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Tag: stretch wrapping

End of Packaging Line Solutions

Posted on by David Priestman

More and more processes at the end of today’s production and packaging lines are digital and networked. But what’s the best way to organize these processes to ensure they run smoothly as possible? Mosca will be showcasing complete strapping and stretch wrapping solutions that can be fully integrated into upstream systems at LogiMAT 2024 (Hall 4, Stand 4D21). The Mosca KZV-111 and Movitec Saturn S6 rotary ring stretch wrapping machine are two solutions designed to secure entire pallets. For strapping individual packages, the Mosca product portfolio includes the SoniXs TR-Connect and SoniXs MP-6 T.

Full or partial packaging line automation offers great potential for increasing efficiency and throughput in high-volume industrial operations with multi-stage production, packaging and securing of palletised products for transport. Efficient integration of all line components is critical. Mosca CEO Timo Mosca explains: “When different machines are setup to work together seamlessly, they need to be compatible with each other as well as with add-on conveyor technology and other equipment. The SoniXs TR-Connect we are presenting at LogiMAT is just one of our high-performance machines that can be easily integrated into complex IoT applications. We will also be demonstrating the SoniXs MP-6 T in combination with a robotic arm from Pinger Robotic to show what such a fully automated packaging system can look like.”

Ready for the Internet of Things and high performance

The SoniXs TR-Connect comes with an all-inclusive digital package. This machine was launched on the market in 2023 as the successor to the SoniXs TR-6 Pro and SoniXs TR-6 Base. Featuring an integrated WebHMI, it can be operated via LAN interface using customer devices or optionally via tablet attached to the machine. Users can view key parameters – including performance, strapping settings and availability – and easily adjust them to their specific requirements. The data generated by the machine can also be used to comprehensively analyse performance and predict maintenance intervals.

The machine’s standard interface makes it possible to seamlessly integrate the units into a fully automated line, where it shines with an output capacity of up to 45 strapped packages per minute. Thanks to automatic Cycle Rate Adjustment (CRA), the machine adapts to the throughput of upstream machines and processes. When it receives info about changing package sizes via sensors or interface signals, it can also automatically change product data presets.

Robotics enable production line integration

The Mosca exhibit at LogiMAT also features a SoniXs MP-6 T machine designed for strapping single boxes and packages. This table version is normally loaded manually with packages wider than a minimum 60 cm. In the application at LogiMAT, the strapping machine requires no human intervention. This cost-effective solution uses a robotic arm from Pinger Robotic to easily load the SoniXs MP-6 T with small packages. Thanks to robotics, the stand-alone machine can be integrated into a fully automated line. The robot is also extremely flexible when it comes to transporting boxes and can load them into the SoniXs MP-6 T lengthways or crossways as required. When extra-secure cross strapping is required, the robot inserts the package, removes it after strapping, turns it around and repositions it in the machine. Johannes Wieder, Mosca Sales Manager Logistics explains: “Thanks to their outstanding versatility and small footprint, solutions like the robotic arm presented at LogiMAT offer an extremely practical alternative to inflexible conveyor technology.”

Power for secure pallets

After products have been bundled and boxes are securely closed, there is one more important step necessary in intra and retail logistics: packing and securing the products on pallets. For this application, Mosca will be showcasing two solutions from its product portfolio at LogiMAT 2024: the Movitec Saturn S6 rotary ring stretch wrapping machine and the KZV-111 pallet strapping machine. The Saturn S6 secures up to 120 loaded pallets per hour and is suitable for high production volume throughput. In the demonstration presented at the trade fair, a load unit enters the top selling machine manufactured by Movitec, a Mosca subsidiary. The unit is then secured by a ring stretch wrapper without having to be moved again. The Saturn S6 is ideal for stacked smaller, single product cardboard boxes that are also weather protected thanks to the stretch wrap.

On the other side of the roller conveyor, the KZV-111 is ready to take orders at LogiMAT. This machine uses SoniXs ultrasonic technology to strap packages in just 12 seconds with maximum efficiency and minimum emissions. The strap lance moves through the pallet base and the sealing unit approaches the load unit from above. The KZV-111 is available in different versions with a strap lance or closed strap frame designed for handling palletised or non-palletised products. This model is ideal for palletised goods that are packed in boxes and do not require additional moisture protection.

Packaging company launches automated e-Commerce system

Posted on by David Priestman

Partnering with shrink and stretch wrapping specialist Yorkshire Packaging Systems, Clearmark Solutions has launched its latest innovative and labour-saving automated e-Commerce system.

Mounted within the innovative bagging unit, Clearmark’s Direct Print & Apply ICE Vulcan labelling machine integrates seamlessly with the Hugo Beck Flexo e-Comm range of bagging machines. Processing more than 1,200 packages per hour, the labour-saving system prints and applies address labels with precision directly onto the film as the product is enveloped into a shipment bag.

Fulfilling e-Commerce GDPR compliance rules and guaranteeing accurate labelling for problem-free delivery, the ICE Vulcan receives real-time address delivery data and can communicate in a range of protocols including ZPL and SATO.

