When it comes to folding carton manufacturing, a tiny flaw can lead to major headaches like frustrated customers, product returns and a reputation on the line. That’s exactly what one carton company was facing: multiple complaints per week about carton window defects, including misaligned, wrinkled, or even missing windows.
Determined to fix the issue, the company turned to Valco Melton’s WindowChek system, a vision-based inspection technology that goes far beyond traditional sensors.
The Problem: Standard Sensors Weren’t Enough
Before installing WindowChek, the manufacturer relied on standard sensors to detect missing windows. However, these sensors couldn’t catch window skew, wrinkles, dogears, or glue errors, leaving them unable to meet their customers' strict quality standards.
The result? Nearly every production run containing carton windows led to costly complaints.
The Solution: Smarter Detection with WindowChek
To regain control over quality, the company implemented Valco Melton’s WindowChek system on their Heiber+Schröder window machine and Bobst EXPERTFOLD with Impack GenieCut In-Line Window Patcher. Unlike traditional sensors, WindowChek uses advanced camera technology and software to identify and eliminate key defects before cartons leave the production floor.
This system automatically removes cartons with defect windows and, in addition, allows operators to visually monitor the process in real-time.
What WindowChek Detects That Sensors Can’t:
- Window Skew – Prevents misaligned windows that impact branding and product presentation.
- Poorly Applied Windows – Ensures smooth, flawless windows.
- Glue Application Errors – Catches excess glue, missing glue, and misapplied adhesives.
- Precise Positioning – Detects even minor shifts in window placement to maintain consistency.
The Results: Zero Complaints & Faster ROI
The impact was immediate: customer complaints dropped to zero within nine months of implementing WindowChek. Operators no longer had to rely on guesswork, they could see and fix issues in real time, to guarantee that only perfect cartons made it to shipping.
Even better? The system paid for itself in less than a year, proving that investing in better inspection technology saves both time and money.
Quality Without Compromise
For carton manufacturers, precision matters. With WindowChek, this company didn’t just improve quality; they transformed their entire production process to build trust, reliability, and customer satisfaction.
Are window defects hurting your bottom line? Read more about what WindowChek can do for you and contact us today!
Categorized in: Folding Carton