From roller to truck: Körber’s revolutionary machine

LUCCA.Last year we broke up with the presentation, among the many innovations, especially on the packaging front, with the presentation of the Casmatic Zephyrus, the robotic machine for packaging tissue products. However, research into the Körber factories, which were at the forefront of the design and construction of machines for the paper industry, continued, and less than eight months after the presentation of Zephyrus (which took place at Miac in October 2021), Via Diodati has opened its factory to present the latest news. News that, summed up in an extreme way, is represented by the possibility of delivering, turnkey, an entire factory for processing tissue products: from the main spool, to reach the finished product, wrapped and placed on pallets. It is the Körber ecosystem. “Today we present a complete conversion process,” explains Oswaldo Cruz Junior, CEO of Körber.

An entire production concentrated on a few meters, and which is essentially developed on four machines. Of course, the paper company can, if desired, decide to buy only one of these machines, but the revolution that Körber has illustrated for his potential customers since yesterday morning (by exploiting the contemporaries in the It Tissue exhibition) is represented, more than by machines, of a kind of philosophy, of simplification. All thanks to a highly elastic technology that is able to adapt to the customer’s needs at all stages of processing. But it’s also easier to start a new production line: with a single contract, companies can buy all the machines for a complete production process.

And that journey from the roll to the box was illustrated, step by step, machine by machine, by the various technicians, with Manrico Giusfredi acting as cicero between the various stages of the production process. The first of these machines is represented by the Perini Vega S8 line, for the transformation of large diameter rollers. The line is also the protagonist in an example of its efficiency and practical function, when from the moment the mother wheel is loaded (an operation that takes place in the total safety of the operator), only three minutes pass to the passage to the roller. From here we move on to the second jewel, Mtc Itf Change, the machine intended for the production of interleaved and capable, through the replacement of the drawer (the drawer arranged outside the machine and whose replacement requires only a few quick maneuvers) can change the format of the carving, all in a simple and automated way. And production is continuously subject to a control system that is automatically able to detect the quality of the cut, enabling immediate intervention, drastically reducing production downtime. Then comes he, Casmatic Zephyrus, the revolution in packaging we learned about last October. A robotic machine that is able to provide maximum flexibility in the product packaging process. For example, it is capable of making a single package for two different types of products, for example those in roll and those in folded. The packaging process looks very much to ecology with the use of Kraft paper, recycled LPs and bioplastics. The final container, in cardboard, can not only be reused, but also forms a perfect packaging for e-commerce, a constantly growing market.

We have reached the finished can product, but the options that Körber offers do not end there. There’s the last little gem: it’s called Pa15, and it’s a machine that automatically takes the box out of Zephyrus and, based on its dimensions, automatically studies the best arrangement for the pallets, and then loads the same boxes on pallets, ready for to be loaded on trucks. Machines that function as an orchestra, Giusfredi explained and, like an orchestra, have a director, represented by the computerized system, with which an operator can control the entire process from a control room.

In addition to simplicity and flexibility, the two characteristics most mentioned so far, there is another, no less important, economy. Here, savings involve several aspects, from production time to space, up to the particularly important, especially now, energy consumption (which also means lower environmental impact): “To give an example – explains Oswaldo Cruz – the packaging factory is the one where most energy is consumed, also necessary to secure the vacuum.Well, here we have managed to save 30% on energy consumption ». L

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