Ellemoi Kanto installs first Bobst Mastercut 106 PER in Japan

Japanese converter, Ellemoi Kanto, has enhanced its die-cutting capabilities and productivity after investing in a BOBST MASTERCUT 106 PER– the first installation of its kind in Japan. The install was done earlier in the year, and went smoothly despite the pandemic.

Almost 20 years after first purchasing a BOBST die-cutter, the SP 104 ER, Ellemoi Kanto once again turned to BOBST.

“When we first bought the SP 104 ER all those years ago, it was one of the fastest on the market, with a maximum speed of 8,000 sheets per hour,” said Hideyuki Matsumoto, Plant Manager at Ellemoi Kanto. “Recently, with demand for ever faster turnaround times and even higher quality standards, we found that the SP 104 ER was creating a bottleneck in production. We recognised the need to increase productivity while ensuring quality was maintained.

“The maximum speed of the MASTERCUT 106 PER, at 11,000 sheets per hour, made this an attractive investment choice. We knew that if we upgraded our printing presses and converting lines in future, the MASTERCUT would be able to handle any change. Essentially, we have future-proofed our production line with one key investment.”

Ellemoi Kanto is part of the Kami Shoji K.K Group which employs more than 1,100 people across Japan. The company supplies tissue, toilet rolls and incontinence products, along with other hygiene products.

“When I first decided that we were going to need to invest in a second die-cutter, I originally considered the EXERTCUT 106 PER and I went to see this machine in action at BOBST in Switzerland. While there, I was provided with a full factory tour and saw the MASTERCUT too. I knew that I wanted to buy the fastest machine available, as speed and production were the main reasons I was in the market for a new die-cutter. During the demonstration, a BOBST specialist transferred the tooling from the EXERTCUT 106 PER and put it on the MASTERCUT 106 PER. I found it very impressive to see that without any alteration on the tooling, the MASTERCUT could run at the maximum speed of 11,000 sheets per hour,” Matsumoto added.

“Our ethos at Ellemoi Kanto is to always act with vision and stay one step ahead. The MASTERCUT is enabling us to live that philosophy. In the months since it was installed, we are already seeing a significant increase in production capacity. Thanks to this investment, we are also looking to move to one-man operation for this machine which will free up a valuable resource in the business to support efforts elsewhere on the production floor,” said Matsumoto.

MASTERCUT 106 PER is the most highly automated and ergonomic die-cutters on the market. The top-of-the-range machine delivers unmatched productivity thanks to fast, uninterrupted production and short set-up times, while also ensuring supreme quality.

It is the only die-cutter that can be set from just a single point of control and automates functions from ‘feeder to delivery’. This translates to minimal operator intervention during operation. Stripping and blanking tools settings are automated thanks to the new MATIC Plus system, which uses cameras to measure the position of tools and then aligns them automatically in register to the printed sheet. Jam detection and settings have also been automated, as has the non-stop rack system in the delivery section.

As a ‘next-generation’ die-cutter, MASTERCUT can incorporate TooLink, a platform that connects the die-cutter with a digital ID that enables instant recognition through the machine’s HMI. The machine automatically detects chip-equipped tools and provides a production-ready job recipe, leading to both waste and time savings of up to 15 minutes during job changeovers. It also allows automatic job recall without any operator intervention.

Ellemoi Kanto invested in BOBST Helpline Plus remote assistance service when purchasing the machine. Helpline Plus enables BOBST experts to access machines via a secure internet connection, enabling them to diagnose and troubleshoot any issues remotely. In this way, customers can reduce costs and minimise the need to call a BOBST technician by up to 80%.