Achieving quality leap in self-adhesive labelling with Valmet IQ Moisturizer

A key investment

A pivotal moment occurred for Smith & McLaurin years ago at the ICE exhibition when they were introduced to Valmet’s moisturizing system. At that time, they were struggling with significant quality challenges on their current steam moisturizer, including low moisture levels and inability to control moisture profiles which lead to cross-directional curling. Moreover, the cumbersome manual adjustments required for steam valves added to their operational challenges.

Recognizing the potential of Valmet's solution, Smith & McLaurin made the strategic decision to invest in the Valmet IQ Moisturizer in 2023. This decision was based on several factors, including it was a water-based system offered by a reputable global supplier with innovative technology, and clear benefits for their current needs. Additionally, they were able to calculate the return of investment due to the elimination of steam usage and the additional costs associated with boiler maintenance.

Enhancing operation efficiency and production performance

The Valmet IQ Moisturizer has revolutionized the work of the operators at Smith & McLaurin. Start-up times are now much shorter, as the system automatically adjusts once the machine is up to speed, eliminating the need for manual steam valve operations. Furthermore, moisture levels are pre-set for each grade, resulting in a significant increase in on-spec production time.

Speed can now be easily maintained because the steam humidifier is no longer restricting the speed. The moisture can be controlled more accurately and efficiently than before." comments Jim Yule, Chief Engineer, Smith & McLaurin.

Improved quality and reduced waste

The implementation of the Valmet IQ Moisturizer has significantly increased operational efficiency and end-product quality at Smith & McLaurin. It has eliminated the problem of low moisturizing capacity and enables effortless maintenance of machine speed without the moisturizer being a capacity limitation.

The reduction in curling has reached up to 101% for some products when compared to the old steam humidifier, with an average reduction of 63% across the inspected product ranges. Moisture levels have increased by up to 32% on certain products compared to steam humidifying, with an average increase of 19% within the inspected product ranges.

Moisture content is now more uniform, and levels can now be easily controlled. Also, release liner curl has been eliminated totally and it is not a quality problem anymore. Additionally, waste has been reduced, especially during the start-up, where breaks could easily occur due to soaked sheets caused by steam leaks.

  Curl amount and backing material moisture with steam humidification vs. Valmet IQ Moisturizer  

A successful project and great collaboration

Smith & McLaurin was impressed with Valmet's project performance throughout the installation process. During and after the commissioning phase, any issues were promptly and professionally addressed by Valmet. The Valmet IQ Moisturizer proved to be easy to use, with positive feedback from production. It simplified operations significantly, eliminating the need for manual steam valve adjustments and saving over £4000 per year in maintenance costs from the decommissioning of the Fulton boiler.

‘Valmet is a good partner we can trust. The collaboration between Smith & McLaurin and Valmet has been excellent from start to finish. The project was executed professionally, and despite being a major change in operating philosophy for production, it has been highly successful.’ comments Jim Yule.