From left to right: Marcus Short (Joint Managing Director) and Jordan Pugh (Head of Operations)
Speed, precision and control – three core requirements that premium carton manufacturer, Qualvis, had when seeking a new folding-gluing solution to support its major investment strategy.
The chosen machine was a Koenig & Bauer, complemented by the innovative Side Seam Gluing Solution from Baumer hhs. The adhesive technology replaces existing glue wheel units used to bond the side seams of folding boxes, delivering efficiency and productivity benefits to converters.
Explaining the company’s investment programme, Marcus Short, Joint Managing Director of Qualvis, said: “We started a large investment plan in early 2024 to enable us to increase capacity at our site and respond to the growth of our existing customers, as well as be able to serve new customers too. In addition to the folder-gluer, we have also invested in a new Koenig & Bauer printing press which will be installed and commissioned during Q1 2025 – the improvements delivered in folding-gluing means we have also had to strengthen our assets along the line to ensure we are achieving optimum performance.
“Our focus is on artisan brands, premium food packaging and cosmetics markets, which have seen positive growth in recent years. With our mix of work, a percentage is high volume, straight-line gluing and we required machinery and equipment that would enable us to compete more efficiently, in line with market demands,” said Marcus.
The Koenig & Bauer folder-gluer became fully operational in July 2024, taking the number of folder-gluers at the 72,000ft2 facility in Thurmaston, Leicester, to three – a reduction from five.
“The capabilities of our new machines enable us to reduce the number we have on site. Crucially, we have ensured that speed doesn’t come at the cost of quality. When choosing the folder-gluer, we needed it to have a gluing system that matched and complemented the machine’s performance,” Marcus added.
In folding carton production, adhesive is traditionally applied by a glue wheel or disc to bond the side seams. However, this technique introduces issues such as glue waste and lengthy cleaning time to the production floor. Baumer hhs’ Side Seam Gluing Solution consists of a gluing nozzle that applies adhesive to glue flaps from below in a non-contact process.
The combination of the PX 1000 cold glue application head, Xact Up Controller and DPP8 glue delivery pump is at the heart of the system. The PX 1000 high closing force ensures perfect gluing and prevents contamination. The integrated light barrier reliably detects every glue flap and independently controls the gluing process. Non-contact application also offers the option of segmenting the bead of glue, rather than applying a stream of adhesive. This ‘glue save’ mode makes it possible to significantly lower adhesive consumption, cut costs and reduce CO2 emissions for the first time inside seam gluing.
Jordan Pugh, Head of Operations at Qualvis, said: “I think the feeling at first was ‘why would you replace the wheel units?’ Now the question is, why would you not? Glue gun type application is commonly used for intricate, low speed jobs, yet this system runs as fast as we want it to, without all the issues that have simply become accepted due to lack of an alternative method.
“With Baumer hhs’ Side Seam Gluing Solution we have far fewer gluing issues. Adhesive doesn’t flick off, which can create troublesome residue buildup either on the cartons themselves or on the machine, and with the ability to apply short segments or ‘stitches’ of glue, we achieve a much more precise application and overall cleaner finish.”
Jordan added: “It’s a very clever system and very easy to use. The operator has greater control over the application on the run; you can choose exactly how much glue is applied, according to the speed of the line, unlike a wheel system where it’s almost a one-size-fits-all approach.
“In addition, we save a substantial amount of cleaning time at the end of each shift. Previously, we would allow 45 minutes, but this is now as quick as 30 seconds – a phenomenal time saving and real hidden benefit that we were not expecting when we first installed the system.”
Baumer hhs has made the switch to non-contact gluing simple for converters. While Qualvis has invested in a new folder-gluer, the technology can be integrated and retrofitted onto existing machines. The existing glue wheel unit is removed from the machine and the Side Seam Gluing Solution installed in exactly the same position.
Purposely designed to ensure ease of use and accuracy, the gluing nozzle applies adhesive to within 1mm on glue flaps from beginning to end and the system can be configured to specify precise application quantity and glue pattern. Glue consumption can be reduced by up to 50% thanks to the ability to apply short segments of glue, instead of a continuous bead, without compromising adhesive strength in the side seam.
Christoph Herrmann, Business Development Manager for Baumer hhs, said: “The Side Seam Gluing Solution supports maximum availability of folder-gluers and increases both output and added value. The Xact Up controller’s automatic mode reduces set-up time during job changeovers and provides complete control to the operator in relation to adhesive application. Additionally, it enhances the sustainability of box production by reducing glue waste and water used during cleaning.
“Qualvis is already reaping the benefits of this innovative gluing system in a short space of time. The advantages it brings to the production floor are superb and it has played a part in Qualvis being able to increase capacity and see return on its investment strategy, setting the company up for success in the years to come.”