How does the system prevent jams during the folding and gluing process? | Keshenglong&Shinko Guide

How does the system prevent jams during the folding and gluing process?

During the high-speed folding and gluing operations in flexo printers, preventing jams is critical to maintaining efficiency and product quality. Understanding how the system prevents jams helps flexo printer professionals optimize performance, reduce downtime, and protect machinery. The following article explains the key mechanisms and technologies used to prevent jams during the folding and gluing process.

Jam Prevention in the Folding and Gluing Process

Key Prevention Mechanisms

- Advanced Sensors and Detection Systems

- Optical sensors detect misaligned, overlapping, or missing materials in real-time.

- Load sensors monitor pressure and sheet movement, sending automatic alerts if irregularities are sensed.

- Modern printers use high-speed cameras to provide continuous quality monitoring and fault detection.

- Source: (https://www.flexography.org)

- Automated Material Alignment

- Precision guide rails ensure accurate feeding and alignment of substrates.

- Automated squaring mechanisms keep sheets straight before entering the folding and gluing units.

- Servo-driven guides adjust positioning dynamically to accommodate minor material variations.

- Consistent Glue Application

- Controlled glue dispensing systems prevent excess glue, which can cause sticking and jams.

- Sensors ensure accurate glue patterns on each substrate, minimizing waste and misapplication.

- Regular calibration prevents clogging and buildup in glue applicators.

- Source: (https://www.paperbox.org)

- Adaptive Speed Control

- Speed sensors adapt feed rates based on substrate thickness and job complexity.

- Variable-frequency drives (VFD) regulate motor speeds to avoid bottlenecks or congestion.

Maintenance & Operator Best Practices

- Scheduled Cleaning and Inspections

- Routine cleaning reduces debris buildup, a common source of jams.

- Scheduled inspections catch wear or misalignment early.

- Operator Training

- Hands-on training helps operators quickly identify and address bottlenecks.

- Clear start-up, shut-down, and emergency protocol reduce risk during job changes.

- Data-Driven Monitoring

- Data logging tracks jam incidents and identifies trends for proactive maintenance.

- Real-time diagnostics provide immediate feedback to operators.

Industry Standards and Compliance

- Adhering to ISO 12647-6 for flexographic printing ensures process consistency.

- Mandatory quality checks at critical control points help maintain system reliability.

Benefits for Flexo Printing Professionals

- Reduced Downtime: Efficient jam prevention increases overall equipment uptime.

- Improved Product Quality: Fewer interruptions yield consistent folding and gluing results.

- Lower Operating Costs: Preventive mechanisms reduce the risk of costly breakdowns.

Authorities and References

- Flexographic Technical Association (FTA)

- Paperboard Packaging Council (PPC)

- ISO 12647-6 Standards