Examples of implementations and case studies
Elimination of curvature defects in corrugated cardboard packaging
Thanks to the Perfect Fold technology, corrugated packaging manufacturer Solpap has completely eliminated claims of curvature defects.
Elimination of curvature defects in corrugated cardboard packaging
Assignment
Czech corrugated packaging manufacturer Solpap wanted to improve the bending quality of its packaging and reduce the number of complaints about the shape accuracy of its products.
Solution
We used Perfect Fold technology, which applies softening liquid contactlessly to the two lines of packaging to be folded. The softening liquid reduces the stiffness of the paperboard, allowing it to be folded precisely at the folding edges without much effort.
Results
Since the installation of Perfect Fold, Solpap has not dealt with the curvature of the fold and has no complaint about this defect. Aside from zero complaints, the boxes are overall straighter and customers are happier.
Production of filters for FFP3 breathing masks
Thanks to a collaborative robot solution, the customer can produce per shift more than 8,000 masks with the highest level of respiratory protection.
Production of filters for FFP3 breathing masks
Assignment
The customer's request was to create a solution for creating an assembly for the filter and its anchorage in a plastic body at an application temperature of 110 °C.
Solution
The solution was to use an application head attached to a collaborative robot that cooperates with the production operator. It was necessary to select an appropriate adhesive and set the optimum dosage for the assembly with a wide dimension tolerance field.
Results
The technology adjusted in this way communicates with the robot and doses adhesives as needed automatically. It can produce more than 15,000 filters a day.
Automation of the ironing board gluing process
Switching from a manual work station to automatic allowed the customer to save 25% of the costs for adhesive and 4 production workers
Assignment
Czech corrugated packaging manufacturer Solpap wanted to improve the bending quality of its packaging and reduce the number of complaints about the shape accuracy of its products.
Solution
We used Perfect Fold technology, which applies softening liquid contactlessly to the two lines of packaging to be folded. The softening liquid reduces the stiffness of the paperboard, allowing it to be folded precisely at the folding edges without much effort.
Results
Since the installation of Perfect Fold, Solpap has not dealt with the curvature of the fold and has no complaint about this defect. Aside from zero complaints, the boxes are overall straighter and customers are happier.
Assignment
The customer's request was to create a solution for creating an assembly for the filter and its anchorage in a plastic body at an application temperature of 110 °C.
Solution
The solution was to use an application head attached to a collaborative robot that cooperates with the production operator. It was necessary to select an appropriate adhesive and set the optimum dosage for the assembly with a wide dimension tolerance field.
Results
The technology adjusted in this way communicates with the robot and doses adhesives as needed automatically. It can produce more than 15,000 filters a day.
Assignment
The customer's request was to optimise the existing process of ironing board gluing, which took place using a manual application gun.
Solution
The solution was to switch to an automatic production line. Firmly positioned application heads dose adhesive in a precise constant quantity and in a faster production cycle.
Results
Thanks to the new solution, the customer could save a quarter of the costs for adhesive consumption and 4 production workers, who could be utilised in other parts of the production process.
Automation of the ironing board gluing process
Assignment
The customer's request was to optimise the existing process of ironing board gluing, which took place using a manual application gun.
Solution
The solution was to switch to an automatic production line. Firmly positioned application heads dose adhesive in a precise constant quantity and in a faster production cycle.
Results
Thanks to the new solution, the customer could save a quarter of the costs for adhesive consumption and 4 production workers, who could be utilised in other parts of the production process.
Robotic application of dispersion adhesive for a furniture manufacturer
The automation of the work station allowed the customer to save 6 workers on one shift, who can now be utilised for other production activities.
Robotic application of dispersion adhesive for a furniture manufacturer
Assignment
A furniture manufacturer contacted Kaletech with the requirement to deliver technology for the application of a cold adhesive for anchoring construction bolts. This operation had been made manually so far.
Solution
The solution consisted of an automatic application system for a dispersion adhesive using an industrial robot. The gluing device control unit communicates with the robot and applies the adhesive precisely in the required amount depending on its movement.
Results
Thanks to this solution, the customer acquired a work station operating with sustainable quality and higher production. They saved 6 workers, who can now be utilised for other production activities.
Automatic measurement of hot-melt adhesive quantity
Thanks to the automatic adhesive application management system, we made it possible for our customer to save €35,000 a year on rejects and material.
Automatic measurement of hot-melt adhesive quantity
Assignment
A leading automotive upholstery manufacturer contacted Kaletech with a request for automated measurement of adhesive application for upholstery for car door panels. The customer's main requirement was to keep the adhesive deposit between two layers of upholstery materials constant.
Solution
The solution consisted of the use of a travelling thermal camera which scans and measures the adhesive coating thickness. It evaluates and gives a warning if the layer breaches the limits or indicates future irregularities and produces a report for quality control. The device has the possibility to change the gluing parameters on-line.
