Background:
A large flexible packaging company operating out-of-state was facing ongoing technical challenges with a triplex laminating machine, originally manufactured in the mid-1990s. This machine, which processes a variety of poly, foil, and paper products, had been running with limited production due to multiple issues, including poor web handling, inconsistent tension control, and repeated e-stop faults caused by intermittent drive communication errors. For several weeks, the machine had struggled to complete automatic cutovers, leading to increased production waste and a growing backlog of orders. The customer had sought assistance from a local system integrator, but after a week and a half of support with limited improvements, they turned to Sure Controls for a more comprehensive solution.
The Challenge:
The machine’s inability to maintain stable tension control and complete automatic cutovers was severely impacting production efficiency. Additionally, intermittent drive communication faults would cause the machine to stop, further disrupting operations. Given the age of the equipment and the complexity of the issues, the customer required a higher level of technical expertise to address the root causes effectively.
The Solution:
After the initial consultation, Sure Controls provided the customer with a comprehensive list of potential causes for the machine’s issues and recommendations for what should be checked or verified. Key actions included: mechanical inspection, electrical calibration, system adjustments and proper validation.
The Results:
Thanks to Sure Controls’ methodical approach and in-depth technical support, the customer saw immediate improvements in the performance of their triplex laminating machine. Key results included:
- Restored Full Production Capacity: The machine was able to resume full production, successfully completing automatic cutovers without issues.
- Enhanced Tension Control: Tension loops were stabilized, allowing for precise tension control within +/- 5 lbs., significantly reducing material waste.
- Improved System Reliability: Repairs to the drive communication network eliminated the recurring e-stop faults, resulting in smoother and uninterrupted production runs.
- Eliminated Backlog: With the machine back to optimal operation, the customer quickly cleared their order backlog and regained production efficiency.
The Conclusion:
This case highlights how Sure Controls’ comprehensive technical expertise can resolve complex machine issues, even in older systems. By diagnosing the root problems and implementing tailored solutions, our team helped the customer restore reliable production, minimize waste, and ensure consistent, high-quality output.
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