If delivering four tonnes of industrial finishing kit is considered a challenge at the best of times, delivering it in four feet of snow to a company in Derbyshire’s High Peak could be regarded a nightmare.

But thankfully for Glossop Cartons, its Bobst Expertfold 110 A2 CS folding line, which was received in the middle of the UK’s pre-Christmas big freeze last year, arrived in one piece.

"It was actually snowing when the machine arrived," explains Glossop Cartons managing director Jacky Sidebottom.

"Unloading and getting it into the plant was eventful, particularly because we are at the top of a steep hill, but we managed to get it into the plant in a safe manner."

The Expertfold was bought to strengthen Glossop Cartons’ position in the ever-competitive packaging market. And while it may not be the cheapest machine available, the old adage ‘you get what you pay for’ certainly rings true as far as Sidebottom is concerned.

Launched at Drupa 2008, the Expertfold was Bobst’s replacement for the Mistral. Both the control system and operator interface were updated and, as you would expect, the machine is faster than the Mistral, both in its top running speed of 450 metres per minute and the speed it can deliver four-corner boxes, which is 28,000 per hour.

Range of applications
Because it can be customised to individual needs, Bobst says the Expertfold is aimed at a wide variety of sectors. A handful of commercial printers have bought the machine, but it is predominantly used by carton makers dealing in food, pharmacy, general carton and corrugated markets.

Operating in a highly consolidated sector, Glossop Cartons has to make sure it is at the forefront of modern technology to compete – and according to Sidebottom, this kind of highly specced machine meets the £5m-turnover company’s requirements.

The Expertfold is designed to makeready very quickly, which, according to Bobst, is one of its key selling points. It is a modular machine that can be configured in a number of different ways to produce straight-line, crashlock and four- and six-corner cartons. This modular approach means elements can be easily added. These include the EasyFeederGT feeder, the CartonPackGT automatic packer and the HandyPackGT collecting table, all of which are included with the machine installed at Glossop Cartons.

EasyFeederGT comes complete with a loader/batch inverter that allows the blanks to be fed with the printing on top, in other words, as delivered by the die-cutting shop. In addition, the Easyfold is fitted with the latest Leary glue application system, which is integrated with the machine’s ‘flipper-ejector’ to remove any non-conforming cartons from the line without slowing production.

With the CartonPackGT automatic packer, meanwhile, the company is able to pack long runs of folded and glued cartons at high speed into shipping containers.

It can also be fitted or retrofitted with special modules such as a capacity fold device for making 3D boxes and folders, or an AccuBraille add-on for the fast application of Braille embossing.

On top of all these mod cons, the Expertfold also enables Glossop Cartons to fold a wider range of substrates than before, opening up new markets in the process.

"Although the machine was a replacement for an older model, the object of the purchase was to enable us to glue difficult styles of carton more easily and to improve the quality and efficiency in our gluing department," says Sidebottom. "It’s a versatile machine offering good value for money."

Value for money is one thing that Sidebottom is always keen to achieve – she admits to being rather prudent when it comes to opening the company purse. Machinery, however, is the one area where she allows herself a freer rein.

Talking to Sidebottom, it’s clear that a state-of-the-art office is not a priority and company cars do not interest her, but machinery is a different matter: "When the business started out in 1982 it was happy to take on old machinery, simply to get established," says Sidebottom. "But once we’d been up and running for a few years and were able to invest in new kit, we realised only the best would do. Though if you are going to spend a lot of money on a machine, make sure it is worth the outlay."

Sidebottom is keen to ensure that the machine brings a competitive edge to her company and, so far, the Expertfold has lived up to expectations. "It’s not the cheapest piece of equipment on the market, but it’s been worth the investment," she says. "It is difficult to quantify how much we have saved or made from it yet, but it has definitely made the department more efficient. There’s less work in progress in front of the gluers."

Along with efficiency savings, another key benefit has been its ease of use – the folder’s operators are apparently all very happy with their latest toy. "The operators like the touchscreen control, and the fact that it is remote control means it can be operated from down the line," explains Sidebottom. "The Bobst HandyPackGT we have at the end of the line helps with packing, and when that is not in use it doubles as an extended delivery."

Although Sidebottom is adamant that she won’t spend for spending’s sake, given her enthusiasm for the Expertfold, she won’t rule out the possibility that she may one day loosen the purse strings once again and invest in a second model. Only this time around, she’ll probably opt for a summer delivery.

SPECIFICATIONS
Top running speed 450m/min
Speed when handling four-corner boxes 28,000 per hour
Max carton or solid board weight 800gsm
Footprint 12.3x6.3m
Weight 4.3 tonnes
Price from £200,000 (€230,000)
Contact Bobst Group
01527 519700

COMPANY PROFILE
Carton maker Glossop was formed in 1982 by Sidebottom’s father Raymond Every, who took a £35,000 government grant secured against the family home to start it up. He passed away in 1984, but his family continued the business and it has stayed in family hands throughout its near 30-year history. In its time, the firm has grown from a business that only em-ployed three members of the same family to a £5m, 55-staff company dealing with blue-chip clients. In 2010, it even made an acquisition, taking on Manchester printer Clowes and saving around 20 jobs in the process.

Why it was bought it… Ultimately the machine was bought as a replacement for an older machine as part of Glossop’s ongoing investment in upgrading its kit. However, managing director Jacky Sidebottom felt its versatility, ease of use and the improvements it would bring to the gluing department were the key factors in bringing this particular folder on board.

How it has performed… Aside from being delivered in conditions that Captain Scott would have found tricky, the machine has so far lived up to its billing. It has been easy to use and has made the department far more efficient.