Results
The new solution is more efficient from the point of view of adhesive consumption and thanks to the automated measurement system, the quality of uniformity of its application is monitored continuously. Our customer saves €27,000 per year on rejects and €8,500 on adhesive consumption.
Application of hot-melt adhesive for rear car seats
The control unit communicates with an industrial robot and adhesive is applied in the precise quantity and in the desired locations.
Assignment
A furniture manufacturer contacted Kaletech with the requirement to deliver technology for the application of a cold adhesive for anchoring construction bolts. This operation had been made manually so far.
Solution
The solution consisted of an automatic application system for a dispersion adhesive using an industrial robot. The gluing device control unit communicates with the robot and applies the adhesive precisely in the required amount depending on its movement.
Results
Thanks to this solution, the customer acquired a work station operating with sustainable quality and higher production. They saved 6 workers, who can now be utilised for other production activities.
Assignment
A leading automotive upholstery manufacturer contacted Kaletech with a request for automated measurement of adhesive application for upholstery for car door panels. The customer's main requirement was to keep the adhesive deposit between two layers of upholstery materials constant.
Solution
The solution consisted of the use of a travelling thermal camera which scans and measures the adhesive coating thickness. It evaluates and gives a warning if the layer breaches the limits or indicates future irregularities and produces a report for quality control. The device has the possibility to change the gluing parameters on-line.
Results
The new solution is more efficient from the point of view of adhesive consumption and thanks to the automated measurement system, the quality of uniformity of its application is monitored continuously. Our customer saves €27,000 per year on rejects and €8,500 on adhesive consumption.
Assignment
A request from a leading car seat manufacturer involved the delivery of adhesive application technology capable of collaborating with an industrial robot in order to make the production automatic.
Solution
The application head applies a spray coating of hot-melt adhesive. Depending on the movement and position of the industrial robot, it deliberately omits the places above holes.
Results
The result is a fully automated work station with the precise application of the desired layer of adhesive in the desired locations.
Application of hot-melt adhesive for rear car seats
Assignment
A request from a leading car seat manufacturer involved the delivery of adhesive application technology capable of collaborating with an industrial robot in order to make the production automatic.
Solution
The application head applies a spray coating of hot-melt adhesive. Depending on the movement and position of the industrial robot, it deliberately omits the places above holes.
Results
The result is a fully automated work station with the precise application of the desired layer of adhesive in the desired locations.
A universal application head allows variable production
The technical solution allows the customer to produce several products on one line.
A universal application head allows variable production
Assignment
The customer's requirement was to deliver gluing technology which would allow them to change the parameters and gluing width according to the needs of individual products.
Solution
The solution was to design a unique application head with 78 modules and a blade that allows intermittent adhesive application.
Results
The customer can set the parameters and width of gluing for individual products without stopping production for complicated adjustment of the machine.
Retrofitting of a fifty-year-old formwork machine
Thanks to the solution from Kaletech, the customer saved the costs of constructing a new production line.
Retrofitting of a fifty-year-old formwork machine
Assignment
The customer's requirement was to upgrade a 50-year-old formwork machine. Compared to standard production, the edges had to be banded to avoid penetration of moisture in the formwork.
Solution
Kaletech managed to synchronise the operation of the machine with a modern adhesive application system, thus making the original obsolete machine competitive again.
Results
Thanks to the retrofit, the customer can continue using their production technology. In this way, the need to make a considerable investment in a new production line is avoided.
Labelling of bottles with a variable number of joins
The program automatically determines the number of applied coats according to the production program.
Assignment
The customer's requirement was to deliver gluing technology which would allow them to change the parameters and gluing width according to the needs of individual products.
Solution
The solution was to design a unique application head with 78 modules and a blade that allows intermittent adhesive application.
Results
The customer can set the parameters and width of gluing for individual products without stopping production for complicated adjustment of the machine.
Assignment
The customer's requirement was to upgrade a 50-year-old formwork machine. Compared to standard production, the edges had to be banded to avoid penetration of moisture in the formwork.
Solution
Kaletech managed to synchronise the operation of the machine with a modern adhesive application system, thus making the original obsolete machine competitive again.
Results
Thanks to the retrofit, the customer can continue using their production technology. In this way, the need to make a considerable investment in a new production line is avoided.
Assignment
The customer's request was to deliver gluing technology for bottle labelling. They required versatility and the possibility to use the technology for multiple product types, each with a different number of joins.
Solution
The solution was the use of seven application modules for sprayed adhesive application and connection of the control unit with a PLC production program.
Results
The modules apply adhesive at the desired height according to the specific product. Everything is controlled automatically and it is not necessary to adjust the machine settings.
Labelling of bottles with a variable number of joins
Assignment
The customer's request was to deliver gluing technology for bottle labelling. They required versatility and the possibility to use the technology for multiple product types, each with a different number of joins.
Solution
The solution was the use of seven application modules for sprayed adhesive application and connection of the control unit with a PLC production program.
Results
The modules apply adhesive at the desired height according to the specific product. Everything is controlled automatically and it is not necessary to adjust the machine settings.
