Operator safety has been brought to the highest standards without compromising accessibility
The BOBST MASTERFOLD folder‑gluer range for corrugated board converting has undergone a complete modernization, aligning with the company’s strategy to deploy its vision across all product lines and equipment. The result is a machine which delivers greater production efficiency, simplified operations, and exceptional safety, setting new standards in the corrugated board industry.
The flagship workhorse of BOBST’s corrugated board folding‑gluing range has been updated to incorporate state‑of‑the‑art technologies and exceed the highest safety and security standards on the market. The transformation increases the machine’s automation capacity, uses new digitalization and connectivity capabilities to streamline the set-up process, and delivers maximum operator-friendliness.
As Sacha Bourgeois, RD&E Director of BOBST folder-gluer line, explained: “We have completely modernized the MASTERFOLD 170 | 230 | 300 to create a new machine which sets a benchmark for corrugated board folder-gluers.”
Minimum setup time, maximum accuracy
Equipped with HMI SPHERE, the new MASTERFOLD can now be linked to the BOBST Connect data platform, helping converters to make informed decisions based on data directly retrieved from their machines. The platform enables remote job data setup from the back office and a simple download of job parameters on the machine, while Matic setups, such as the automated positioning of the main transport equipment, the calibrating shaft, and the speed variator of the folding section, contribute to faster changeover times.
On the feeder, pneumatically locked feeder ramps streamline changeovers, while the fully Matic blank aligner, which was recently introduced on the EXPERTFOLD 106-215 and now available on the MASTERFOLD, simplify and accelerate feeder setup. “The machine setup time in general has been reduced by up to 20 minutes. Automated positioning of the transfer and delivery section alone adds up to 15 minutes of productive uptime for repeat jobs,” added Sacha Bourgeois.
These changes bring the top-of-the-range machine into a new era of digital, connected and automated converting, maximizing machine uptime and setup precision. Configuration data can be prepared in advance, reducing operator workloads and minimizing the risk of human error.
Complete automatization of the folding-gluing line is possible with peripherals, such as SPEEDPACK, the automatic packer, as well as the ROBOLOADER and ROBOPALLETIZER, for fully automating blank loading and batch or bundle palletizing.
Pierre Binggeli, Head of the Folder-gluer line, Peripherals and Robotics at BOBST, said: “A new generation of operators expect modern equipment, while converters are confronted with inexperienced staff and customer requirements such as short deadlines and job runs. Digitalization and automation are therefore an important part in our commitment to address these needs.”
Key changes aim to reduce reaction times and walking distances when operating MASTERFOLD, enhance production visibility, and simplify setup procedures. The new HMI interface is clearly structured and takes the operator step-by-step through the different machine modules. Command panels on each of these modules allow direct and immediate intervention, even at the back of the machine. Additionally, a video overview of the main folding-gluing steps at the feeder and the transfer section provide clear operational feedback and essential information for quick intervention. During production mode, the machine can be slowed to 5m/min so the operator can pass through the safety light curtains and perform adjustments inside the running machine.
Driving sustainability
Combined with stable blank transport and precise folding and gluing, the enhanced MASTERFOLD line prevents production waste and unnecessary returns. With an additional liquid creaser, skewing can be further minimized and the gap between the folded corrugated cardboard panels accurately set. A glue and fold control device can also be integrated into the machine and combined with the ACCUEJECT ejection device, so that non-quality boxes are automatically removed from the production process and zero-fault output is guaranteed.
Reducing the physical workload on the shop floor is an important part of creating a more sustainable and attractive work environment for operators. This is especially important in corrugated board converting. Improving working conditions therefore goes hand-in-hand with enhanced safety and security. Security light curtains keep the machine parts accessible, while ensuring complete security during production. The new MASTERFOLD 170 | 230 | 300 are fully compatible with the EU security standards that will take effect in 2027.
The new servo motors on each machine module contribute to lower energy consumption, while the BOBST Connect Energy Monitoring allows to identify additional opportunities for electricity savings.
In addition, industry-leading service and support help BOBST customers to get the training, support and equipment necessary to get optimal performance and maximum return on investment from a machine that will last for generations. For the very first time, BOBST is providing customers with the support of dedicated data analysts to support its customers.
“With the enhanced MASTERFOLD, we’re going beyond the machine itself to combine connected workflows, automation and dedicated data support. It’s all about helping converters reduce setup times, improve consistency and get more value from every job by giving them the tools and insight to run their operations more efficiently, every day,” concluded Pierre Binggeli.