For 3 Sigma Corp. (Troy, OH), a producer of specialty pressure-sensitive adhesive-coated products, having perfectly flat substrates are imperative to create quality coated products. So when it began encountering curling issues on its hot-melt units as the paper reached the lamination point, the company knew it was time to replace its existing tension controls.

3 Sigma retrofitted its three hot-melt machines with FMS USA, Inc.'s (www.fms-technology.com) CMGZ612A digital tension controller. “We received a good price and were impressed by the quality of the product,” says Randy Corns, production manager. “They were even better than what we hoped for. We thought it would be about the same (as the old tension controllers) but it had better control of the tension.”

The CMGZ612A can control the unwind brake or drive, intermediate drive or the winding drive and has two channels/independent closed loops for control of two tension zones in any configuration. A correction input for diameter signal, line speed or reference value is provided for each channel. The controller can then continuously adapt the tension to the changing diameter.

“We can control the curl better by adjusting the tension,” Corns adds. “(Now) the tension is very consistent and steady.”

The CMGZ612A has a 2-millisecond cycle, which enables it to react quickly to changes. Since the installation of the controllers, 3 Sigma has experienced increased productivity and less rework and scrap.

Since the addition of the FMS components in 2004, 3 Sigma has been experiencing double-digit growth. In 2005, the converter added 45,000 sq ft to its facility to house its current solvent coaters. “We've had several customers requesting solvent-based products,” Corns explains. “Adding the solvent coaters allows us to be more competitive and to take on the solvent-adhesive market.”

3 Sigma serves small- to medium-sized label converters, providing them with p-s roll label products such as solvent-based adhesive constructions, pattern-coated products (its specialty), multi-ply constructions, coated film stock, among others. It also manufactures repositionable RPN mail and news labels, Universal Coupon Film™, Anchorseal® and Extend-a-Seal™ lines.

Using its “fitness-for-use” criteria, 3 Sigma constructs specialty products for its customers based on specific requirements. According to Corns, being a specialty converter is the reason the company has been growing exponentially and will continue to do so.

“The big change seems to come from the fact that the manufacturing of commodity items being sent overseas is growing and the manufacturing of specialty items is staying here,” Corns concludes.

3 Sigma also gets specialty projects from an unlikely place—its own competitors. “They are calling up and asking us to do their smaller orders, which are a truckload for us,” he says.

To keep up with demand, 3 Sigma has been adding equipment steadily to be ready for whatever products it needs to make. “We just have to be versatile and grow with our customers,” Corns explains.

Not only does 3 Sigma have to be able to make the products, but it has to be able to do it within a three-day turnaround, five for custom projects. And customers want them even faster, which is where having the right equipment, components and materials come in to play. The FMS components enable the converter to keep up with the demand in that they reduce or eliminate the time it needs to rework products.

“The FMS units are simple to use and whenever we have an opportunity to replace controls, we're probably going to go with FMS,” Corns says.