In the competitive landscape of packaging manufacturing, ensuring product integrity and maintaining high-quality standards are critical challenges. Valco Melton's PackChek represents a game-changing solution in hot melt inspection technology, offering manufacturers an innovative way to guarantee packaging quality and build customer confidence.
Cutting-Edge Inspection Technology
PackChek utilizes a powerful combination of thermal and visual imaging to inspect the heat signature of each glued package:
- Thermal imaging identifies the heat signature of each hot melt adhesive bead
- Visual imaging verifies correct positioning and detects physical package issues
This dual-imaging approach allows for precise detection of various defects, including missing glue beads, weak adhesive application, misaligned glue patterns, and even physical package issues like crushed or open flaps.
Versatility and Integration
One of PackChek's key advantag
es is its versatility. The system can be installed on virtually any production line where hot melt adhesive is applied, making it ideal for case sealers, cartoners, wrap-around machines, and more.
Unlike traditional hot melt sensors that face space constraints within packaging machinery, PackChek is typically installed at the machine's discharge, simplifying retrofitting and integration into existing lines. This strategic placement eliminates the space constraints that historically made retrofitting difficult.
High-Speed Performance
PackChek is designed to keep pace with modern production demands. The system can handle line speeds exceeding 300 feet per minute and inspect up to 10,000 cases per hour, making it perfectly suited for high-speed cartoning operations. This comprehensive approach allows for precision detection without compromising production speeds.
Customizable Defect Detection
The system allows for highly customizable defect definitions through its intuitive 24-inch touchscreen interface. Quality managers can:
- Define specific "glue windows" for precise inspection parameters
- Set predetermined tolerance levels for:
- Maximum number of missing beads
- Maximum number of poor-quality beads
- Critical bead placement (must be present and within tolerance)
- Excess glue detection (adhesive outside defined areas)
These settings can be enabled or disabled separately based on specific product requirements, giving manufacturers complete control over their quality standards. This flexibility ensures that PackChek can be tailored to meet specific constraints for various products and packaging types.
Real-Time Monitoring and Adjustments
Unlike batch-sampling methods that identify problems after production, PackChek provides real-time feedback, allowing operators to:
- Make on-the-fly adjustments to glue patterns
- Address adhesive application issues without stopping production
- Program automatic ejection after any predetermined number of consecutive faults
- Maintain high-quality standards while minimizing waste
Data Tracking and Analysis
All defective images are saved and can be recalled for up to six months, depending on the number of faults. This feature enables comprehensive quality tracking and analysis, allowing manufacturers to:
- Identify trends for process optimization
- Support continuous improvement initiatives
- Maintain detailed quality documentation for compliance and customer requirements
- Make evidence-based decisions using actual production data
Transforming Quality Control into Strategic Advantage
Forward-thinking manufacturers use PackChek to transform quality control from a necessary expense into a strateg
ic advantage that delivers measurable business benefits:
- Reduced waste through early detection and correction of issues
- Decreased customer complaints related to defective packaging
- Enhanced quality documentation for compliance requirements
- Strengthened sales position through demonstrated quality control
Building Customer Confidence Through Demonstrated Quality
Quality assurances can differentiate your products and strengthen customer relationships. PackChek provides tangible evidence of your commitment to excellence—verification that every package undergoes rigorous inspection with advanced technology and a commitment to delivering perfect packages consistently.
• Reduce downtime with real-time heat seal imaging that improves operator setup and quality confidence in the process settings, delivering confidence in product quality
• Comprehensive defect management: customizable alerts, automatic rejection, logging, and job storage
• Prevent costly returns and downtime while helping to troubleshoot processes
Interested in learning more about PackChek or the rest of the ClearVision suite? Send us an email at [email protected] or give your local office a call today to begin discussing the unique needs of your facility!
Categorized in: Packaging Vision Inspection