Sack Bottomer with Digital Gluing Technology https://www.copybook.com/companies/windmoller-and-holscher/article...

Sack Bottomer with Digital Gluing

Technology

The first W and H paper valve sack bottomer featuring digital gluing
technology celebrated its world premiere at the end of October with an
audience of 300 visitors in attendance.

Under the slogan THE NEXT LEVEL, engineering company Windmöller &
Hölscher (W&H) and paper sack manufacturer dy-pack had invited specialists
from the trade to the dy-pack multiwall factory in Wenden-Gerlingen, Germany.
During live demonstrations at dy-pack's paper sack factory, the new AD®8330
CNC valve bottomer impressively demonstrated that its innovative digital nozzle
gluing technology is definitely going to revolutionize the principles of multiwall
paper sack production known so far.

The World's First Bottomer with Digital Gluing

System
"The extraordinary response to the announcement of this event and the great
interest shown in our new AD8330 bottomer has satisfied us that our engineers
have succeeded in setting another milestone in multiwall engineering history.
Marking the world's first bottomer with digital gluing system, it is bound to open
new perspectives and potentials to the paper sack industry", says Dr. Jürgen
Vutz, CEO/W&H, following the presentation of the AD8330, expressing his firm
belief that the new machine will prove a success in the time to come. As reasons
for his optimism he emphasizes lower per-unit costs resulting from reduced pre-
production handling requirements, shorter change-over times and a notably
reduced water penetration from the glue into the paper. Less water in the sack
walls – not only does it mean improved quality, but, on top of that, allows for
shorter drying times and, as a result, reduced storage costs.

1 of 5 7/11/2019, 3:24 PM
Sack Bottomer with Digital Gluing Technology https://www.copybook.com/companies/windmoller-and-holscher/article...

Traditional Bottom Gluing Systems

Traditional bottom gluing systems were based on the use of pads to apply the
adhesive to the paper. This involves the availability on site of a great number of
different size parts and gluing patterns, which would normally have to be changed
for each new order or may require regrinding. This obviously takes time and
major paste pad management requirements, facts that are bound to have a
negative impact on profitability and productivity, especially in view of increasing
sack size diversification, ever-smaller order volumes and resulting more frequent
job changeovers. – This is where the new digital gluing system takes effect.

Gluing System Technology

In place of pads, the gluing system of the AD®8330 uses contact nozzles
guaranteeing an exactly defined glue application pattern and perfectly reliable
functioning, since contact with the moving webs keeps the nozzles clear of glue
build-up. In order to remain so also during production interruptions or when
switching off individual glue beads for different sack dimensions or when
changing the adhesive, the nozzles are automatically pivoted off or flushed with
water. The core element of the gluing system is the flow regulator. It guarantees
consistent glue application at all times – independent of the machine's speed and
the viscosity of the adhesive. In order for the glue bead pattern to exactly match
the geometry of the bottom and to ensure tight joints, the nozzle heads feature a
segmented design and are separately CNC adjustable. Precise glue application is a
requirement to ensure that the least necessary amount of water is introduced into
the paper, resulting inbetter quality joints and reduced storage time.

Decreasing Set-up Time, While Increasing Production

Because of the use of contact nozzles, size changeover of the AD®8330 is

accomplished notably faster than previously. It is not necessary to prepare any

2 of 5 7/11/2019, 3:24 PM
Sack Bottomer with Digital Gluing Technology https://www.copybook.com/companies/windmoller-and-holscher/article...

pads for a new production job. An easy to handle graphic tool makes it easy for
job management or the operator on the machine to enter sack dimensions and
glue patterns, while at the same time calculating automatically the glue pattern
data on the basis of the dimensions entered. Corrections, if any, can be quickly
made on line. Once generated, the data sets are permanently saved and can be
push-button retrieved with practically no lead time, when running repeat orders
or similar specification sacks.

Not only does this minimize set-up time, but at the same reduces pre-production
handling requirements. Since glue pad management is not needed any longer,
production costs are reduced and potential trouble sources eliminated.

3 of 5 7/11/2019, 3:24 PM
Sack Bottomer with Digital Gluing Technology https://www.copybook.com/companies/windmoller-and-holscher/article...

Corrections in regard to geometry or glue pattern can be made any time with the
machine running. Thanks to shorter set-up time, complex production processes
requiring frequent changeovers will no longer impede but rather enhance the
productivity of the system.

