Recent months have seen the market success of innovative Plusline technology that integrates secondary packaging and palletizing in a highly efficient and extremely compact system. The Overlayer & Tower+ system is a combination that delivers flexibility, precision and speed for both bundled products and DRPs (Display-Ready Pallets). It’s a solution that’s proving popular in Europe and gaining ground in North America too, in response to new retail initiatives where customers take the product directly from pallets rather than shelves.
This also brings benefits in terms of environmental impact as it eliminates secondary packaging.
A new end of line paradigm
The Overlayer & Tower+ system optimises the end of line by integrating bundler, layer former and palletizer in one ultra-compact and completely automated solution. Requiring only 15 metres rather than the conventional 40, this technology improves space management, increases productivity, reduces machine downtime and ensures high-quality end products, without compromising on performance. It also maximises operational safety, with one operator controlling multiple lines from one workstation, minimising the need for manual intervention.
Plusline introduces a new era in packaging
Process simplification
Plusline has always had a mission to reduce complexities associated with primary and secondary packaging in the tissue paper industry and Overlayer is concrete proof of this. Unlike traditional bundlers, this patented solution forms layers directly, avoiding the need for separate technology. It can also handle both bundled and display-ready products, combining different formats and creating optimised layer mosaics with no limits on their configuration. The system is completed by Tower+, the PLUSLINE palletising line that stacks layers from the Overlayer and adds interlayers where required. Compatibility with both half and full-height Euro, UK, NA and Australian pallet formats ensures maximum versatility for the global market.
Operating efficiency and reduced costs
As well as process-related benefits, this solution also delivers significant cost savings. While traditional systems require three different machines in the process, with Overlayer & Tower+ two are enough. This results in energy savings of 50% and a drastic reduction in idle time.
In addition, by eliminating the need for two different suppliers, one for the packaging and one for the palletizing, customers reap the benefits of a single provider in terms of assistance, spare parts management and commercial negotiations.
A philosophy geared towards integration and automation
This innovation is the perfect fit for Plusline’s philosophy and its mission to create a fully integrated and automated factory. It’s a concept aligned with Together, the technology that revolutionised the industry by integrating trim cut, log saw and wrapper in a single, compact machine. Overlayer & Tower+ complete the process by including palletizing. The result? An entire automated production line in just 23 metres, managed from a single supervision and control station. A bold step forwards towards the smart, safe and efficient factory.
From theory to practice: installations and future prospects
More than just a future-forward vision, this technology is already a consolidated reality. The first installations are now operating in South America, while in Futura LAB’s Andromeda 3 line the Overlayer & Tower+ system is integrated directly after Together. This showcases a complete line in action, managing the entire production process from mother reel to packaged and palletized product. Futura and Plusline like to think of Andromeda 3 as the solution that delivers seamless efficiency by fully integrating the converting, packaging and display-ready palletizing functions. The clear mission of collaboration between the two companies is to provide customers with innovative solutions that improve productivity, optimise processes and reduce costs.
Andromeda 3 and Overlayer & Tower+ mark a radical change, designed for companies that invest in automation and integration and have their sights set on the future.
Plusline S.r.l.
It has its headquarters in Bologna’s packaging valley, and a team of highly experienced technicians and professionals behind it, whose
in-depth knowledge of the product andthe production process guarantees reliability and results.
In addition to its in-house expertise, Plusline has also formed a strategic partnership with Futura to develop joint projects and perform cutting-edge technology trials.
Plusline introduces a new era in packaging. You are about to enter an age in which technology will dramatically simplify the user experience, redefine product protection and deliver improved, sustainable productivity.
In short, an era in which you will have everything you’ve been looking for.
Products
Bundlers, Machines for tissue packaging, Wrappers.