This fast, uninterrupted one-in-one-out process delivers faultless labelling precision. By interfacing seamlessly with a company’s Order or Warehouse Management System, it safeguards sensitive customer data and helps to eliminate any potential operator error.

Streamlined, failsafe and labour-saving

Citing the labour and cost saving benefits on high volume e-Commerce packing lines, Clearmark’s Steve Hancock estimates that to achieve the same level of hourly throughput manually would require between eight and 10 bench packers: “As well as being labour intensive, the repetitive nature of this work means that it’s more prone to human error.

“By further developing our unique Direct Apply application for the e-Commerce market, we are able to remove the complexities of the traditional pneumatic tamp application seen in other systems. By applying directly onto the moving film, it allows a smoother, quicker, more reliable label application, which is essentially maintenance free.”

Jonny Braithwaite, Director at Yorkshire Packaging Systems, concurs: “This seamless e-Commerce bagging and labelling process eliminates errors and ensures absolute reliability and data security as well as 100% compliance with GDPR laws.”

Efficiency in the bag

Designed for any bagged e-Commerce consumable application, ranging from fashion apparel, household furnishings, stationery, white good spares, the Flexo e-Comm measures the length of the product for the bag length and adapts accordingly. It adjusts to the product dimensions sealing the front and side edge and squeezing the air out to form a tightly-fitted bag.

The machine is compatible with all fully recyclable centre-folded films (LDPE 04). This includes biofilms and up to 70% recycled content films. Optional open bag perforations and bag resealing adhesive strips are available.

Aligned to these sustainability efforts, the fully integrated ICE Vulcan direct print and apply labeller with its unique non-pneumatic ‘air-less’ design, accurately places every label on demand, without the need for an applicator. Height adjustable, the Clearmark printer system boasts Intelligent Motion technology. This unique feature enables precise automatic control of components and an 80%  reduction of wear parts that traditionally cause unexpected downtime and additional cost.

“Direct Apply is far more reliable and faster than traditional tamp label printing,” reaffirms Hancock. For e-Commerce operations, where throughput is key to ROI, even the slightest hesitation between the data transfer and application of a label will have an effect on throughput.

“The ICE Vulcan prints three times faster than traditional applicators on the market, using a solid-state printhead mechanism and no compressed air. As a totally integrated e-Commerce bagging and labelling solution, there should be no stops and starts. Just a fluid process maintaining a consistent line speed.

“No other label supplier comes close to the speed and reliability of the ICE Vulcan for e-Commerce operations,” states Braithwaite. The innovative concept is clearly not lost on e-Commerce warehouse and logistics operations. Serious discussions are already underway to install the Flexo-500 with ICE Vulcan at one of the UK’s top-10 online and click-and-collect soft furnishing businesses.”

Stretch Wrapping is Ecological and Cost-effective

Posted on by Keith McKinley

Life cycle management, sustainability and environmental friendliness are terms that are now firmly anchored not only in the minds of end consumers, but also in the minds of more and more companies. However, the consistent implementation of such measures should also have as positive an effect as possible on costs.

Robopac Germany, a company of the international Aetnagroup, focuses on intelligent packaging machines for stretch wrapping technologies in the food and beverage industry, which are tested and permanently updated in its own TechLabs. Premium versions include, for example, a new generation of high-performance ring wrapping machines with patented Cube Technology, suitable for wrapping and stabilising pallets with stretch film.

For many packaging companies, it is a technical challenge to always wrap pallets with a wide variety of goods stably and with as little film as possible. Each load is different in height, width, weight and is made of a different material. For example, pallets with canned goods have to be wrapped differently than beverage crates, bottles or milk cartons. Often, several layers of film are packed in the lower part of the pallet to make it seemingly more stable for transport. In fact, it’s the other way around.

The load often fluctuates the most at the top and would need more support here through a larger film volume. This is exactly where Robopac comes in with its mix of technical, physical and scientific know-how. At the customer’s site, if requested, a service technician will check the pallets to be wrapped – prior to wrapping them with stretch film. They then individually set the appropriate program on the machine to ensure optimum wrapping. With the help of Cube Technology , exactly the right amount of film is applied at exactly the right place with exactly the right pre-stretch. The pre-stretch ensures the correct containment force of the load and thus maximum stability.

Another positive side effect of the patented wrapping technology is that in some cases up to 70 percent of film material can be saved in this way without sacrificing the highest possible quality. However, not every stretch film is equally suitable for use in these high-performance packaging machines. The film material must, for example, run at high wrapping speeds and have strong flexibility and load stability, such as films from manupackaging.

Converted to the daily goods throughput of an average brewery of 1,400 pallets, around 280kg less plastic can be used here. Multiplied by an annual production, the savings amount to up to 70,000kg of plastic or the equivalent of €140,000.

On the cost side, companies can expect some massive changes in the near future. Since January 1st, 2021, the federal government still pays €0.80 to the EU for every unrecycled kilogram of plastic. However, there are plans to distribute these not inconsiderable expenses among companies in the future. In other words, this means a correspondingly high financial burden for companies with a high plastic consumption. Prices of up to €2 per kilogram are currently being discussed. On the other hand, companies that consistently recycle or already use intelligent wrapping technology in their packaging will have a permanent advantage.

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