Preface
With over fifty years of experience in post-printing equipment, SBL Machinery has practical installation experience with at least thousands of Folder Gluer Machines worldwide. This includes both direct installation experiences and assisting dealers in the process. While there are commonalities in the installation and acceptance criteria for Folder Gluer Machines, Die Cutting Machines, and Hot Stamping Machines, differences arise due to variations in functionality. This article aims to assist buyers in ensuring a high-quality acceptance and stable production capacity for newly purchased Folder Gluer Machines. Additionally, we hope readers can gain more knowledge in the field of Folder Gluer Machines. Without further ado, let’s dive into the content of this issue!
1.Machine Installation Space and Location
Drawing upon SBL Machinery’s extensive experience in assisting customers with machinery installation over the years, many clients still tend to overlook or misunderstand certain aspects of this project. Beyond simply reserving physical space, individuals often neglect to consider the operational and maintenance space required for the machine. Taking a comprehensive view of all production equipment is essential in this regard. Additionally, when comparing Folder Gluer Machines and Die Cutting Machines, it’s important to note that Folder Gluer Machines require a longer, narrower, and lower space, while Die Cutting Machines necessitate a shorter, wider, and higher space.
1-1. Ensuring Adequate Installation Space Evaluating Equipment Dimensions
- Evaluating Equipment Dimensions
Before deciding on the installation site, it’s crucial to meticulously evaluate the dimensions of the Folder Gluer Machine, considering aspects such as length, width, height, and potential expansion space. Using SBL machinery as a reference, the TS-550W model, the smallest in the folder gluer machine series, has a total length of 9150mm, while the TS-1650WNV model, the largest in the series, spans a total length of 22628mm.
Apart from confirming machine specifications from the contract or product data, it is recommended to reconfirm dimensions with the sales team. Occasionally, due to the addition of optional accessories or the selection of specific models, the machine’s dimensions may slightly differ from the specified figures on paper. - Safety Passages
Reserve ample safety passages to ensure operators can freely enter and exit for necessary maintenance and repairs. Consideration for safety passage dimensions should be given in front, behind, to the left, and to the right of the machine. The suggested dimensions for the reserved space can be found in section 1.2.
1-2. Considering Machine Operation and Maintenance Space
- Front and Rear Clearance
Provide ample front and rear clearance to facilitate easy access for operators to various parts of the machine for adjustments, inspections, and maintenance. Also, take into account the movement space for hand trucks or track conveyors when loading and unloading paper. Considering the constraints of daily operations and maintenance in limited space, it is advisable to reserve at least 1 meter or more of clearance in the front and rear. In cases where the factory space allows, a recommended reserve of 1.5 meters or even 2 meters provides optimal convenience. - Side Clearance
Ensure sufficient side clearance for maintenance personnel to carry out essential tasks. The side clearance should consider basic requirements for personnel passage and work, with a recommended minimum reserve of at least 60cm. In situations where space is abundant, a suggested reserve of 1 meter or more is advantageous.
1-3. Preventing Overcrowding and Considering Workflow
- Adjacent Equipment
When the Folder Gluer Machine is positioned near other production equipment, ensure there is ample space between them. This serves to prevent potential interference between machines and requires consideration of the workflow sequence in the printing production operation. Organize the layout of machines based on the production order. - Safety Clearance
Account for the operation and vibrations of neighboring machines, ensuring a sufficient safety clearance during the installation process.
2. Visual Inspection
In comparison to Die Cutting Machines and Hot Stamping Machines, the proportion of the metal cover area on the Folder Gluer Machine is relatively lower, making the visual inspection somewhat more straightforward. Firstly, we will pay attention to the condition of the machine’s outer casing. By examining the surface of the casing, we can assess whether there are smoothness, scratches, abrasions, or damages. This not only impacts the aesthetic appearance of the machine but also directly influences its overall durability and lifespan. Regarding relevant labels and markings, as well as the examination of the control panel, these two aspects are commonly overlooked by customers during the acceptance of machine installation. In case of any anomalies during the visual inspection, it is recommended to promptly communicate with the manufacturer for subsequent replacement or repair activities.
2-1. Exterior and Visual Inspection
- Machine Casing
Examine the surface of the machine casing for smoothness and check for any noticeable scratches, abrasions, or damages. - Paint Condition
Inspect the machine’s paint for uniformity and the presence of peeling or oxidation.
2-2. Identification and Marking Inspection
- Clarity of Markings
Confirm the content of all markings and labels, such as operational directions, clarity of ruler numbers, and whether they adhere to the equipment’s identification standards. This inspection is crucial for ensuring the smooth production and yield of the machinery in the future, ranking just below the importance of visual inspection. - Warning Signs
Verify the presence of necessary safety warning signs to alert operators about specific risks. This is essential for ensuring safe production.
