JBC Technologies Solved the Problem, Delta ModTech Doubled the Throughput
JBC Technologies is a precision die cutter and flexible materials converter, specializing in custom solutions for medical, aerospace and defense, and battery energy storage applications.
The company is known for tackling technically demanding projects that require advanced engineering support and design-for-manufacturability expertise.
“We get all the fun parts,” said Engineering Manager Dominic Bowlin. “We usually don’t get any of the easy ones.”
Their elite engineering team was put to the test when JBC took on an especially challenging continuous glucose monitoring (CGM) patch overlay project.
Summary
Challenge: New materials and a tricky application
For JBC, the CGM patch overlay project introduced several new challenges, including a new part design. The part required a fabric-based material that was going to be difficult to convert consistently.
“Fabrics tend to be a little bit challenging due to their fibrous structure,” Bowlin explained. “If cuts are incomplete, residual fibers can create downstream quality and handling issues.”
The project also required a niche island-placement process that involved the precise placement of a deadening film in the center of the part. JBC also had a number of process challenges, including static buildup and slug removal.
“There were a lot of moving pieces,” Bowlin said.
Because of the process complexity, JBC knew that Delta ModTech’s Crusader was the right system for the project. They also relied on Delta’s process engineers to help maximize the Crusader’s capabilities.
Solution: Combining JBC’s engineering expertise with Delta’s process support
JBC developed the initial baseline process internally. But the throughput was falling short of the original production targets. “It was definitely a bit tenuous at first,” Dominic said.
Delta provided a number of recommendations, including more advanced re-registration strategies.
“We were doing a niche island placement of a deadening film in the center of the part, which is a technically complex processing application.“
Dominic Bowlin, Engineering Manager
The collaboration also included tooling innovations such as bump dies that applied pressure during transfer applications without cutting material.
They also helped fine-tune web tension considerations for stretch-prone materials and optimize slug management. “With this family of parts, there were a lot of slugs,” Bowlin said.
Throughput Improvement: From 150 pouches per hour to 400
JBC’s initial production runs had averaged roughly 150–200 pouches per hour, with each pouch containing 25 parts.
After Delta’s recommended process optimization and tooling refinements, throughput significantly improved.
“We are closer to 300 to 400 pouches an hour now.”
Dominic Bowlin, Engineering Manager
The improvement represented roughly double the original throughput while helping create a more stable and repeatable process. For JBC, however, the project was never just about hitting a single number.
“Continuous improvement is a big priority for us,” Bowlin said. “Now what does it look like to get to 500 an hour?”
Working with Delta ModTech: A platform JBC’s engineers trust
JBC has been a long-time partner of Delta, and Bowlin cites numerous advantages to working with the converting machine manufacturer.
Beyond the technical support, Bowlin emphasized the operational advantages of Delta’s platform.
“Delta presses are consistently the preferred choice among our engineering team.”
Dominic Bowlin, Engineering Manager
Bowlin said the team values the ability to standardize across Delta platforms, simplifying both engineering and day-to-day operations. “It’s nice to have a platform that you like, and then you can standardize across it,” he said.
The team also finds the Crusader® easy to use. In fact, they own multiple machines and often use them interchangeably.
JBC also highlighted Delta’s responsiveness in service and support as a major differentiator. “Service is second to none with them, and it’s critical to our operational success.”
Making the not-so-easy jobs easier
For JBC Technologies, the CGM project reinforced the value of combining their strong internal engineering expertise with Delta’s experienced equipment and process engineers.
As Bowlin explained, some manufacturing challenges are not about whether engineers can create a functioning process. They also require the right combination of machine capability, process expertise, and industry experience.
That’s where the partnership between JBC Technologies and Delta ModTech helped transform a difficult CGM application into a scalable manufacturing process.
