Every day, the team at Sauer System wakes up thinking about improved solutions for making a square box. The field team thinks of faster ways to install them and get the best performance possible. The engineering team works on improved designs. The production team makes plans to produce these solutions faster and at scale. And the sales team considers how to get the word out.
More than ever, the corrugated industry needs an organization that cares about these things. Sauer System, with its industry leading tooling, machine upgrades, application knowledge, and field presence, is that organization.
“We want to be known as the square box people,” says Peter Sauer, VP of Sales and fourth generation to serve the industry. “We want to be your first call if you are struggling with square box issues on any make, model, or vintage flexo folder-gluer.”
Since its founding in 1926, Sauer has been an industry leader. As the 1929 purchase order for scoring tools pictured below illustrates, Sauer’s involvement with the corrugated industry started early on. Sauer provides the box-making industry with tooling for scoring, creasing, crushing, slotting, die cutting, slit-scoring, and perforating. Many of the applications for these tools were pioneered by Sauer System.
Per Sauer, “In addition to working with corrugated box makers, we have a long history of working with machine manufacturers such as S&S, Koppers, Langston and McKinley. And we continue working with today’s OEMs. As corrugated box making machines have evolved, so has Sauer tooling. It is an integral part of improving the performance of today’s high-speed flexo folder-gluers.”
One of the cornerstone solutions in Sauer System’s arsenal for folding a square box is the G3 male scoring profile. The G3 profile has evolved and improved over the years for optimal scoring on today’s paper grades, including board with heavy recycled content. The G3 was brought to market in 2008, then revamped in 2010, and then again in 2016. This process continues today through empirical data-driven analysis. Sauer has always been committed to having the best and most proven scoring technology available.
As part of its scoring system, Sauer System provides precision ground polyurethane female scoring heads and rings to run against the male scorers. The consistent outer diameter of the female scorers allows for even scoring pressure and reduced liner fracturing. Per Sauer, “We noticed that other manufacturers’ female scorers may vary in diameter. Our bonded females are ground within .002.” They are precise and consistent. They provide even scoring pressure and allow us to successfully utilize softer durometers. It is amazing how imprecise females, with a hard durometer, create issues. They can shut down a complete machine line due to poor score quality leading to unacceptable gap variation.”
More recently, Sauer System has presented the industry with a variety of folding section upgrades. One upgrade that gained market acceptance immediately is the Sauer System Hold-Down Roller Eliminator (HDRE). This upgrade replaces the hold-down rollers used in modern flexo folder-gluers with a sturdy, spring-loaded system that puts continuous pressure on the transfer belts. This improves sheet control through the folding section and eliminates individual failure points. Another upgrade is the Sauer System FRX Adjustable Folding Rod System. The FRX system improves fold quality by controlling box flaps during folding. As an aid to machine operators, swivel points are index stamped to allow for faster and repeatable setups.
Sauer rounds out its offering with training and field service. Per Sauer, “In our industry, companies that seek to solve real-world problems must have a team in place to support their products and solutions. The team must have technical knowledge, expertise, and experience. Sauer’s team participates in the challenge of solving real world box-making issues on a daily basis.”
Sauer System continues to bring new products to market including split folding belt pulleys, improved precreaser profiles, and more folding section upgrades. “Gap variation is the enemy,” says Sauer. “It is amazing how tough it can be to identify the root cause of gap variation, but in every case, we are determined to work through the issues. We have identified at least 32 machine issues that can cause gap variation. Our troubleshooting process includes all of them.”
During a recent meeting of the minds, Rick Putch, long time industry veteran and Director of Technical Services and Process Improvement for National Steel Rule, was quick to praise Sauer System, “I learned about Sauer’s attention to detail nearly 50 years ago when breaking into the steel rule die making trade. Their machinery and tooling for cutting die manufacturing was then, and still is exceptional. To solve rolling score issues in die cutting, I often try to mimic the G3 scoring profile because of the success I have seen with it on flexo folder-gluers. Taking a tour of their facility recently, I was awe-struck with their capabilities, process repeatability, and personnel. Sauer indisputably understands the developments in containerboard and what’s needed for making a square box. When TAPPI was looking for an author for an updated edition of the Corrugated Defect Remedy Manual, I didn’t even have to think twice, I tapped Sauer. Their knowledge regarding scoring and folding is unparalleled in the industry.”
Meanwhile, Sauer sees the expectations of the industry growing as box makers and OEMs consolidate.
The team at Sauer believes that the way to solve the square box problem is a solid understanding of a machine’s operation and mechanical fundamentals. “From the company’s founding, Sauer System has built its box making knowledgebase. When we say the reason for inconsistent manufacturer’s gaps is a scoring problem, you can be confident we’ve seen it before. If the scoring profile is not optimized for the grade of board, chances are we have a solution. Reliable, precision mechanical parts will always be necessary to produce a square box.”
And nearly 100 years later, the Sauer System still works.
