Since 2015, a Jetbox folder gluer from Wilhelm Bahmüller selected number has passed through, a separating belt Maschinenbau Präzisionswerkzeuge GmbH has been divides the shingled stream into individual packs. automatically closing and gluing the various carton types. At the end of the production line, however, physical workers For packages with an automated base, the rotary module of were still needed until recently. They manually removed the the power packer then ensures homogeneity by rotating one cartons, separated and turned them, and then fed them to part package by 180 degrees. These cartons fall onto the the bundling unit – a laborious and time-consuming process unrotated cartons in the collection chute and form a uniform that limited the productivity of the line. This prevented the package that can be easily stacked. From the chute module, full capacity of the folder gluer from being exploited and the bundles are pushed into the strapping module, where large bundles were difficult to strap. MOSCA’s inline needling units are used. Depending on requi- rements, they strap the bundles either once or twice in parallel To optimise this process, Mayer Kartonagen called on two using five-millimeter-wide PP strapping. To ensure a continu- long-standing partners and specialists, namely Bahmüller and ous supply of strapping, the units are equipped with a double MOSCA. For more than a decade, the company has been strap dispenser that automatically switches to the second sourcing its strapping machines from MOSCA, including strap coil as soon as the first one is empty. several free-standing models for manual loading, a fully au- tomated UATRI inline strapping machine, and a fully automa- ted packing press with an ultrasonic unit for pallet strapping. SoniXs units used in inline strapping for the first time Mayer Kartonagen has also enjoyed positive experiences with The machine at Mayer Kartonagen is completely new and the Bahmüller folder gluer for more than five years. is the first Powerpacker to use MOSCA’s ultrasonic techno- Simple and efficient logy. While other strapping machines traditionally use heat to seal the strap material, the SoniXs unit developed by The result of the collaboration was a state-of-the-art Power- MOSCA uses ultrasonic technology. This not only avoids packer equipped with SoniXs inline units. Glued cartons are vapors, but also eliminates energy-intensive warm-up times. fed fully automatically from the folder gluer into the Power- packer, sorted into packs, and finally strapped. This saves This process had not been used in inline strapping machines time and has given a new boost to productivity at Mayer before: “The aggregate used in inline strapping is significantly Kartonagen. Depending on the number of items per different from our other SoniXs aggregates”, explained package, the Powerpacker can strap between 7,800 and Christian Zwieb, Sales Manager MOSCA Engineering at 13,000 cartons every hour, with a maximum output of MOSCA. “In order to use SoniXs technology in the Power- 20,000 packages. This enables Mayer Kartonagen to packer, we had to develop completely new aggregates that achieve an increase in output of 20 to 35 percent, depen- are mirror images of each other.” For strapping, a linear ding on the pack shape. Aziz Kaplan, Production & Techno- needle moves into the aggregate from above and picks up logy Manager at Mayer Kartonagen, commented: “The the strap. To seal it, the sonotrode then presses the strap Powerpacker with SoniXs ultrasonic technology represents ends together and welds them through ultrasonic vibrations. a clear step into the future for our production line.” With these new inline units, the Powerpacker is perfectly The final step at the end of the packaging line is now as simple prepared for the various pack formats that Mayer Kartonagen as it is efficient. All the operator has to do is specify the number requires. No matter whether the packages are very small or of cartons per package and set the size of the boxes. The large display packs, with a minimum distance of only 100 mil- machine then takes over. The shingled stream of cartons is limeters between the two strapping units and a collection fed directly from the folder gluer to the power packer via a shaft height of 400 millimeters, packages of almost any size press belt, where sensors count off the boxes. As soon as the can be securely strapped and subsequently bundled. 33