Drupa 2016 has seen the premiere of the all-new BOBST MASTERFOLD 110 A3 folder-gluer, which brings new levels of productivity to the folding and gluing of cartons. Available in two widths, 75cm and 110cm, the completely redesigned MASTERFOLD features running speeds of up to 700 meters per minute, increased automation, up to 15% faster set-up, a 10% increase in throughput, added versatility in the types and styles of packaging it can handle, and a re-thought safety concept centered on the operator which is complemented by a 10% reduction in noise. The MASTERFOLD 110 A3 on display at drupa 2016 features new and updated versions of many BOBST folder-gluer technology modules, including EASYFEEDER / BATCH INVERTER, ACCUCHECK and SPEEDWAVE as well as CARTONPACK, the latest version of which can save 20% in labor costs by its use. The MASTERFOLD also features an eye-catching new design.

Jacques Reymond, Head of Product Marketing for BOBST's Business Unit Sheet-fed says, "We believe that the new MASTERFOLD is the most productive folder-gluer in the world and answers customer concerns about how they can decrease setting times to cope with reducing run lengths and how they can achieve the high net outputs they need to maintain margins. This new machine can perfectly fold and glue more than a million boxes in a single shift. Yet the setting and running of such a powerhouse machine has never been easier or quicker thanks to a host of new systems and innovations that we have developed. The new MASTERFOLD models are also truly versatile machines. They are highly configurable, so they can be tailored perfectly to users' needs, adapted as those needs change, and grow with their businesses."

BOBST has designed and manufactured folder gluers for over 70 years and the new MASTERFOLD models show that the company is still leading innovation in the design and manufacture of this equipment, delivering technology that helps clients reduce costs, improve productivity and open up new markets.

Designed for quick setting and easy access
Achieving high productivity, especially in an industry where average run lengths are dropping, requires the ability to set machines quickly and accurately. On the new MASTERFOLD models, both the machine and any BOBST peripheral equipment can largely be set fully automatically, based on the job data entered, so reducing job set-up times to the strict minimum. Stored jobs can be recalled on the new Human Machine Interface (HMI) which also saves time during make-ready. Units such as the line's ACCUFEED module, or optional modules and peripherals such as SPEEDWAVE 3, EASYFEEDER/BATCH INVERTER 4, and CARTONPACK 4, have all been designed to be set quickly and easily with minimum operator intervention. Similarly, the new open frame design, which replaces barriers and guards with light curtains, maintains high levels of operator safety, but also means faster access to the machine, while podiums on each module mean that making adjustments is easier. In common with the previous version of the MASTERFOLD, many tools and elements stay on the machine when not in use, an approach that saves time on almost every make-ready.

New high-speed pre-feeder
The entire folding and gluing process depends on the accurate and consistent entry of blanks into the machine. This is ensured on the new MASTERFOLD by the proven ACCUFEED unit with integrated blank aligner. Automating the feeding process on the MASTERFOLD line at drupa is EASYFEEDER/BATCH INVERTER 4 – which builds on BOBST's thirty-year experience in developing pre-feeders. This latest generation allows feed-end operatives to be more productive, or to multi-task, while the smooth entry of blanks, and the maintenance of a consistent height of them in the gluer's feed hopper, helps maintain consistent feeding and so reduces both production stops and the risk of marking.

Every carton checked
The new ACCUCHECK 2 is another highlight of the MASTERFOLD premiered at drupa. This optional module is the only in-line quality control system available in the market that gives carton makers 100% checking of their products at the high speeds today's lines need to run at. This allows them to service clients that have "zero-fault" requirements, such as pharmaceutical and cosmetics brands, and, increasingly, those in liquor, food and other markets. The new ACCUCHECK 2 inspects cartons at speeds of up to 500 meters per minute and, along with inspecting the print and the text on the blanks, this new model also features: checking of embossing; inspection of foil-stamped or very reflective surfaces; and also has an all new blank cleaning device, exclusive to BOBST, which cleans every blank before it enters the inspection zone, making checking even more precise. As with the previous version ACCUCHECK, if a blank does not meet the quality specifications input by the user, it is ejected from the production stream, ensuring that 100% of the cartons reaching the packing line are compliant with the client's requirements.Almost instant crash-lock setting carton makers configuring their new MASTERFOLD can opt for the latest generation SPEEDWAVE 3, BOBST's innovative patented device for crash-lock bottom carton manufacture. Along with providing the consistent, high-speed folding of crash-lock boxes and perfect control of the front flap fold-over, SPEEDWAVE 3 is up to 80% faster setting than conventional crash-lock units, providing valuable additional uptime. The new version has been re-engineered to be even more sturdy, allowing it to run at higher speeds while also producing less noise.

CARTONPACK 4 - Capitalizing on performance
A high speed line is of little use if the products cannot be efficiently packed. The new MASTERFOLD models are available with CARTONPACK 4, which provides the fully automatic, intelligent packing of all types of boxes with fully automatic sheet layer insertion and needing almost no operator intervention. With its new automatic case erector from BOBST partner Lantech, that can handle up to ten cases per minute, CARTONPACK 4 can pack more than 200,000 boxes per hour and can run for up to 30 minutes without an operator.

More intuitive and productive operation
Making a machine easier and more logical to operate always contributes to increased productivity and with this in mind the ergonomics of the new MASTERFOLD have been looked at in depth by BOBST's engineers. This machine has an entirely new, and highly intuitive, Human Machine Interface (HMI), the central control unit of the machine. Larger than its predecessor, all the settings for the machine are accessed from a single page on its 22" full color, HD touchscreen. This new HMI easily guides the operator through the complete setting of the machine and peripherals step by step, and can now store up to five thousand jobs, making repeat runs ready to go very quickly and speeding up any changes needed during production.

An additional HMI is placed at the machine's feeder, while cameras allow the operator to monitor activity through the HMI without the need to continuously walk the machine. The new design of the MASTERFOLD means that all parts of the production line are instantly accessible, reducing set-up time, while the easy access open-frame platforms allow the operator to easily move within the machine for setting. The A3 configuration includes light barriers to ensure safety during the production process.
If the machine does stop unexpectedly, LED lighting indicates to the operator which section to go to, allowing them to get the machine back in production in minimum time.

Eco-friendly
The new MASTERFOLD is a quieter machine, creating a healthier working environment, while its more consistent folding quality means less waste. BOBST machines also have the longest service life in the industry, saving valuable natural resources.

Services that are Internet ready
Along with access to the worldwide network of BOBST services centers, which supply telephone and on-site technical support, spare parts and upgrades, packaging makers who invest in a new MASTERFOLD also have a machine which is ready equipped for BOBST HELPLINE PLUS and CONNECT services. These enable remote troubleshooting, access to production monitoring apps, and the ability to be integrated into plant management software.