How to automate the production of products? Learn about a new machine for cutting, folding and packaging material in bales from CPP “PREMA” S.A.

How to automate the production of products? Learn about a new machine for cutting, folding and packaging material in bales from CPP “PREMA” S.A.

Nowadays, when competition in the market is increasing, entrepreneurs are looking for ways to speed up and improve production processes. One of the key aspects in production is the use of appropriate equipment and machines that allow automation of certain stages of work. It is one such device that we want to talk about today. The bale cutting, folding and packaging device we designed is designed to measure a preset length of material from a spool, and then wind it to the appropriate width to transport it to the bale folding section. The felt is then bagged and sealed. After the label is placed on the bag, the finished product is transferred to the interleaving device for the product grouping sections. After a preset quantity is obtained, the whole thing is transferred to a cardboard box using grippers on a special feeder. The entire process is protected by a fence and safety curtains. The fence does not protect the process itself, only the equipment and the working area of their operation.

In our article, we want to introduce readers to the functioning and advantages of this type of equipment. We will be discussing the process of folding nonwoven fabric and felt (polish audio only), as well as describing in detail the various stages the material goes through by using the designed device. We also want to draw attention to the benefits of automating production processes, such as improving quality, increasing productivity or work safety. In this tutorial article, we will also present how to operate and maintain the device.

Position 1 - Loading and fixing the spool

The first step in the process of preparing material for further processing is to place a specially prepared shaft with a spool on a forklift. The shaft with spool is then transferred to a socket with bearings that allow it to rotate. In order to prevent the material from unwittingly advancing, which could affect the safety and quality of the process, a brake is used. The next step is to run the material through guide rollers and a buffer that adjusts its length and width for further processing.

Position 2 - Measuring the material

The second station in the manufacturing process consists of several steps. The first is the measuring of the material, which is done with rods arranged parallel to each other. One of the rods is movable and equipped with a clamp that allows the material to be blocked before being rolled. The width of the material to be rolled is about 400 mm, but can be changed during the process. Once the material is rolled up, it is cut with a knife at a designated point, and then the movable bar is loosened so that the grippers can move it to the next station. The length of the material is confirmed with an external encoder, which ensures that the required amount of material is measured accurately.

Render maszyny do składania materiału w belach

Position 3 - Folding into cubes

Grippers transport the material to a cube folding station. It involves folding the material in half twice, which means that a 400 × 1000 mm section of felt yields a 400 × 250 mm cube.

Position 4 - Wrapping in foil and labeling

After the felt is folded into cubes, the products are shrink-wrapped, using a heat sealer. The package is then moved to a label printer location. The printer places the previously prepared label on the foil bag.

Position 5 - Grouping and packaging boxes

The finished product is transferred to a section, where it is transported to the grouping area. We accumulate the preset amount that is needed to fill the entire box. The whole product, with the help of a bunch of grippers, is transferred to the grouping package. When packing the finished product into boxes, it is important to pay attention to the optimal grouping of products. This allows you to fill the entire box and minimize the amount of empty space in it. When choosing a grouping method, it is worthwhile to be guided by customer needs and preferences.

Position 6 - Box dispenser

The dispenser allows manual application of unfolded boxes to be filled with products. Three empty boxes can be pre-positioned on it. The boxes are automatically transported to the loading point, where they are filled with the appropriate products. Once the loading process is complete, the box is moved to a location where the operator can pick it up and prepare it for transport.

Basic specifications

The machine, designed and manufactured by CPP “PREMA” S.A., is used for cutting and winding felt, nonwoven or other material in bales from 1000 to 4000 mm long and 1000 mm wide. The material is wound onto spools with a diameter of 700 mm. The machine is powered by 400 VAC and controlled by 24 VDC. The machine requires compressed air with a minimum pressure of 6.5 bar (MPa).


In the following article, we described a new machine for automating the production of felt cubes or other materials in bales, which was designed for one of our customers by the automation department at CPP “PREMA” S.A..

The machine consists of six sections: loading the spool, measuring the material, folding into cubes, wrapping and labeling, grouping and packing into boxes, and a box dispenser. CPP “PREMA” S.A. has been assisting in the automation of production processes in many industries for many years, and the experience gained and the qualified staff ensure each launched application’s element’s high quality of execution.

Innovation in bale folding machine

More than 240 pieces in just one hour, capable of continuous work 24 hours a day, ability to assemble cubes from a variety of materials in different weights, the most effective feeding medium and proven solutions that can increase your company’s production efficiency.

It is worth remembering that if you have any questions about dedicated solutions, the staff of CPP “PREMA” S.A. can help you choose the right system with solutions for bale folding machines.