Slitting and Rewinding
Traceability? Zero Defects? Overcoming New Challenges for Converters
By Raúl El Fakdi, Slitting BU director, and Jordi Prat, Slitting technical sales director, I
ndustrial automation has revolutionised the fl exible packaging sector, allowing companies to improve effi ciency and reduce errors in their production processes. However, implementing these solutions is not only about optimising production times, but also ensuring worker safety and fi nal product quality. A clear example of this positive impact is the testimony of Plásticos Sierra del Oro, which recently implemented automation in its production line with Comexi. Their experience highlights the tangible benefi ts of this technology and how it has transformed their daily operations.
PLÁSTICOS SIERRA DEL ORO: A GROWING CONVERTER
Plásticos Sierra del Oro is a packaging converter serving various industries, particularly the food sector, while expanding into others such as pet food. They off er fl exographic printing, lamination, micro/macro perforation, and plastic fi lm slitting. Founded in 1995 in Murcia (Spain), their relationship with Comexi dates back to the company’s inception, with Comexi machinery present in all production processes.
CHALLENGES BEFORE AUTOMATION Before installing the automated system, Sierra del Oro faced several challenges in its production line. Manual load handling required signifi cant physical eff ort from operators, posing ergonomic risks. Additionally, machine operators were under constant pressure, aff ecting their focus on critical aspects of the process.
Another major challenge was ensuring accurate data collection in the factory. Automation enables reliable productivity data collection directly, eliminating the need for operator intervention. This speeds up processes, facilitates analysis and improves decision-making to enhance productivity.
“The main reason for installing automation was to eliminate manual load handling by our rewinders, improve data collection quality and increase line productivity. The machine operator now works with less pressure and fatigue, allowing better focus on key process aspects,”
explains Miguel Angosto, deputy manager of Plásticos Sierra del Oro.
CHOOSING COMEXI: EXPERIENCE AND TRUST
After evaluating various options, the company chose Comexi due to its experience and track record in the industry. The partnership between the two companies spans over 20 years, with Comexi playing a key role in Sierra del Oro’s development. Years ago, Sierra del Oro made a signifi cant leap in quality and capacity by acquiring high-productivity dual-turret slitters. The next logical step was optimising processes by automating remaining manual tasks. “We analysed several options and Comexi’s convinced us the most. Our partnership began over 20 years ago, helping us become a benchmark in the industry.”
AN EFFICIENT DESIGN PROCESS AND COMPREHENSIVE SUPPORT
One of the most valued aspects of the project was the turnkey solution design process, carried out in close collaboration with Comexi’s technical and commercial teams.
“The design process was highly effi cient thanks to close collaboration between our team and Comexi’s. The support was excellent in all aspects. Having a single company handle the
entire project, with full knowledge of all interacting elements, greatly contributed to the project’s success,” highlights Miguel Angosto.
ERP INTEGRATION AND IMPROVED TRACEABILITY
The automated system also enhanced integration with their ERP, optimising factory data management. This integration eliminated manual data entry by operators, reducing errors and streamlining production processes. “Integration with SAP improves data collection quality and eliminates manual data entry, accelerating processes and reducing errors,” concludes Miguel Angosto.
KEY BENEFITS OF AUTOMATION Investing in automation has proven to be a strategic move for packaging companies, off ering signifi cant benefi ts:
1. Increased Productivity: Maximises eff ective operation time, allowing lines to run at higher performance levels. 2. Zero Errors: Automation eliminates manual coil handling, drastically reducing error risks. 3. Lower Labour Costs: Optimises human resource allocation, focusing on higher-value tasks. 4. Improved Ergonomics and Safety: Reduces risks associated with load handling, protecting employee health.
5. Enhanced Quality Control and Traceability: Automation and ERP integration minimise errors and improve quality standards.
6. A Single Supplier for the Entire Solution: Choosing Comexi as the sole supplier facilitates integration and ensures effi cient, coordinated after- sales service.
AUTOMATION AS A KEY TO COMPETITIVENESS
Implementing automated end-of-line systems not only enhances effi ciency and quality in production processes but also reduces costs and optimises worker safety. As demand in the fl exible packaging industry continues to grow, automation becomes a strategic necessity for companies aiming to remain competitive.
44
March 2025
www.convertermag.com
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