2-3. Control Panel Inspection
- Buttons and Switches
Test all buttons and switches to ensure their responsiveness and normal operation. - HMI (Human-Machine Interface)
Check the clarity of the HMI panel screen display, ensuring no abnormal flickering or display errors. Also, assess the operation interface language, making necessary adjustments to align with the commonly used language by machine technicians. Typically, adjusting the operating speed is done through the HMI, confirmed with the installation factory. Understand how to adjust the folder gluer speed and interpret the meaning of machine error codes from the HMI, along with common troubleshooting for these codes.
Monitors
Automatic folder gluer machines, due to their longer overall length, often have surveillance cameras installed at the operator’s control console. When accepting this setup, pay attention to two key points: 1 whether the camera images are clear without noise, and 2 if the video playback function is functioning properly.
3. Operation and Performance Testing
The initial two sections, focusing on the installation of the machinery in its designated space, its positioning, and the inspection of its appearance, are considered more “static” checks. Subsequently, the acceptance of the Folder Gluer Machine involves a “dynamic” aspect, encompassing speed testing, paper creasing and bottom Hook testing, and assessments of stability and safety.
3-1. Speed Testing
Typically, the operational speed of the Folder Gluer Machine is measured in meters per minute based on the distance it can cover. The speed of an automatic folder gluer machine typically ranges from 50 to 300 meters per minute, while some exceptionally high-speed models (e.g., Bobst) can achieve speeds of up to 400 meters per minute.
For this testing phase, you can conduct the test using the paper working material provided by the machine’s original manufacturer, or you can prepare different types of adhesive box paper for future testing. The tests can be carried out with an empty machine and when working materials are in place to ensure the machine operates smoothly at both high and low speeds. It is recommended to conduct segmented tests for high and low speeds because, at times, different rotational speeds may necessitate adjustments to the machine’s relevant parameters (e.g., glue temperature).
3-2. Creasing and Bottom Hook Testing
3.2.1. Creasing
3.2.2. Bottom Hook
3.2.3. Inspection Criteria
- Verify the clarity and sharpness of the corners, ensuring there are no burrs or blunt edges.
- Check for symmetrical corners, avoiding any deviations or distortions.
- Ensure the corners seamlessly integrate with other parts of the box, without lifting or indentations.
- Inspect the bottom hook for smoothness, free from dents or protrusions.
- Confirm the seamless alignment of the bottom hook with other parts of the box, avoiding lifting or indentations.
- Assure the bottom hook’s solidity, without any cracks or damage.
3-3. Stability Testing
The typical process for positioning and basic installation of the Folder Gluer Machine requires approximately two to three days. Completion of acceptance and education training typically takes three to five days. You might wonder how to assess the machine’s stability within this relatively short timeframe. Generally, machine stability can be evaluated using the following methods:
3.3.1. Product Yield
Regardless of whether the folder gluer machine is operating at high or low speeds, the primary consideration is the product yield. If high-speed operation is constrained by the size or thickness of the paper, adjustments to a slower speed may be necessary. In such cases, it is advisable to have the original equipment manufacturer’s technician provide guidance. The objectives are to determine the maximum speed at which the target working material can operate and for the customer to learn how to adjust the mechanical settings for optimal production yield and efficiency. When inspecting the products of the folder gluer machine, focus on the following three key points:
- Folding Precision
Ensure that the folding positions and angles of the paper or corrugated board are fixed and accurate. - Adhesive Firmness
Verify the precise position of the glue on the paper or corrugated board, appropriate glue quantity, and resistance to easy cracking. - Product Integrity
After the completion of the folder gluer process, examine the finished paper or corrugated board for an intact appearance without missing corners or damage.
3.3.2. Observation of Machine Operation Sound and Vibration
The operational mechanism of the folder gluer machine is relatively gentle in impact compared to a die-cutting machine, resulting in lower overall decibel levels. In theory, normal machine operation should not produce any unusual sounds or vibrations. If there are unexpected sounds or vibrations, it is essential to determine whether there are improperly installed components or if any unexpected incidents occurred during transportation, leading to the generation of such sounds or vibrations.
3-4. Safety Testing
Safety testing for the folder gluer machine represents the final and indispensable checkpoint after the completion of installation. Its primary goal is to ensure the machine’s safe and reliable operation, mitigating the risk of accidents during usage. Undoubtedly, prioritizing the safety of machine operators stands as the paramount concern, surpassing all other functionalities and performance considerations.
- Inspection of Safety Devices
Ensure the proper functionality of safety guards and the accessibility of emergency stop buttons by checking their opening, closing, and movement. - Evaluation of the Effectiveness of Safety Devices
For instance, in the scenario of machine operation, safety guards should only be openable when in the closed position. If, during machine operation, the safety guard or window is opened, it should either trigger an immediate shutdown or the machine should lock the safety guard or window. Evaluate the responsiveness of the emergency stop button during machine operation, ensuring that the machine promptly enters a stopped state.