INTEGRATED END-OF-LINE SOLUTIONS

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.

Total accessibility, with no work at height.

The lifting motor, which controls the machine’s moving unit, is installed at ground level, eliminating the need for operations at height.

This configuration reduces risks for operators, simplifies maintenance tasks, and allows for faster repairs, significantly reducing machine downtime.

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.

True integration, designed for daily operation.
In integrated end-of-line systems, the difference lies in the ability to build a coherent system.

TOSA develops and manufactures the entire plant as a single system, applying all its design principles — mechanical, electrical, and operational — across all levels.

This translates into:

• uniform operating logic across all machines

• Consistent and easily recognizable operator interfaces

• Aligned technical documentation

• Simplified management of the entire system

For operators, this means learning one machine and being able to manage the entire line.

For maintenance, this means faster and more precise interventions thanks to shared standards.

The result is a truly integrated system that is easier to use, faster to manage, and provides a single point of contact for every need.