PP/PET STRAPPING 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.

Energy efficiency and simplified machine architecture
Our machines and strapping heads are designed without the use of pneumatic devices, eliminating the need for compressed air.

This choice makes it possible to reduce energy consumption, simplify the machine’s architecture, and lower operating costs, while improving reliability and operational continuity.

High performance, simplified maintenance

The TOSA ALFA series strapping head is designed to work with PP and PET strap and is built on a modular architecture consisting of two independent units: tensioning and sealing.

The units can be quickly detached without tools, allowing maintenance and replacement operations to be carried out in a very short time and with total simplicity.

The head integrates brushless motors with onboard electronics and encoders, enabling precise control and full parameterization from the HMI, without the need for mechanical adjustments.

Key features:

• Modular Plug & Play system

• Full control from HMI

• 48V power supply for safety and efficiency

• No pneumatics

• No welding fumes

Available with vibration sealing unit (standard) or ultrasonic sealing units (optional). The ultrasonic sealing units are characterized by a complete absence of noise and dust during the process.

Maximum flexibility for variable production

The system allows the type of strap used to be changed automatically, adapting to pallets with different characteristics.
It is possible to handle variations in material (PP/PET), thickness, dimensions, or strap type — including branded strapping — without operator intervention and in less than 30 seconds.

An ideal solution for dynamic production environments, where flexibility and speed are essential.

Operational continuity without operator intervention
The automatic strap change system allows for the replacement of an empty reel in less than 30 seconds, without interrupting the production cycle.

The solution is designed with two roll trolleys positioned in separate safety areas, allowing the operator to prepare the new reel while the machine is running.

The system automatically manages the transition between reels, ensuring operational continuity, safety, and reduced downtime.

Beyond strapping, complete protection

In some applications, the strap alone is not sufficient to ensure load protection.

That’s why we offer integrated solutions that enhance safety and preserve product integrity during transport.

Strapping machines can be equipped with:

• corner posts application systems

• cardboard applicator systems

• wood beam applicator systems

to ensure a protected, stable load ready to handle every stage of the logistics process.