Converting Focus - January 2012

Proteus Packaging Maximizes Folding Carton Production

KENNESAW, Ga.—Following the installation last summer of a high-performance Diana X 115 folder-gluer and Diana Packer packing system from Heidelberg, Proteus Packaging aimed to make the most of its capability for fast, efficient production of short- and long-run folding cartons for pharmaceutical, food, and other markets. With several months' worth of production under its belt, the company claims to have exceeded all expectations.

"What made sense for us, given the speed of the Diana X 115, was to put a packer on it to reduce the need for manual labor, and we're very happy that we did," said executive vice president and COO Tim Wayman. "The performance of both machines has been a revelation. The full-rated speed of the Diana Packer is two-to-four times what we experienced with hand packing. We're now able to handle a greater number of high-volume jobs faster and with greater efficiency than ever before. In addition, our output is up, and our per-piece costs are down."

In this initial phase, Proteus has placed an emphasis on becoming proficient with run speed maximization. Once that is accomplished, Wayman said, the company will focus on further minimizing set-up times on both Diana machines.

At Proteus, the Diana X 115 and Diana Packer support an equipment lineup that includes a Speedmaster XL 145 VLF press, a Speedmaster XL 105, and, in postpress, a Dymatrix 145 diecutter.

Recycled PE Cores

WARMINSTER, Pa.—Double H Plastics now produces precision, extruded plastic cores in reprocessed, as well as virgin high-density polyethylene (HDPE). Sizes offered handle the full range of requirements, from narrow web to wide web, in lengths to 84 inches.

Users can purchase standard lengths, or order them pre-cut on Double H Plastic's precision core cutters. The company also provides cores in custom dimensions of wall thickness, diameter, and other specifications. Special packaging is also offered, and the cores can be both re-used and recycled.

Being moisture-resistant, these cores are dimensionally stable and can be sterilized. And because of their minimal dusting, they're suitable for clean room applications. For film converters and others, cores can be supplied with the specified surface characteristics.

Compact Splicer

WEST CALDWELL, N.J.—CTC International has introduced a smaller version of its CS1224 "Clamshell" Splicer, engineered for non-stop packaging and converting applications. This smaller version is designated the CS1214 Splicer; is only 36˝ long, allowing it to fit in the most compact areas; and can accommodate two full 14˝ diameter rolls.

The new Splicer features CTC's Clamshell Splicer mechanism, which opens 90 degrees into a horizontal plane providing a flat work table to more easily prep the splice. The two unwind shafts for the supply rolls are located at the bottom of the machine close to the floor minimizing material handling during roll loading.

The Splicer also features CTC's "Splice at any speed" System, which guarantees that a change in line speed during the splice will not affect the registration of preprinted materials. Additional options include: splice in register, Ethernet interface, heat seal splicing, wash down or wipe down construction, and CE, UL, or CSA compliance. The machine is customizable for a variety of roll and core sizes and varying line speeds.

Montalvo Upgrades for Increased Productivity

GORHAM, Maine—The Montalvo Corporation offers customers a wide variety of professional upgrades on many pieces of converting equipment, including narrow-web presses, printing presses, corrugators, laminators, cutters, slitters, sheeters, filmers, extruders, waxers, diecutters, and embossers.

President Ed Montalvo says, "We have worked with many customers in numerous markets to accomplish these upgrades to their converting equipment. These improvements have increased productivity and also profitability for our customers."

Montalvo specialists assist with system evaluation, installation, and setup of their equipment on customers' machines. Upgrades can include electronic web tension controls, load cells, clutches, safety chucks, brakes, brake pad assemblies, and other Montalvo products. pP