How to reduce setup time on a flexo folder gluer?

Optimizing Flexo Folder Gluer Performance: Key Considerations for Industry Professionals

Flexo Folder Gluers (FFGs) are integral to the production of corrugated boxes, folding cartons, and other packaging materials. Selecting the right FFG and optimizing its setup time are crucial for enhancing operational efficiency and return on investment (ROI). This guide addresses common questions and provides insights to assist in making informed decisions.

1. What Factors Influence the Cost of a Flexo Folder Gluer?

The cost of an FFG is influenced by several key factors:

• Level of Automation and Technology Integration: Machines with advanced automation, such as servo drives, computerized control systems, and automatic plate mounting, typically have higher upfront costs but offer significant long-term savings through reduced labor and improved efficiency.

• Number of Printing Colors and Precision: FFGs capable of printing multiple colors (e.g., 1-color to 6-color systems) and offering high precision are more expensive due to the additional print units and sophisticated engineering required.

• Brand Reputation and Quality Components: Established brands known for quality and reliability often command higher prices. Machines manufactured in countries with advanced engineering standards, such as Japan, tend to be more expensive but offer superior durability and performance.

• Customization and Special Features: Specialized capabilities, such as jumbo-size printing or unique die-cutting features, add to the base cost but can enhance production capabilities.

• Ancillary Equipment and Peripherals: Additional equipment like strapping machines, palletizers, and automatic loading systems can increase the overall investment but are often necessary for a complete production line.

2. How Can Setup Time on Flexo Folder Gluer Lines Be Improved?

Reducing setup time is essential for increasing productivity and minimizing downtime. Strategies include:

• Automation and Job Memory Systems: Modern FFGs equipped with automation and job memory functions can recall previous settings, significantly reducing changeover times.

• Quick-Change Tooling: Implementing quick-change tooling systems allows for faster adjustments and minimizes manual intervention during setup.

• Operator Training: Comprehensive training programs ensure operators are proficient in machine settings and troubleshooting, leading to faster and more efficient setups.

• Maintenance and Calibration: Regular maintenance and precise calibration of machines prevent unexpected delays and ensure consistent performance.

3. What Are the Maintenance Requirements for Flexo Folder Gluers?

Proper maintenance is vital for the longevity and optimal performance of FFGs:

• Daily Maintenance: Cleaning glue nozzles and checking air filters to prevent blockages and ensure smooth operation.

• Weekly Maintenance: Calibrating belt tension and lubricating moving parts to reduce wear and tear.

• Annual Maintenance: Replacing bearings and other critical components to maintain machine reliability.

Suppliers offering remote diagnostics can predict 85% of failures before downtime occurs, allowing for proactive maintenance planning.

4. Are Used Flexo Folder Gluers a Viable Option?

Purchasing used FFGs can be cost-effective but requires careful consideration:

• Inspection: Thoroughly inspect critical components like folding heads and conveyors for signs of wear.

• Service History: Review maintenance records to assess the machine's operational history.

• Spare Parts Availability: Ensure that spare parts are readily available to avoid future downtime.

Newer models (≤5 years old) often provide better ROI through higher efficiency and reduced maintenance costs.

5. How Critical Is After-Sales Technical Support?

After-sales support is crucial for minimizing production downtime:

• 24/7 Support: Choose suppliers that offer round-the-clock remote support and on-call engineers.

• Spare Parts Availability: Opt for suppliers with regional spare parts hubs to ensure quick delivery.

• Training Programs: Ensure that comprehensive training is provided to operators to enhance machine utilization.

Prompt and effective support can significantly reduce operational disruptions and maintain production schedules.

6. How Does Automation Level Impact ROI?

The level of automation in FFGs directly affects ROI:

• Semi-Automatic Systems: Reduce labor by approximately 30% compared to manual folding, with a payback period of 6–12 months.

• Fully Automated Systems: Achieve labor savings of up to 70% and offer a payback period of 14–18 months for production volumes exceeding 15,000 units daily.

7. Are Specialty Gluers Compatible with Recycled Materials?

High-end FFGs can handle recycled materials:

• Adjustable Compression Rollers: Accommodate variations in recycled corrugated density.

• Wider Glue Application Margins: Compensate for fiber inconsistencies in recycled materials.

8. What Are the Delivery Times for Flexo Folder Gluers?

Delivery times vary based on machine complexity and customization:

• Standard Configurations: Typically delivered within 15–60 days post-order.

• Customized Models: May require longer lead times depending on specifications.

Conclusion: Advantages of Keshenglong & Shinko Flexo Folder Gluers

Keshenglong & Shinko offer several advantages in the FFG market:

• Integrated Solutions: Provide cost-competitive integrated lines combining flexo printing, slotting, die-cutting, and case making.

• Advanced Technology: Incorporate Japanese R&D and high-quality components for superior performance and durability.

• Customization: Offer specialized capabilities tailored to specific production needs, enhancing operational efficiency.

Investing in Keshenglong & Shinko FFGs can lead to improved productivity, reduced setup times, and a higher ROI in the packaging industry.

References:

• (https://www.shinkomachinery.com/guides/flexo-folder-gluers-guide.html)

• (https://www.shinkomachinery.com/article/how-to-operate-a-flexo-folder-gluer-efficiently.html)

• (https://www.shinkomachinery.com/flexo-folder-gluer-cost-factors-1.html)

• (https://sunautomation.com/open-close-or-set-while-run-which-flexo-folder-gluer-is-right-for-the-job/)

• [How to Maximize Your Folder-Gluer Productivity (https://impack.ca/learning-center/folder-gluer-productivity-maximize)