SECONDARY PACKAGING SOLUTIONS WITH PE FILM

Designed to reduce maintenance to a minimum.
Our machines are built on a “design for low maintenance” philosophy, which involves designing every component to minimize intervention and simplify long-term management.

Technical solutions such as lubrication-free toothed belts, lifetime-lubricated sliding components, centralized lubrication points, and direct-driven lifting units allow for a reduction of up to 75% in routine maintenance, improving safety, cleanliness, and operational continuity.

Smart, data-driven maintenance.

Maintenance is an integral part of the design and is managed through an advanced approach that combines various technologies:

• Preventive Maintenance Smart Interface

A graphic interface that guides the operator in planning preventive maintenance, signaling directly from the panel when action is needed to maintain consistent performance.

• Predictive Maintenance Smart Interface

Continuous monitoring of the operating conditions of critical components such as motors, belts, and the pre-stretch carriage, with automatic alerts in case of anomalies, allowing for targeted interventions before a failure occurs.

• Carbon Footprint Smart Interface

Real-time visualization of energy and compressed air consumption, with the possibility of recording and integration into management systems.

• Troubleshooting Smart Interface

A guided system for anomaly resolution that reduces identification and intervention times by up to 73%, minimizing downtime and operational stress.

From data to performance.

Through Industrial IoT platforms and artificial intelligence solutions, TOSA machines collect and analyze data in real time, transforming it into operational value.

The M.A.T. (Machine Analytics Tool) allows you to monitor machine performance, collect and analyze data, and generate useful insights to improve efficiency, reduce downtime, and support decisions based on real data.

In addition, WINSTON, our virtual assistant powered by Generative Artificial Intelligence, supports operators in the day-to-day management of machines.

Thanks to a wealth of knowledge built on over 40 years of experience from our mechatronics technicians, WINSTON is able to respond in more than 150 languages, 24/7, providing clear and immediate guidance to resolve any operational situation.

The integration between M.A.T. and WINSTON also enables the creation of intelligent “sentinels”: agents capable of monitoring specific machine parameters and automatically reporting anomalies or critical conditions, allowing for timely and targeted interventions.

This approach transforms data into an active tool for control, prevention, and continuous optimization.

Safety as a Design Principle

Safety is an integral part of our design approach and is developed in compliance with the regulations applicable in the various target markets, in accordance with the latest international standards regarding machine safety.

TOSA has always been among the end-of-line manufacturers that have made safety a distinctive element, adopting and anticipating regulatory evolutions to ensure maximum protection for operators, machines, and loads.

Through structured risk analysis and the use of advanced design tools, we define the performance levels (PLr) for each safety function and implement suitable technical solutions, including anti-fall systems for suspended loads and protection devices designed to guarantee maximum safety in every operating condition.

Uninterrupted operational continuity Automatic film reel replacement system designed to eliminate the operator’s direct intervention during the changeover phase and ensure maximum continuity of the process.
The operator prepares the next reel on a dedicated trolley without interrupting the production cycle. When the reel in use runs out, the machine automatically performs the replacement, with downtime limited to approximately 10 seconds.

+810 hours of real production every year.
Compared to manual management, automatic reel change drastically reduces downtime and operator involvement, transforming a necessary activity into an optimized, continuous and efficient process.

Tailor-made configurations for every product
We design tailor-made bundle preparation systems, developed according to specific application requirements.
Thanks to their high modularity and flexibility, our solutions make it possible to handle different product types and grouping configurations, ensuring precision, efficiency and operational continuity.

Thermal efficiency and reduced energy consumption

Our shrink tunnels are designed to deliver energy savings of up to 30%.

This result is achieved thanks to:

• double-insulated tunnel walls
• modular management of thermal zones
• pre-chamber and post-chamber
• use of high thermal resistance transport systems

A solution designed to optimize energy consumption while maintaining high performance.

Dedicated solutions for highly complex applications
After more than 40 years of experience in the large-size packaging sector, and especially in the world of insulating panels, we have succeeded in standardizing highly complex solutions for the handling of large-sized products, through the use of sealing bars up to 3 metres in length.

Our machines are designed for high-performance applications, with continuous 24/7 operation, ensuring reliability, operational continuity and consistent quality over time. Both shrink film and elastic film can be used, even without the use of shrink tunnels.

These solutions represent the synthesis of application experience and technological development, offering excellent packaging uniformity and holding performance even in the most demanding production environments.