The CorrBox Solution from Baumer hhs introduces a new option, available since mid-June 2024, which is said to elevate the measurement of slot depth in box production on flexo folder gluers (FFG) to a remarkable level. The new ‘Slot’ option offers two key benefits: ease of operation and integration with the high-performance SCX 1000 contrast sensor, reputed for delivering reliable results even at top machine speeds.

“The dimensional stability of the slots is one of the main factors determining the functionality of a folding box. If the slot depth is not die-cut correctly, packaging produced on a flexo folder gluer could easily become unusable: If the slots are not deep enough, the flaps cannot be folded correctly, which can lead to problems when the boxes are automatically erected. If the slots are too deep, holes can form at the corners of the boxes, compromising protection of the goods packed inside or making the boxes unstable. If the geometry and position of the slots are not right, the boxes may not close properly or opposing flap edges may be out of line”, says Marcell van Meegen, head of business development at Baumer hhs.

The new SCX 1000 contrast sensor, developed specifically for this control function, is equipped with a light source and exhibits camera-like capabilities. With its teach-in function, the sensor requires no manual settings from the operator, further reducing setup times for quality assurance. Additionally, the new Slot option is fully integrated into the Xtend3 controller from Baumer hhs, allowing seamless operation via the intuitive user interface. These two features are key factors contributing to the exceptional user-friendliness and efficiency that the Slot option is known for.

Machine operators have the option of manually entering different slot lengths for the bottom and top flaps of boxes in production. Tolerances that determine when deviations should be rated as errors can likewise be entered manually, enhancing both the economic efficiency and sustainability of production processes. The new Slot option also has a function for separately activating or deactivating control of the bottom and top flaps. “Our new Slot option offers all these advantages, giving box manufacturers the flexibility they need in day-to-day operations to meet a wide range of quality demands imposed on corrugated packaging,” says van Meegen.

The functional principle behind measuring slot depth is as simple as it is efficient: By illuminating packaging products, the SCX 1000 creates a sharp contrast between the die-cut slots and the darker background. This enables the high-powered sensor—which controls slot depth between the centre bottom and top flaps —to “see” whether the position, geometry and depth/length of the slots are cut correctly. In addition, the sensor reliably detects cardboard fragments or waste left behind in the slots from the die-cutting process, as well as any missing slots.

If flawed boxes are detected, the CorrBox Solution’s Slot option triggers an acoustic signal to alert the machine operator, visualises the error live on the display of the Xtend3 controller and marks the affected boxes on the side with UV ink. The operator can then easily remove those boxes from the stacks in the delivery section of the machine. Alternatively, this step can also be automated with the Bundle 24 function for CorrBox Solution, available since late 2023. It ejects all bundles containing flawed boxes from the process without the operator having to intervene.

With the information provided by error messages on the Xtend3 controller’s touchscreen, machine operators can react immediately and modify process parameters. For example, cardboard fragments from die-cutting left inside a rising number of slots indicate that the die-cutting pressure needs to be increased or the cutting dies replaced. Flawed slots are shown in red on the live images on the display, good slots in green. Using the intuitive menu, machine operators can, for instance, view and compare the last ten errors. If multiple errors occur in succession, they can have the machine stop automatically by entering the variable threshold number on the Xtend3 controller’s 21.5” display. The system stores all measured data for its various statistics functions. Packaging manufacturers can use this information to optimize their processes. It can be exported in CSV file format for this purpose.

“The Slot option adds yet another function to our CorrBox Solution in addition to Bundle 24. It takes our customers another step closer to the goal of zero defects in packaging production. Our revolutionary system for gluing and quality control in corrugated packaging production on flexo folder gluers has rapidly become established on the global market. Many of our customers around the world have now switched over to this latest generation of equipment, and they are seeing remarkable results that strengthen their competitiveness,” says van Meegen.