The objective of these kits is to satisfy the market demand concerning the quality of the final product. Zero Defects is a way of thinking and doing that reinforces the notion that defects are not acceptable. With a philosophy of zero defects, our customers can reduce the cost of failure and increase revenues through increased customer satisfaction.
Advanced high speed production lines are typically equipped with vision systems looking at each product to detect defect and waste the defective ones in order to ensure no faulty product are sold in the market; traditional waste handling solutions are culling at least 3 products for each defective one (one before and one after) to ensure the “bad one” is actually rejected.
The single culling system (Index11 Award-winning) is the new concept of waste solution that ensures only the defective product is rejected with potential of 33% waste reduction for product application defects. This solution includes the vision system to detect the product defects, the high speed servo drive waste gate (to be able to eject one single product) and the signal handling SW.
The core of the system is the algorithm that handles the signals from vision system to machine PLC and activating the waste gate ensuring that the right product is always ejected. Another important fact is that the single culling system is available for new machines as well as a retrofit kit for existing machines and is now vision system brand-independent so it is potentially adaptable to every machines and vision systems.
GDM has designed a solution able to improve baby diapers overall quality and enhance manufacturers’ sales through consumers’ satisfaction.
The new kit for product longitudinal folding is based on “Coanda” aerodynamic effect and aims to eliminate frictions between web and folding plates. The elliptical folding plates are equipped with a series of small holes manufactured at a specific angle.
Compressed air is blown through them creating a fluid “cushion”, which reduces friction between rear wings and folding plates. Two step folding process (operator and drive) allows splitting the folding sequence into two distinct phases.
In order to reduce the glue quantity consumption and to guarantee the necessary mechanical characteristics of the tape applied onto the rear wing sub-layer, a new type of ultrasonic welding unit has been developed to reinforce the tape fixation.
The system allows using a light quantity of glue just to set the tape on the rear wings web until it reaches the welding unit, where through the Ultra Sonic Bonding technology, the Tape Tab is fixed onto the rear wing sub-layer through a heating process; different welding patterns can be used according to product specification.
GDM high speed unwinding unit is able to run at 600 meters / min in operations with a max roll diameter of 1,500 mm. It includes the “zero speed” splicing technology and the new easy web preparation in order to reduce the time for the splice preparation.
The unit includes a vertical buffer equipped with high efficiency rollers, floating carriage and vertical filling.
