We’ve worked with a leading manufacturer of bedding items to develop a bagging system ideally suited to their products.
The Challenge – A speedy system for bulky items
This manufacturer was looking to speed up their packaging operation, but needed equipment that could handle pillows, duvets and other large products. As these items were to be despatched directly to online customers, they needed to be labelled correctly as soon as they were bagged and clearly separated ready for sortation for the courier network.
The Solution – An adapted horizontal bagging system
The new system uses a Hugo Beck Flexo 700 E-com at its heart, with several adaptations from the standard model:
- The cross-seal has been extended to a width of 800mm to accommodate bulky pillows and quilts with ease.
- The sealing jaw is also able to open to a height of 300mm for the same reason.
- An upgrade to the cross-seal section with ‘seal – guaranteed cut – seal’ using a pneumatic cutting blade for guaranteed separation of packs to ensure streamlining of downstream sortation.
- An adapted film folder was included, to give space for a cross conveyor at the back of the machine, running YPS’s 98% recycled content films.
- A semi-automatic splicer was also incorporated into the film folder, which fuses the new and old film together with no requirement for tape. The splicer results in quick roll changeovers when they are needed.
- A controlled pack presser was added which lowers prior to sealing of the bag to expel the air from the pack. This results in a higher quality seal and improved pack performance.
- A kissing conveyor was included which achieves speedy transfer of products over the sealing area and which enables the machine to pack smaller items if required.
The Result – Fully GDPR-compliant, 14 bags per minute
The resulting bagging system prepares the bulky products for despatch to customers at high speed, achieving a packing rate of 14 bags per minute. The direct ZPL labeller which is standard with this machine was also an attractive feature to the bedding manufacturer. This takes any file and converts it to a label, print and applying for each different order.
The ‘one-in, one-out’ packing system ensures GDPR compliance, with every pack correctly labelled for onward distribution. This unit however also features a “batch mode” which can be utilised with sequential data to run through 1000’s of the same product, running through orders sent to the labeller for one large run rather than the standard ‘one in – one out’ system.
“We discussed the customer’s exact requirements at length with them, recommending a quality system that would bring them significant benefits as it was and then further adapting it to create an ideal solution for them,” explained YPS Sales Manager Jaques-Pierre Macchi.
“Seeing how this system has come together to deliver exactly what they need has been such a satisfying project,” he concluded.
Benefits at a glance
Increased speed
Excellent presentation
GDPR compliance
Increased output
High-speed accurate bagging, with an intelligent direct apply labelling system and customisable bag length producing ideally-sized bags for your products.
- GDPR-compliant integrated labelling system
- Automatic bag size adjustment
- Forms tight-fitting bags for waste reduction
- Direct apply of address label, so no pneumatics are required
- Option of resealing strips and easy-open bag perforations
