Valco Melton
New Akura Coating Solution combines adhesive application and quality inspection for improved process efficiency

29.03.2023 The ICE Europe exhibition was seen as an excellent opportunity for Valco Melton (Cincinnati, Ohio) to showcase their innovative Akura Hot Melt Coating Solution. They offer converters a reliable system to achieve uniform adhesive coating across the entire web width, without the need for manual intervention. This not only ensures better product quality but also reduces the risk of production errors and waste, thus resulting in significant cost savings.

Valco Melton’s Akura Solution.
© Photo: Valco Melton
Valco Melton’s Akura Solution.

The Akura Solution combines Valco Melton’s Akura hot melt coating applicators with their Inspekt range of quality assurance tools. Their Akura applicators feature a number of independent hydraulic zones based on the requirements of each project. Each zone is fed by a gear pump, which ensures an even distribution of the adhesive across the web width. Their Weight-Inspekt grammage control system enables the average grammage of each hydraulic zone to be controlled in a closed-loop with the gear pumps. If any deviations in the adhesive grammage are detected, the system automatically adjusts the adhesive flow for the specific hydraulic zone, ensuring consistent product quality.

Providing a complete solution

As a manufacturer of adhesive dispensing equipment, Valco Melton takes pride in providing a complete solution that covers the entire hot melt coating process, from adhesive melting and dosing, to application, web handling, and quality inspection. To meet the varying needs of different processes, they offer a selection of pre-melters, buffer tanks, and melters that cater to all melting requirements.

Their Inspekt range of quality inspection systems is designed to provide converters with the tools they need to ensure their products are defect-free. Weight-Inspekt grammage control systems measure the adhesive coat weight, independently from the substrate thickness. This in-line system controls product grammage in close-loop with the gear pumps on the applicator without stopping the line, thus preventing product waste. On the other hand, Coat-Inspekt vision inspection system combines real-time error detection with an artificial intelligence system that automatically classifies all errors detected into pre-set categories, providing an immediate and intuitive overview of production status. This, together with the historical data stored in the system, brings users a powerful tool for process analysis, as well as indications on defect positioning for elimination on the following step of the process.

Prioritising product traceability

With their comprehensive Akura Solution and LP Coating Lines, which include Akura applicators and the Inspekt range of quality inspection systems, the manufacturer prioritises product traceability. The solution provides users with a detailed report for each of the rolls produced. This report includes a roll map with the position, details, and images of every defect detected by the Coat-Inspekt vision inspection camera, a map of adhesive distribution across web width and length, and the working parameters defined in the recipe for each of the rolls produced.