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Grupasa builds the future of corrugated manufacturing on Industry 4.0 principles with BOBST

The new BOBST FFG 1228 flexo gluers form a central part of the pioneering company’s recent investment in a second production plant in Ecuador. Having started operations in 2020, this state-of-the-art factory is the most automated of its kind in Latin America, built on the principles of Industry 4.0 to service a demanding and growing market. 

[Translate to Italian:] Mr. Jose Jaramillo Miranda, President of Grupo Papelesa

[Translate to Italian:]

Fully finished banana boxes in one process 
Two BOBST FFG 1228 machines - one three-color and one six-color - support this ambitious endeavor. The flexo folder gluers have been configured specifically for the production of banana boxes, which makes up the majority of output for the agricultural sector at Grupasa. The FFGS convert board produced on a new BHS corrugator. Sophisticated management information software has also been put in place to streamline operations, manage human resources, and facilitate excellent logistics. 

Combining flexo printing, die-cutting and folding of board in a one-pass process, the FFG 1228 is an ideal production line for large formats up to 1160 x 2890 mm. It can process board in various thicknesses from micro flute to double-walled (1.4 to 10 mm) and features quick job changeovers, fully automated slotter and speeds of up to 30,000 boxes/hr (Trifold) for fast and versatile production of the widest range of box types. 

A host of proprietary technologies make the BOBST FFG 1228 the perfect choice for Grupasa by minimizing operator intervention and increasing automation. The six-color machine, which is a 1228 NT RS model, comes with RAPIDSET which enables set up of idle print units while the machine is running for maximum efficiency. Both BOBST machines also feature DDF Direct Drive Feeder for no-crush feeding and high printing quality. This guarantees accurate lead edge to print and is ideal for converting light-weight board. 

In the cutting section, the top rotary die-cutter uses the POSILOCK® quick mount technology and QLA Quick Lock Anvil systems for faster changeovers and accurate cutting at speed. The PCD Folder-Gluer offers progressive folding at high speed with Multi-T belts and board transfer on vacuum belts. At the stacking stage, the machine ensures 100% automated counting accuracy and precise bundle ejection. Each process on the flexo folder gluers is easily controlled and set up at the intuitive MPC3 HMI control station with REGISTRON 55500 employed to perform automatic print register control for excellent print results and low waste. All production data is collected and stored for easy job repeat setups and analytics. 
 

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