Futura and Plusline: a partnership decades in the making

Futura is 20 this year and what a lot has happened in two decades. Not least the integration with Plusline, one result of which is the integration, for the first time, of converting and packaging in a single line, to simplify the production process. It is a process that drives innovation through automation, performance, product quality, safety and space optimization. Simplification is the ultimate goal and the main objective for our customers’ production.
One key benefit is upskilled operators in a safer, more rewarding role who will migrate from operational functions on the machine to technical control via a monitor. The goal is to have one technician for packaging and one technician for converting. These are no longer classic manual line operators, but professionals responsible for checking the proper functioning of a fully automated, self-adjusting line.

Automated handling

With Andromeda, in 2013, we launched the first automatic reel handling system on a converting line. Today, in addition to the optimization of reel management, we can offer the possibility of automatically replacing the embossing rollers and performing maintenance operations from the unwinding area to the rewinder, including cleaning the core.
In fact, the Andromeda system also provides for the total automation of the handling of the finished reel and its cleaning with the machine running.

Automated core reel management

With Camallo, we have made it easier to load, unwind and exchange coreboard reels by eliminating human intervention, creating a totally touchless, faster and totally safe process, with a quick return on investment. Camallo can manage up to 16 reels and be retrofitted on any coremaking system.

Automated rewinder control

With the new Sferica we have fully automated the process of winding adjustment, setting new standards for the market. Much more than a simple camera, Sferica’s vision system measures the position of the log during winding, calculates any error compared with an ideal situation and automatically sets winding parameters. It is a virtual operator which continuously supervises production parameters, adjusting them and, if necessary, activating alarms.

Automated blade change

With the new automatic log saw blade change, monitoring and sharpening system, which operates while the machine is running, we have further optimized production by eliminating any manual intervention and making the process more efficient.

Create new horizons. That’s the power of the twentieth

Compact layout, efficiency and product quality

With Together we have gone further and completely revolutionized the end of line by truly integrating converting and packaging. Together receives the logs directly from the rewinder, generating packaged shelf-ready rolls. The result is an unprecedented level of process continuity, which ensures a substantial increase in speed and simplification of the production flow. It is a unique system that integrates trimming, roll cutting and packaging by eliminating choke belts and conveyor belts. This guarantees compactness of layout which saves up to 65% of space for each line. The improved layout and the absence of choke belts also eliminates slowdowns and bottlenecks, which are among the main causes of roll damage. This is why Together is the most gentle machine on the market in terms of product handling and is therefore ideal for cutting and packaging structured paper rolls such as TAD.

Sustainability and safety

With our JOI Hydro-bond we have made the product more sustainable (no glue or chemical agents) and above all, the embosser area safer, eliminating oil spills and roll contamination. JOI Hydro-bond allows, even at high production speeds, the perfect adhesion of toilet paper plies with the use of water alone and no addition of glue.
It is thanks to the exclusive “Zero Deflexion” steel marrying roll, with its ability to compress the fibers homogeneously over the entire surface and thus fully exploit the “adhesive power” of water, that we can guarantee a more hygienic finished product, which is soft and ecologically superior.
All of our innovations have the ultimate goal of achieving maximum production efficiency, which leads to greater energy efficiency and therefore to saving resources for companies and the planet. These concrete, targeted innovations, are relevant to people’s daily lives and, in the long run, will become the new market standards.