Corrugated manufacturers are pressured with strict customer demands for zero-defect corrugated products. To stand out, plants need to provide consistent and superior quality products that help secure customer loyalty and drive sales. Valco Melton’s camera-based inspection systems give corrugated facilities the competitive edge in addressing common quality issues that make-or-break customer satisfaction and retention.
Common customer complaints in the corrugated packaging industry include problems with glue application, manufacturer’s gaps and print quality. These demands also vary by the type of business: those with automatic case erectors are highly sensitive to glue and gap consistency, while customers requiring high-quality, branded prints (like those in food, hazmat, and allergen packaging) are especially critical of print integrity. As corrugated plants strive to meet these demands quality control systems and processes are essential.
Camera-Based Quality Assurance Systems
GlueChek: Real Time Glue Pattern Inspection
GlueChek inspects each glue pattern in real-time, detecting any gluing irregularities
and notifying operators instantly. This will prevent faulty boxes from reaching customers, reduce product returns and ultimately meet the zero-defect corrugated product standard. GlueChek also saves real photos of each defective pattern, which provides valuable data for operator training and quality control. By guaranteeing well-adhered boxes, GlueChek helps build customer confidence and will bolster your plant's reputation for reliability.
Key Benefits:
- Immediate defect detection
- Photo capture of defects for quality analysis
- Strengthens operator confidence and customer satisfaction
GapChek: Precise Manufacturer's Gap Measurement
GapChek accurately measures the gaps of corrugated boxes. This camera-based inspection system captures images of the front and back of each bundle, GapChek precisely measures gap dimensions and highlights any bundles with defective gaps on a monitor. Its camera-based inspection systems feature optional bundle ejection, ensuring only defect-free boxes reach customers.
GapChek can handle all flute sizes, works with up-fold and down-fold machines and accommodates tapered flaps. The detailed database storage also supports trend analysis and accountability, helping plants take corrective action based on real-time insights.
Key Benefits:
- Fully automatic operation when order data is linked with GapChek, the camera adjusts exposure and position automatically on each order
- Real time defect highlighting and optional bundle ejection
- Supports tapered and square boxes and all flute sizes
- Database storage for quality trend analysis
- Measures each individual finished gap and gives the specific value for each
PrintChek: Detailed Print Inspection
For customers who prioritize branding and print quality, PrintChek provides exceptional defect detection and inspection across entire sheets before they’re die-cut. PrintChek identifies defects such as missing print, smearing, color mismatches and barcode readability and correct code, print to sheet, print to print and registration and sheet size. This detailed analysis certifies that logos and other brand identifiers are crisp and accurate. PrintChek’s advanced analytics capability also allows corrugated plants to measure quality statistics and export them through Excel, offering an excellent resource for quality control teams and marketing. With PrintChek, corrugated manufacturers can confidently promise their customers zero-defect corrugated products.
Key Benefits:
- Spot detection, color registration, and delta-e color measurement
- Identification of stripes, scratches, and ghost printing
- Sheet size, skew and paper quality inspection
Business Benefits
Each Valco Melton camera-based inspection system supports a zero-defect product standard, serving as a powerful sales tool that reassures your customers of the plant’s commitment to excellence. Additional benefits include:
- Rapid ROI: These systems deliver rapid returns by reducing rework, minimizing product returns, and improving customer satisfaction.
- Sales Tool: High-quality products build customer loyalty and word-of-mouth referrals.
- Competitive Advantage: Exceptional quality and a zero-defect corrugated product standard differentiates corrugated plants in a crowded market.
- Reduced Downtime: Valco Melton’s systems are designed to minimize disruptions and make sure production is continuous.
- Access to Support: The ongoing support offered with a quality assurance system allows you to have seamless operations and system maintenance.
- Total Quality Management: These systems form the cornerstone of a plant-wide quality strategy, from glue to print.
- Seamless Integration: ClearVision camera systems can retrofit almost any Flexo Folder Gluer or Die-Cutter.
- Easy Setup: The camera-based inspection systems are user-friendly, for easy set-up and implementation.
- Real Image Verification: Vision inspection systems capture actual photos rather than relying on sensor-generated drawings, providing more reliable defect detection.
Being able to offer your customers a flawless box is a competitive advantage in the Corrugated Industry. Valco Melton’s ClearVision inspection systems empower manufacturers to meet and exceed customer expectations, drive sales, and establish a reputation for unmatched quality. By investing in these advanced inspection solutions, corrugated plants can confidently promise zero-defect boxes that meet the highest standards, ensuring satisfied customers and a thriving business.
Are you ready to maximize sales and build customer trust? Read more about what ClearVision for corrugated can do for you and contact us today!
Categorized in: Corrugated