Braille First for Medica Packaging

July 2008

Pharmaceutical carton specialist, Medica Packaging, part of the Benson Group, is the first plant in the UK to install Bobst's AccuBraille system for the Braille embossing of pharma cartons.

Mark Kerridge, Managing Director of Benson Group, of which Medica is a part, said: "The main benefits to us of the AccuBraille unit are that it will further shorten the supply time to get cartons to our customers, and it will make it easier to maintain the quality of our Braille embossing."

Conventional Braille embossing is applied using a die-cutter, either at the same time as cutting & creasing or as a separate process. One embossing die is required for each carton on the sheet.

The AccuBraille unit, which can be fitted onto Bobst mid- to high-range carton folder-gluers, alleviates a number of known difficulties in Braille embossing using a die-cutter. These include: the difficulty of setting and maintaining good Braille dot embossing on a die-cutter; the die-cutter's restriction on embossing no closer than 5mm to a cut or crease line; and the problems caused at the folder-gluer feeder when feeding Braille embossed blanks.

Lee Alton, Product Manager - Folder-Gluers, for Bobst Group (UK & Ireland) Ltd said: "AccuBraille is a revolution in applying Braille embossing to cartons. Make-ready is quick compared to a 'die-cut & emboss' make-ready, or to the two make-readies needed if embossing as a separate run. The rotary process is low impact, so tools last much longer. Lower AccuBraille tools are universal, which reduces external toolmaker costs. Only one embossing tool is required per job, instead of one per blank station, which cuts tooling costs even further, and extra "male" tools can be made-ready "off machine" while the previous job runs, further reducing make-ready times."

With all pharmaceutical packaging destined for EU use required to have information in Braille by 2010, AccuBraille represents a quick and easy route to compliance. A team from Medica attended the launch of AccuBraille at an Open House event in Lausanne, Switzerland, last spring, and followed this with product trials at the end of last year.

"There has been lots of interest from our customers in the AccuBraille system and we are certainly leading the way on this. We're actively working through change procedures with key customers to bring it on stream for them," said Mark Kerridge.

For Medica Packaging, the availability of AccuBraille confirmed its decision to choose a Bobst Alpina II folder-gluer line to release latent capacity in the plant.

When Benson Group purchased Medica Packaging, Bobst Group (UK & Ireland) Ltd was asked to carry out an analysis of the folder-gluer department. This analysis looked at their existing machinery, the internal processes, and the work mix. Having completed the project, the analysis team determined that the plant needed a flexible, high-speed, folder-gluer, capable of producing straight-line and crashlock cartons, and that they needed some form of packer.

"The launch of our AccuBraille, which no other supplier can offer, was the icing on the cake, and made it clear the Alpina II line, with AccuBraille, and HandyPack GT packer, would be the ideal purchase for Medica to achieve their goals," said Lee Alton.

The Bobst Alpina II 110, version A2, is a 500 meter/minute machine for folding and gluing straight-line and crashlock cartons up to 1100mm x 800mm in size, or down to 76mm x 60mm (35mm folded).

The Alpina II delivers outstanding productivity through hour after hour of consistently high-quality folding and gluing, whatever the material, size and style of the product. Make-ready times are short, despite the power and versatility of the machine.

The Alpina II features:- an integral blank aligning module, for perfect carton entry to the folding & gluing process; fast make-ready because 98% of equipment stays on the machine; easy equipment adjustments using just one hand tool; easy interfacing with all major QA systems; system access to Bobst's unique "flipper-ejector" for removing individual non-conforming cartons at full running speed; and a modular design which means adding further functionality at a later date is easy.

"Having invested in additional print capacity in the form of a Komori S40 last year, we were in a position to release the latent capacity in the plant. The Alpina II line is a key part of the strategy to meet our targets for organic growth," said Mark Kerridge.

Benson Group was already familiar with the Alpina II from their plants in Bardon, Leicestershire, Integrated Packaging in Gateshead, and PDG in Newcastle which have several. The machine is the mainstay of work at the sites and is considered a quality asset.

The Alpina II line at Medica has been fitted with a Leary QA system including code and glue line detection.