Board24, part of the Logson Group, manufacturers of corrugated packaging, sheet board and boxes, has recently purchased pallet strapping machinery from Mosca Direct Ltd to support business growth.
The Logson Group is a UK-based group of corrugated packaging companies, collectively employing over 800 people with an annual turnover of £185m. Board24’s Preston site produce corrugated sheetboard supplied palletised to customers’ specifications.
Due to business expansion, the site at Preston is home to a new corrugator. With the greater output of the new machinery, the business required palletising equipment that could keep up with increased levels of productivity. Senior management at Board24 turned to Mosca to help with their requirement. The Preston site is a new customer for Mosca, but Board24 at Coalville already has Mosca equipment on site and was confident in passing on good feedback to other sites within the group. After also hearing positive reviews about Mosca SoniXs pallet strappers from others within the industry, Board24 invited Mosca’s Business Development Manager, David Shepherd, and Technical Manager, Nick Brewin, to perform a site assessment. The best fit for the application was selected as a Mosca KCR-131 pallet press with a SoniXs sealing head, additional top-edge protection with label printing and application facility. The KCR pallet press with SoniXs sealing head can strap up to 200 pallets per hour, including the application of top-edge protection and labelling. Comparable competitor machines are only capable of processing a maximum of 150 pallets. Board24 also opted for a ‘spare’ sealing head plus test rig, which means troubleshooting and maintenance can be completed in-house and out of line without having to stop production or take the whole machine out of service. This investment in high quality machinery is a positive move for Board24 and demonstrates commitment to delivering the best quality products and service to both existing and prospective customers.
Board24 is delighted with its new Mosca equipment which has had a substantial impact on productivity since installation. Thanks to a tried and tested combination of components plus SoniXs technology, the KCR-131 is able to operate at a high speed while being extremely economical.
Existing non-Mosca pallet press machines used at Preston have called for the use of separate machines for label application; however the new Mosca KCR has been custom built for Board24 to incorporate top-edge protection, label printing and application into one machine. Increased efficiency is therefore achieved as the need for conveying equipment to move a pallet to a separate label printing machine is removed. This also means less floor space is required and less involvement from operators, further streamlining and automating processes.
Operations Manager at Board24 Preston, Eric Marshall, speaks highly about his experience with Mosca and the new equipment: “Installation was seamless and had zero impact on productivity as it was carried out over a weekend. The [Mosca] engineers were courteous and attentive and not only worked effectively with their own equipment, but were organised and effective working alongside other systems which were installed at the same time such as conveying equipment and IT.” Eric continues; “We have had no problems since the installation in early 2015 and the test rig and spare head have proved invaluable! It feels like we’ve had them forever. Mosca have provided fantastic training to our engineers and operators and, looking to the future, we would not even consider any other supplier for future requirements as we have been so impressed with Mosca.”
Mosca’s SoniXs ultrasonic technology uses a patented high-frequency sonotrode to produce a strong and consistent seal. This ultrasonic sealing system is suitable for both PET and PP strapping material and offers a seal that is much stronger and far more resistant to tearing than a traditional heat-weld. SoniXs technology reduces sealing time as it only consumes energy “on demand” (when the seal is made) and this, combined with the omission of heating time, leads to a 50% increase in strapping speed. In addition, no fumes, vapours or smells are produced due to melting strap and there is no residue build-up that needs to be disposed of, making it clean as well as efficient. SoniXs technology offers an increased working life – up to 50% longer than a heat-sealing head – because there are no moving parts therefore making the head almost entirely free of wear, reducing component and incurred maintenance costs over its lifetime.
Standard features of the Mosca SoniXs KCR-131 include 3 strap track guides with 3 strap guide lances, 2 sealing units (1 unit laterally adjustable), Siemens PLC control system, operation via a Siemens 8” touch panel which includes changeover facility from PET to PP minimum conveyor height 300mm and easy integration in to any processing line.
Mosca KCR pallet strapping machines are part of a vast range of automatic, semi automatic and fully automated strapping machines. Based on a modular design, Mosca strapping machines fit easily into existing lines to replace old machines or as part of a new project to improve throughput due to their speed and efficiency.