What does it do?
It’s a hand-fed machine that wraps and forms rigid boxes and slip cases in one operation. Typically these are paper wraps for luxury packaging, where the alternative is slow hand wrapping, or expensive fully automated lines.
It is made in China but imported into the UK by Perfect Box Solutions (the packaging wing of Perfect Solutions Group, which also includes Perfect Bindery Solutions), which then modifies it with new software, PLC (programmable logic controller), plus taking it up to safety and guarding standards, including larger light barriers, two-button starts and safety resets.
Why the name?
“Optimus Prime was named after the Transformer character due to the face on the front of the machine,” says Hannah Giddins, box production machinery specialist and sales director for PBS.
She says: “It ‘transforms’ the world of slip case and bottle box production by automating the wrapping of cover materials around the box carcass, and/or by forming the box and wrapping it in one process. The vacuum feature means there’s no need to corner tape. It’s perfect for on demand and short run production of bottle boxes, slip cases and drawer boxes.”
When was it launched and what types of work is it intended for?
It was launched in 2021 and the first machine was sold to a large packaging company that produces whisky bottle boxes for many UK distilleries. “Book manufacturers could also benefit from this machine to add value to their books by supplying them inside a slip case,” says Giddins. “Other customers have produced drawer box type products to hold coins from the Royal Mint.
“Customers can choose to have one or two machines: the first to form/wrap the box, the second to complete the tuck-in – the flaps inside the box. We have advised customers that the inside tuck-in can be completed by hand to save them purchasing the second machine, although for longer runs they may not wish to do this manually!”
How does it work?
Optimus Prime can work with die-cut or grooved blanks and can start with flat boards or pre-formed and taped carcasses. It offers two different functions, with five different sheet designs depending on the sequence you choose to wrap the box in. The first option is to pre-form a box carcass using corner tape. The operator would then glue the cover material and place the box into position on the glued sheet. The operator then places the box and glued sheet onto the mould/tool for the machine to wrap the cover material around the box. The second option is for Optimus Prime to form the box, when pre-grooved or die-cut boards are placed flat onto the glued sheet and the vacuum will hold it on the mould/tool. As it’s wrapped the cover sheet acts instead of glue/tape to keep the box formed.
There’s no restriction on board type or thickness. Cover materials can be printed, laminated, standard coated or uncoated stocks. Hot animal glue is recommended, although vegan glue works – its slightly longer open time can slow down production. Setup is manual, with the operator turning handles to set the pressing rollers against a test carcass on the mould/tool. There are touchscreen settings for positioning the roller heights, etc. Dwell time, speed and other settings are all managed on the touchscreen controls. The sheet design is chosen, which then determines the wrapping sequence and operation.
Moulds/tools are produced from nylon or are 3D printed. Those for vacuum require some machining and steel bars to be installed on the mould/tool.
If two machines are installed, they can handle, for instance, slip cases and trays separately side by side, boosting efficiency. Otherwise, a single machine has to be reset between cases and trays.
Does it replace an earlier product?
No, it is a new addition to the PBS range, for completely different products.
How fast or productive is it?
The speed of production will depend on materials, glue, operator and production setup. For example, you might have one operator gluing a sheet, another operator placing the box onto the glued sheet, another operator placing box and glued sheet onto mould and operating the machine, and another operator to remove the completed product and do quality control checks. Or you could just have one operator doing all of this. As a guide, Giddins says throughput can be about 250 products per hour.
What’s the USP?
It’s unique in the PBS range and also bridges the gap between all-manual production and much more expensive fully automated lines. For instance PBS’ F6 and F7 Box Wrapping machines can process lid and base/tray style boxes, with a maximum box depth of 100mm, and not slip cases. Optimus Prime uses a different wrapping process that means it can handle boxes up to 360x360x120mm.
How easy is it to use?
Giddins says: “It’s a little more complicated to set up than our other box wrapping machines as there are more manual adjustments, and different sequences and sheet designs to get your head around, but once you understand it you could have the machine set up in about 30 minutes.”
What training, service and support, is offered?
“We use our sister company Perfect Technical Solutions to complete all safety work, installations, training and service,” says Giddins. “They can also produce the moulds/tooling if customers want to outsource, and can assist with sheet designs and technical drawings.”
What does it cost?
The price is £36,427, including safety upgrades, delivery, installation and training for up to four operators. The first mould/tool is free with the machine.
Are there any UK users?
Three so far.
SPECIFICATIONS
Speed Depends on style of product, typically 250-500 items per hour
Box/slip case dimensions Max: 350x350x120mm (LxWxH); Min: 40x30x10mm
Machine dimensions Depends on guarding options
Power Single phase, 16A, 220v, 800w Commando socket required
Price £36,427
Contact Perfect Box Solutions 01993 840077 www.solutionsgroupuk.com/box-solutions
ALTERNATIVES
PBS says it doesn’t know of any direct alternatives. Other machines that can wrap and form slip cases of this size are much more automated and expensive, including its own 1246B/D Fully Automatic Box Production Line with one or two wrapping units.
