, operators can view the rejected carton images, adding a layer of transparency and control, making troubleshooting faster and more effective by viewing the exact reasons on the screen that were used to determine a reject.
As the folding carton industry continues to evolve, the adoption of controlled extrusion application and intelligent inspection continues to accelerate. What was once viewed as an upgrade is quickly becoming a baseline expectation for modern folding carton operations.
For converters seeking to remain competitive, the focus is shifting from simply running faster to running smarter; reducing variables during the carton production process, improving visibility, and recording inspection capabilities, ensuring that every carton meets the required standard.
Being knowledgeable about new technologies and solutions available puts factories in a position to succeed. Manufacturers looking to upgrade their gluing or add quality inspection can instantly benefit from Leary’s solutions. Learn more at www.whleary.com.
