Abbott Action, a premier provider of corrugated packaging and POP displays, announced the recent installation of new ClearVision systems at their plant in Attleboro, Massachusetts. This collaboration marks a significant milestone as Abbott Action becomes the first independent corrugated plant in the Northeast to install Valco Melton’s state-of-the-art PrintChek and GapChek systems.
With these systems and Abbott’s proactive approach to quality assurance, they can now guarantee 100 percent inspection of the print and manufacturers gaps on every box and sheet, making it possible for Abbott Action to deliver nothing but perfect boxes to their customers.
Valco Melton’s PrintChek and GapChek systems represent the pinnacle of vision-based inspection technology for the corrugated industry. PrintChek, installed on Abbott Action’s Apstar rotary die cutter, is positioned after the last print down and before the die cut section.
PrintChek’s camera and lighting modules are enclosed in a robust housing designed with the corrugated environment in mind. A high-flow, low-pressure blower supplied with the system, provides air across the plenum, keeping lighting and cameras free of dust, ink, and debris. This thoughtful design also features a shutter mechanism that closes and protects the lights and camera lenses during maintenance and wash-up.
The system utilizes a series of color line scan cameras for full sheet print inspection on FlexoFolderGluers and DieCutters. PrintChek images and analyzes every sheet to detect defects, including issues with print-to-sheet, print-to-print, color, barcodes, spots, hickeys, blemishes, and other non-print-related board damage. The system’s full-sheet inspection capabilities allow operators to run at full speed with 100 percent confidence.
GapChek, implemented on Abbott Action’s Isowa Falcon, focuses on measuring and ensuring the accuracy of every manufacturer’s gap. GapChek straddles the discharge conveyor after the counter ejector, employing two cameras that automatically move across the conveyor to find and image the finished manufacturer’s joints.
These images are then analyzed, measured, and classified as passing or defective using ClearVision’s proprietary AI process, making GapChek a powerful tool to provide near real-time feedback to operators as well as sorting individual defects from the production stream. A visual statistical process control (SPC) chart and measurements of CP and CPK values are also displayed on the 22” touch screen HMI.
Abbott Action has also implemented Valco Melton’s GlueChek system, further solidifying their commitment to delivering flawless products. GlueChek, installed right after the gluing station, utilizes advanced camera technology to analyze glue patterns, ensuring that no gluing problems make it to the customers.
The system takes a picture of every glue tab, meticulously examining the glue pattern for any defects such as, missing glue, glue volume, glue position, and more. When a gluing problem is detected, GlueChek immediately notifies operators through an alarm, marks the defective box, and saves an image of the gluing issue.
These systems give Abbott’s leaders the confidence and data they need to deliver quality boxes to their customers, even at the highest production rates, and with stringent demands from their customers.
The implementation of Valco Melton’s PrintChek, GapChek, and GlueChek systems has significantly enhanced Abbott Action’s production capabilities and quality assurance processes. The impact of this investment is best described by the company’s leadership:
“Abbott Action has been working with Valco Melton for years, we truly enjoy their support of our organization. As we have grown our business, the quality we deliver to our customers is paramount. It is exciting to utilize the cutting-edge technology that not only creates a more efficient production environment, but it also allows us to deliver the highest standard to our customers,” says Sam Abbott, CEO Abbott Action.
This underscores the strategic importance of the ClearVision systems in Abbott Action’s commitment to delivering superior quality products to their customers. The partnership between Abbott Action and Valco Melton demonstrates how cutting-edge technology can drive innovation and excellence in the corrugated packaging industry.
Valco Melton is a provider of adhesive application equipment and quality assurance systems for the corrugated industry. Their ClearVision suite of inspection equipment offers comprehensive solutions for box manufacturing process inspection.
Abbott Action is a third-generation family business, founded in 1935.
