Baumer hhs has announced its CorrBox Solution, a modular glueing system for corrugated converters featuring a sensor that can detect adhesives without the need for additives, and a multi-application head for various viscosities and a smoother start-up process.

As part of the CorrBox Solution, Baumer hhs says it developed the PGD 1000, a sensor with camera-like properties that apparently gives corrugated converters the freedom to glue any packaging without having to account for the monitoring process or surface type. In addition, the company claims that the PGD 1000 means that customers no longer have to decide between sensors or cameras for monitoring adhesive applications.

Andreas Schneiders, corrugated business development manager at Baumer hhs, explains: “Previously, adhesives were mixed with additives that fluoresce under UV light to appear blue, yellow, or green. The purpose of the additives was to create contrast between the surface of the packaging and the glue tracks so that cameras and sensors could detect the adhesive.

“In view of the wide variety of packaging surfaces – white, brown, printed – this task was always quite a challenge. The additives made the adhesives up to 50% more expensive, they were unacceptable under food safety laws in some cases and they limited purchasing options.

“The PGD 1000 eliminates all of these issues. The new sensor reliably detects adhesive on corrugated board without any fluorescing additives whatsoever. And it doesn’t matter if or how the surface of a substrate is printed.”

Thomas Walther, head of business development at Baumer hhs, adds: “Having a flexible choice of adhesives was one of our main goals in developing the CorrBox Solution. In view of the dramatic situation of global supply chains, our customers benefit even more from this kind of flexibility today.”

According to Baumer hhs, the CorrBox Solution also features a multi-application head based on the technology behind its PX 1000 cold glue applicator, which it claims is more tolerant of viscosity fluctuations thanks to a newly designed electromagnetic drive that achieves a 42% higher closing force (compared to the PL-500 predecessor model).

The company adds that the PX 1000 module for the multi-application head opens and closes faster than other comparable heads with electromagnetic drive. With its high closing force, the company says that even adhesives that have thickened after long idle periods can be reliably dispensed.

Moreover, Baumer hhs says that the nozzles on the multi-application head can be lowered into an optional water bath that effectively prevents them from drying out, even over extended periods, and eliminates any contamination or residue build-up. Overall, the new multi-application head reportedly guarantees premium glueing results even at the limits of viscosity range and offers “excellent” start-up behaviour.

According to Walther: “Customers are starting to report that the multi-application head doubles the duration of uninterrupted production between two cleaning cycles. In other words, it cuts cleaning in half.

“The risk of glueing errors is reduced to the same extent. Another advantage is the up to 60% reduction in glue consumption.”

Baumer hhs also claims that it uses an optimised stitching algorithm that works hand-in-hand with the speed of the PX 1000 application head, allowing the continuous line of glue applied previously to be divided into a series of short segments without any tailing. This allegedly results in significant savings on adhesive and, in some cases, increased adhesive strength, while also reducing glue consumption.

The CorBoxx Solution is operated and set up using the Xtend3 controller from Baumer hhs. According to the company, settings that have been entered only once by an expert are separated from parameters entered by machine operators, the need for which is apparently minimised by the solution.

Additionally, the company says that many parameters can be stored in the controller and easily adapted by an operator using simple plus/minus keys. The company claims that Xtend3 supports short setup times, while repeat orders can reportedly be retrieved with the push of a button from saved settings.

With the sensor, machine operators can also follow the glueing process line, in real-time, on the screen of the Xtend3 controller, Baumer claims. New functions reportedly include edge detection, where the PGD 1000 can check inside and outside glue lines towards the outer edge to prevent inside glueing.

Schneiders says: “Xtend3 is known for its unique, intuitive, menu-driven interface. We’ve optimised the user interface of our CorrBox Solution to meet the specific needs of the corrugated industry.”

Baumer hhs notes that the open infrastructure of the CorrBox Solution means that the system can grow with customers’ long-term needs, offering future-proof equipment. Customers can apparently choose from various models, a number of different control and monitoring functions, and optional software features.

Schneiders concludes: “Sustainable packaging regulations, zero-defect production, rising cost pressure, the increasing shortage of skilled workers, and the instability of global supply chains – a number of challenges affecting the industry right now prompted us to rethink adhesive application and monitoring in corrugated packaging production.

“We had several goals in mind, some of which initially seemed incompatible. The result of our efforts is the revolutionary CorrBox Solution system for flexo folder gluers (FFG). It boasts unprecedented performance and flexibility, and gives our customers significant advantages.”

Last year, Baumer launched a hot melt system for applying pressure-sensitive adhesive on corrugated and cardboard surfaces that it says can achieve consistent application quality and a high melt rate.