Preface
Since our previous blog post, “AI in Die Cutting Machines: Expected Transformations“ received an overwhelming response from customers, they have eagerly awaited the next articles in our AI transformation series on the remaining two topics: folder gluer machines and hot stamping machines. As Kai-Fu Lee, who has held prominent roles at companies like Apple, Silicon Graphics, Microsoft, and Google, once stated, “AI will replace 50% of jobs worldwide by 2030.” The potential impact and influence of AI on various industries in the future is, therefore, beyond imagination.
SBL Machinery, a trusted name in the post-print packaging equipment industry for over fifty years, specializing in folder gluer machines, die cutting machines, and hot stamping machines. In this issue, we will have an in-depth discussion and development forecast on the expected changes in AI in folder-gluing machines. Without further ado, let’s get straight into the content of this issue!
1. AI-Driven Performance Enhancements in Folder Gluer Machines
Folder gluer machines play a vital role in the packaging process, ensuring efficient folding and gluing of boxes and other packaging materials. The integration of AI technology is poised to enhance precision, reduce material waste, and optimize performance.
1-1. AI in Material Recognition and Processing:
- Minimizing Errors and Waste
Traditional folder gluer machines rely on manual adjustments, which can lead to mistakes in material recognition and processing. With AI, these systems can use image recognition to automatically identify material types (e.g., cardboard, paperboard, or corrugated materials) and adjust settings accordingly. This ensures that each material is handled optimally, reducing waste and ensuring a consistent production process.
For instance, AI-equipped folder gluer machines use high-resolution cameras and deep learning algorithms to identify material types in real-time. Based on the recognized material, the machine adjusts the folding speed, glue dosage and temperature, ensuring flawless operation and minimizing errors. - Reducing Manual Setup Time
AI can automate the setup process based on product specifications, reducing the time technicians need to spend on manual adjustments. When producing packaging with varying shapes and sizes, the machine’s AI system can automatically adjust folding mechanisms and glue application points. This drastically reduces preparation time, enhancing overall production efficiency.
1-2. Predictive Maintenance in Folder Gluer Machines
Just as with die cutting machines, AI’s predictive maintenance capabilities offer tremendous value for folder gluer machines. Sensors embedded within the machine continuously monitor critical aspects such as temperature, vibrations, and adhesive application rates. Using IoT technology, this data is transmitted to a central system for real-time analysis.
When irregularities such as excess vibration or incorrect adhesive patterns are detected, AI can alert operators, enabling preventive maintenance before issues escalate. This minimizes machine downtime, prevents material waste, and ensures a smooth production process.
2. AI Enhancing Product Quality in Folder Gluer Machines
As the packaging industry becomes more competitive, product quality consistency is critical. AI offers advanced solutions for quality control, allowing manufacturers to achieve higher levels of accuracy and product yield.
2-1. AI in 100% Automated Inspection
- Replacing Manual Inspection
Traditional inspection methods rely on sampling, where only a portion of the products is examined. With AI, 100% of products can be inspected in real-time, ensuring that every finished product meets high-quality standards. AI systems can evaluate various factors such as glue application accuracy, fold alignment, and dimensional correctness.
For example, AI vision systems can inspect each package at multiple stages of production, identifying even minor defects such as improper folding or uneven adhesive application. - Continuous Operation with Precise Standards
AI-based inspection systems operate continuously without the limitations of human fatigue. This ensures that products are inspected consistently and objectively according to predefined standards.
2-2. Principles of Model Evaluation
AI systems in folder gluer machines are designed to learn and adapt over time. Through ongoing data analysis, AI can improve its ability to predict potential defects and automatically adjust machine parameters to prevent them. For instance, if there are frequent glue coating problems on a specific material, the artificial intelligence system will be able to analyze the problem and adjust the appropriate glue quantity, temperature, and coating position to solve the problem based on the individual problem.
As more data is collected, the AI system becomes increasingly intelligent, fine-tune production processes or manufacturing parametersto enhance overall quality and reduce the likelihood of defects.
3.AI Enhancing the Skills of Folder Gluer Machine Technicians
As AI becomes more integrated into manufacturing equipment, it is also transforming how technicians are trained and how they interact with the machines.
3-1. AI-Based Knowledge Systems and Assistance
- Building a Knowledge Base
AI can turn manuals, specifications, and process data related to folder gluer machines into structured, searchable databases. This knowledge base allows technicians to access critical information quickly, whether for troubleshooting or optimizing machine performance. - Real-Time AI Assistance
AI systems can assist technicians during machine operation by providing real-time guidance. For example, if a technician is troubleshooting a gluing issue, the AI system can analyze the current status of the machine and suggest specific methods, such as adjusting the position of the glue or increasing or decreasing the dosage and quantity of glue, to effectively solve the problem.
3-2. AI-Powered Training Platforms
- Personalized Learning and Skill Development
AI can help folder-gluer machine technicians learn how to adjust the machine’s hardware folding accessories to accommodate different box types. For example, technicians can use an AI-assisted learning application that provides specific machine adjustment guidance based on the selected box type, such as auto-lock bottom boxes or double-tuck lock boxes. Once a technician selects a box type, the AI will automatically display the required folding accessory adjustment positions for that type and provide step-by-step instructional videos or 3D simulations. This approach allows technicians to intuitively understand and correctly set up the machine. In this way, AI not only assists technicians in overcoming the operational challenges of different box types but also helps them quickly master efficient adjustment techniques. - Simulated Training Environments
AI-driven simulators can replicate real-life folder gluer machine operations, allowing technicians to practice without the risk of damaging equipment or wasting materials. This virtual training helps develop problem-solving skills and operational knowledge while keeping production costs low.
4. Conclusion
AI’s integration into folder gluer machines promises a significant leap forward in precision, efficiency, and product quality. With advanced material recognition, automated adjustments, and predictive maintenance, manufacturers can expect reduced waste, minimized setup times, and fewer unplanned machine downtimes. AI-powered inspection ensures that product quality is maintained consistently, while intelligent training platforms enable technicians to continuously enhance their skills. As AI technology continues to evolve, the future of folder gluer machines looks bright, opening the door to even greater operational efficiency and product innovation.
Like us at SBL Machinery, do you look forward to the exciting transformations AI will bring to folder gluer machines?