In the international industrial landscape, reliability and innovation remain key factors for manufacturing companies. A concrete example of these topics in action is the collaboration between Clevertech, Baumer and Tosa, three companies being used to combine their expertise to develop tailor-made end-of-line solutions for a major global player in the cleaning and hygiene industry.
These three industry leaders are part of the Smart Packaging Hub, the ecosystem of excellence that brings together key players in the sector to develop innovative and synergistic solutions. The Smart Packaging Hub is a specialized network focused on secondary and end-of-line packaging innovation, connecting top Italian companies with international customers seeking advanced solutions. The value of this platform lies in its ability to offer not only cutting-edge technologies but also targeted consulting and technical support, thanks to the synergistic collaboration between the involved partners.
This very collaboration has resulted in a recent successful project. The customer is a major Mexican company specializing in the production of vegetable oil for human consumption and both bar and liquid soap.
The project, characterized by high technical complexity and tight implementation timelines, demonstrated the added value of an efficient supplier network capable of delivering an integrated and fully tested system, ensuring the customer a high-performance plant tailored to its needs. All with a single point of contact: Clevertech, the project’s lead contractor.
A turnkey integrated solution for end-of-line process
From the initial briefing, the client aimed to revolutionize its end-of-line process by integrating a new one-gallon shaped bottle format and managing both American carton packaging and shrink film wrapping.
“The customer needed a single supplier to handle the entire project,” explains Giorgio Zanardi, Executive Sales Manager at Clevertech. “To achieve this goal, Clevertech took on the role of general contractor, coordinating activities and ensuring a fully integrated solution, where all machines operate in synergy through a unified software system and an optimized mechanical and electrical design. The plant was engineered to minimize downtime (MTTR, Mean Time to Recover Between Failures), ensuring maximum operational efficiency”.
Thus, Clevertech partnered with Baumer and Tosa, forming a winning synergy that outperformed the competition. “The system shipping from Italy is the second plant we are supplying to the same client,” adds Zanardi, “a sign of their appreciation of our ability to provide integrated solutions under a single general contractor, with full-service support, in a region where we have a service center with over seventy technicians.”
Technical challenges and the importance of specialized consulting
One of the main challenges faced in the project was managing the stability of shrink-wrapped bundles.
“Initially,” continues Zanardi, “the client believed it was necessary to integrate separators within the shrink wrapper to improve the bundle’s load-bearing capacity. However, the machine had already been designed, and this request would have significantly increased complexity. Thanks to our shared experience, we demonstrated – through tray design optimization and material adjustments, followed by practical testing – that the bundle’s stability could be ensured without the use of separators”.
This solution simplified the line’s configuration and significantly reduced material costs, delivering substantial savings for the client while showcasing the value of expert technical support.
Energy efficiency and sustainability start with integrated design
Another key aspect of the project was enhancing the plant’s energy efficiency.
“By adopting next-generation servo motors and controlled motors,” explains Antonio Calitri, Key Account Sales Manager at Tosa Group, “we enabled more efficient energy management, reducing consumption compared to the previous production line.”
This translated into economic savings for the client while also contributing to environmental sustainability, aligning with the growing focus on sustainability within the manufacturing industry.
“At first glance”, Calitri continues, “the project might have seemed straightforward, as the required production speed was not extreme, unlike other machines. However, achieving a perfect match with the client’s technical specifications involved a significant level of complexity. Our companies’ synergy was the key to success.”
A critical point of the project: the compact layout
Another crucial aspect of the project was optimizing the available space within the client’s facility.
“Often,” notes Calitri, “lines need to be installed in spaces already occupied by other machinery. Meeting all operational requirements within a compact space is a challenging task and highlights the reliability of the brands involved.”
The compact layout not only refers to the physical integration of the machines but also to the harmonization of different systems, ensuring seamless coordination in terms of both impact and functionality, optimizing the overall workflow.
The added value of pre-installation testing
A significant advantage of the Clevertech, Baumer, and Tosa collaboration was the comprehensive system testing before delivery.
“For example, the Tosa stretch wrapper,” explains Zanardi, “was first tested at Tosa’s facility before being integrated into the overall system at Clevertech, where we conducted final testing. This approach allowed for the verification of the entire configuration, preventing potential issues before the system was installed at the client’s site.”
It significantly reduced startup times, minimized operational disruptions, and maximized efficiency.
Customer satisfaction and future outlook
Thanks to the seamless integration among Clevertech, Baumer, and Tosa, and the high level of technical support provided, the customer received an efficient, reliable system perfectly tailored to its production needs.
The synergistic collaboration between these three companies proved the value of a highly specialized network, capable of delivering not just high-quality machinery but also targeted consulting and technical support. The customer particularly appreciated the collaborative approach and reliability of the proposed solution, confirming trust in the project partners.
Looking ahead, this project serves as a winning model for the industry, emphasizing the importance of integrated solutions, compact layouts, and energy-efficient systems. The collaboration within the Smart Packaging Hub continues to grow, opening new opportunities for development and innovation in the global market.