LAMATEK™ Relies on Delta ModTech Support to Turn Potential into Performance

LAMATEK, an adhesive-backed foam tape and gasket converter, had invested in a Delta ModTech machine because they knew it would open the door to new opportunities. But winning new business and delivering on demanding project requirements are two different challenges. To produce for new customers, particularly on a complex die-to-die registration project, LAMATEK would have to rely on what truly differentiates Delta ModTech from the rest: its people.

Challenge

Since 1983, LAMATEK has been serving a wide variety of industries with die-cutting, laminating, slitting, and custom converting services. The company had enjoyed steady growth and success over the years, but they eventually hit a ceiling with their more advanced converting capabilities. They had been forced to pass on increasingly complex work.

To break through that ceiling, the company decided to purchase a Crusader® converting system from Delta ModTech. The investment paid off, as they landed a new customer with a challenging die-to-die registration project. This was precisely what LAMATEK had in mind when they purchased the Crusader. Now it had to deliver the goods.

Process Manager John Tice was confident in his ability to run the Crusader. Over the years, he had operated nearly every machine in LAMATEK’s plant and was familiar with the ins and outs of the platform. This project, however, introduced additional complexity, requiring modular components beyond the press alone.

The job required a three-die setup with multiple cuts around the parts, as well as slug removal. Tolerances were tight: .015” on all four walls of the gasket, with everything centered on the pad. The gasket wall itself measured only .2 to .6 inches wide.

For Tice, the core challenge was configuring the camera system so the dies would register correctly.

“The stations had to talk to each other to get that really accurate part, because we had a tolerance of .015”,” he said. “If it’s not working correctly, or you don’t have your tension set up properly, then the parts fall outside of our tolerance and result in waste.”

Solution

John Tice jumped right in and began experimenting with the Crusader, adjusting tensions, modifying web paths, and fine-tuning material feeds. While progress was being made, the team encountered a challenge when it came to integrating Crusader’s modular machine-vision detection system.

The machine-vision system was new to production, but LAMATEK’s team drew on over 40 years of manufacturing and die-cutting expertise to adapt quickly. “It was my first time working with a camera-vision system that could identify parts and communicate across modules,” Tice said.

Delta understands that the Crusader’s modular capabilities can challenge even the most experienced operators. Advanced systems integrations often require support beyond initial machine training. For that reason, the company’s support infrastructure is as critical as the machine itself.

Through a combination of emails and phone calls, Delta’s support team helped John navigate the setup, including identifying the correct plug-in sources for the sensors. With a few targeted adjustments, the line was soon running effectively.

Throughput

LAMATEK’s early experimentation—including changes to the vision system and tension control—initially generated scrap, and part quality suffered.

“But after all my research, working with Delta and making the necessary adjustments, I was able to improve the numbers,” Tice said.

The experience also reinforced that taking on more complex projects requires expertise not only on the operating side, but also in cost estimating.

The die-to-die registration project gave LAMATEK a deeper understanding of the machine’s capabilities and how future jobs should be quoted.

“Understanding the capabilities and process speeds of the machine definitely makes an impact on how we’re quoting things today,” said Dan Bussell, Senior Job Estimator. “Without that knowledge base, it’s harder to quote as accurately as we want to.”

LAMATEK’s combination of refined operating and estimating expertise positions the company to successfully tackle increasingly complex projects in the future.

The Experience: Support Turns Potential into Performance

Working with Delta ModTech created a ripple effect across LAMATEK’s organization. The company is now better positioned to pursue new opportunities, operate at tighter tolerances, and cut more complex geometries. They’ve also simplified documentation and validation.

Still, the Crusader’s full potential cannot be realized without strong support.

“We brought them some challenging applications. Instead of trying to fit us into a standard solution, they worked through it with us. They asked questions, looked at materials, and tried to understand the process,” said Dan Bussell.

John Tice pointed to the impact of specific individuals on Delta’s team, who combined to help LAMATEK solve problems every step of the way.

“The associate who trained us, Jeremy Tummel, was intelligent and knew everything about that machine,” Tice said. “We’ve also worked with Mike Schehr and Eric Maroney. They always get back to us with great information.”

The support stands out in an industry where that level of engagement is not always guaranteed. “It’s great because we don’t just get technical machine support from Delta. Their marketing team also provides us with invaluable insight as to where LAMATEK fits into the market,” said Jennifer Lucano, Creative Director.

In a results-driven business, it is an organization’s ability to turn a machine’s potential into real-world performance that ultimately makes the difference.

---

OVERCOME YOUR BIGGEST CONVERTING AND PACKAGING CHALLENGES