Warping keeps happening? The problem might be with moisture control-Vemede IQ Humidity Chamber lets the data do the talking
Smith & McLaurin is a leading UK manufacturer of pressure-sensitive labels, tickets, and label materials. In 2023, the company made a key investment by replacing the traditional steam re-moisturizing box with a Vemayd IQ re-moisturizing box, taking product quality and production efficiency to a whole new level.
Picture: Wemate IQ Rehumidification System
A Key Investment in Moisture Control
Years ago, at the ICE International Label Show, Smith & McLaurin first came across Wemate's rehumidification system, which became a significant turning point for the company. At that time, they were facing serious quality issues with their existing steam rehumidification boxes, including insufficient humidity levels and uncontrollable lateral profiles that caused CD crosswise warping. On top of that, the cumbersome manual adjustment of the steam valves made production operations quite challenging.
Seeing the huge potential of Wemate's solution, Smith & McLaurin made the strategic decision in 2023 to invest in the Wemate IQ Rehumidification Box. This decision was based on several factors: it's a water-based system provided by a reputable global supplier, featuring innovative technology that effectively meets their current needs. Plus, since it eliminates the need for steam and the extra costs of boiler maintenance, the return on investment is also pretty straightforward.
Picture: Smith & McLaurin Production Site
Improving Operational Efficiency and Production Performance
The Weimade IQ Re-moisturizing Box has completely changed the way Smith & McLaurin operators work. Startup times have been greatly reduced, and the system automatically adjusts once the machine reaches operating speed, eliminating the need for manual steam valve operations. Additionally, the re-moisturizing level for each paper type can be preset, significantly increasing the production time of qualified products.
Since production is no longer limited by the speed of the steam re-moisturizing box, production speeds can be maintained effortlessly. Compared to before, control over the re-moisturizing level is more precise and efficient.
Jim Yule
Chief Engineer, Smith & McLaurin
Enhancing Quality and Reducing Waste
The implementation of the Weimade IQ Re-moisturizing Box has significantly improved Smith & McLaurin's operational efficiency and end-product quality. It completely solved the problem of insufficient re-moisturizing capacity, allowing machine speed to be easily maintained, and the re-moisturizing box is no longer a bottleneck.
Compared to the old steam re-moisturizing system, warping in some products has decreased by 101%, with an average reduction of 63% across all inspected product ranges. For some products, the re-moisturizing level increased by 32% compared to steam re-moisturizing, with an average increase of 19% across all inspected products.
Moisture content is now more uniform and easier to control. Meanwhile, bottom paper warping issues have been completely eliminated, so they are no longer a quality concern. Additionally, the scrap rate has been significantly reduced, especially during startup – previously, steam leaks would easily dampen the paper, causing frequent breakages.
Chart: Comparison of Warpage Levels and Base Paper Moisture Between Steam Rehumidification and Voith IQ Rehumidifier
Successful Projects and Excellent Collaboration
Throughout the entire installation, Smith & McLaurin were impressed by Voith's project execution capabilities. During the commissioning phase and beyond, any issues were met with Voith's quick and professional response. The Voith IQ rehumidifier is easy to operate, and the production team gave positive feedback. It greatly simplifies operations, eliminates the need to manually adjust steam valves, and, with the retirement of the Fulton boilers, saves over £4,000 in annual maintenance costs.
"Voith is a reliable and excellent partner for us. The collaboration between Smith & McLaurin and Voith has been outstanding from start to finish. Project execution was professional and thorough, and even though this was a significant change for our production practices, the results have been extremely successful," Jim Yule commented.