How fast the AD®8330 adjusts to the new dimensions was impressively
demonstrated during live presentation of the machine. Setting up the system for a
different glue quantity and adhesive type and bringing the new glue patterns into
place was completed in no time. Not less important: saleable production was
demonstrably run from the very first sack, as visitors could see for themselves.
Other sack samples taken during production proved that the high product quality
was being maintained even during acceleration of the machine to the maximum
production speed of 330 sacks per minute. Another highlight of the presentation
was the demonstration of a glue pattern change with the machine in operation,
accomplished on-line via the touchscreen of the PROCONTROL®TS operator
console and including changeover from full-surface to economy gluing. The same
operator console had previously been used to enter the new data relative to
bottom cap length, valve position, valve type and material, as well as glue
application.

On-line Quality Check

For on-line quality assurance, the AD®8330 was equipped with the high
performance image evaluation system TELESCAN®Pro, which checks the bottom
geometry, the presence and position of valves and bottom caps as well as the
bottom cap print for completeness, separately for each individual sack. Defective
sacks are automatically removed via the reject gate of the bottomer.
TELESCAN®Pro uses colour cameras and can therefore reliably identify faults
and defects even with difficult contrast conditions and colour gradations.

Flexibility

In view of increasing product diversification, the industry demands bottomers

that not only provide the largest possible size ranges but, at the same time, allow
for variability of sack constructions. Featuring an extraordinary size spectrum of
1:50 with filling volumes ranging from 2 to 100 litres, the AD®8330 covers the
requirements of traditional markets equally well as the needs of new niche
markets demanding small size consumer packages. A broad range of hinge sleeve
and valve units are available with variation possibilities from tube forming to
thumb notch cutter, longitudinal seam and cross pasting, and also including an
additional unwind with web break sensors as well as web tension control,
allowing for customized sack constructions. As for the AD®8330 presented at the
dy-pack open house, the machine allows producing bottom caps with integrated
carrying handles mainly used for off-the-shelf sale to the end user of building
materials and pet food articles. State-of-the-art servo drive technology of the web
draws provides automatic infinite patch length adjustment and an extended cut-
off length range, when compared to the traditional change-gear concept. Standard
modules or special add-on attachments that may be needed at a later stage, can be
retrofitted with ease.

The Paper Sack Line

The new bottomer at dy-pack was demonstrated in conjunction with the newly
developed AM®8125 CNC universal tuber, a FLEXA®820 end printer,
TRANSYSTEMS®automated material flow elements between the production
machines, as well as an ARCOMAT®3 robot palletizer. Another "first" featuring

4 of 5 7/11/2019, 3:24 PM
Sack Bottomer with Digital Gluing Technology https://www.copybook.com/companies/windmoller-and-holscher/article...

on the paper sack line on show was PROCONTROL®TS as an integrative operator

concept eliminating the need for separate entry of size data for each individual
machine.

FLEXA®820, the in-line printer upstream of the tuber, is equipped with four
doctor blade colour decks for demanding process printing at speeds up to 350
m/min. The integrated "insetter" controller allows for subsequent addition of
special print design details.

The four-ply tuber AM®8125 CNC tuber ideally matches the AD® 8330 bottomer
in terms of output as well as degree of automation (and, therefore, in terms of set-
up time as well). It is laid out for stepped as well as flush-cut applications and can
also handle HDPE film as a moisture barrier. Overall venthole perforation with
skip capability for all webs permits precise micro-perforation for air escape from
the sacks during filling.

The two sections of the TRANSYSTEMS®automated material flow system feature

transport and storage conveyors, turning stations, lifting table, etc. They ensure
constant feeding of tubes to the bottomer as well as of finished sack packets from
the bottomer to the ARCOMAT®robot palletizer. Running at 28 cycles per
minute, ARCOMAT® is the currently fastest paper sack palletizer and capable of
coping with even the maximum production output of the AD®8330 of 330 sacks
per minute, without difficulty and providing perfect stacking quality.

Windmoeller & Hoelscher is an international leader in the manufacture of

machinery and equipment for the flexible packaging industry. Its manufacturing
program encompasses blown and cast film equipment, flexographic and gravure
printing presses as well as finishing machines, industrial sack, bag and carrier bag
machines as well as packaging systems working on the FFS (Form-Fill-Seal)
principle, and woven film converting equipment.

5 of 5 7/11/2019, 3:24 PM