Flexographic printing usually takes place inline: a product passes through the equipment, and one or multiple colors are laid down in an orderly print of the customers design. Flexographic printing usually takes place inline: a product passes through the equipment, and one or multiple colors are laid down in an orderly print. Often the speed of the press is so fast that hi speed camera systems need to be used to make sure the printed material maintains registration. Most often, the printed material also passes through dryers, either between colors, or as a finished product, prior to being rewound.
Placing products into a wrap, tub, pouch, carton, or any means of making the product saleable or transportable is a common controls application. Machine builders create machines to fit their customers product and package type, and the machine needs to be controllable by an operator to run as fast as possible while maintaining absolute safety.
We have been involved in designing sheet feeders, sheet stackers, laminators, perforators, and folders. In every instance, the electrical control design allowed for line and part speeds which met or exceeded customer demands.
We have been involved in extrusion systems for blown film, bags, and oil containment cloths. We have experience in the blow molding industry with robotic operation of the presses, both feeding and extracting parts.
Converting is a misunderstood word to people not in the industry. It can take the shape of unwinding a large parent roll, performing a process on it, such as coating, slitting, perforating, or printing, and then rerolling it, or possibly feeding it into a sheeting machine and then stacking the sheets. It could be taking a large roll, cutting the product into sheets, folding and interfolding it, and sending it into a packaging machine to be wrapped. We have also done rolls of product, cut into sheets and stacked, applied wetting solutions and then put the stacks into pouches or tubs of wet wipe type product.
We have been involved in projects which packaged sterile equipment into sealed bags or pouches.
In most cases, the food processing we have done is in packaging the final product, however, we have provided controls for yogurt mixers. One application involved weighting cheese as it was shredded, and dispensing it onto pizzas. Individual pizza weights controlled the amount of cheese being shredded.
Gain Control has been instrumental in building affordable COP and CIP systems for use in cheese plants. We have also done control systems for butter churns, pasteurization tanks and batch mixing tanks and systems.
Gain Control works with conveying systems, wrapping machines, and palletizing and unpalletizing equipment. We remanufactured a machine which counts and detects numerous various defects in nuts, bolts and fittings at high speed. We have been involved in load and collision monitoring systems for cranes, and railroad bridge controls for numerous configurations of bridges.