Tucker Rocky, American company leader in the distribution of quality clothing and accessories for motorcycling, chose Robopac as partner for tyre packaging which markets across North America. For the company of San Marino it has been a successful challenge: the Compacta S series wrapping machine - that uses horizontal wrapping technology with stretch film- has in fact been developed and modified for a new market and needs, yet never explored before.

Tucker Rocky needs

The Tucker Rocky company - which has seven offices located throughout North America and sells a huge number of items (75,000 pieces in the catalogue) to motorcycle shops or directly to individuals (via Internet) - contacted the US subsidiary of Aetna Group to improve the tyre packaging system, both in relation to the functional and aesthetic appearance and to the reduction of costs and packaging time. In the Tucker Rocky range there are tyres of all sizes and types: for road, motocross, per quod, electric cars, bicycles, mountain bikes. Previously, the tyre packing taking place with the application of two paperboard, cut to measure, applied on the two sides of the tyre and finally strapped. A complex operation that takes too time and that was definitely not very user friendly . The company's objective was also to provide a response to customer complaints that sometimes received, perhaps after a long wait, tyres not in perfect condition. Together with Robopac, an alternative solution to the existing has been therefore looked for.


The solution studied together with Robopac

To deeply understand the needs of the customer, the technical staff of Robopac has thoroughly studied the technical data and the machines available, considering different options. At the end of the preliminary stage, the most convincing proposal foresees a type of semi-automatic tyres packaging with wrap-around packer. During the development of tailor-made machine it was very important the active collaboration of the client company - and in particular of Dan Kent (Director Operations of Tucker Rocky) - who then sent all samples in Italy, taking part in the tests and agreeing the mechanical modifications necessary to make the solution more customized and perfectly suited to the type of product to be treated. The solution, after seeing the layout of the test, was then approved by Tucker Rocky, which then took a first order of nine machines. The new system starts with the operator which positions and stacks the tyres in the conveyor belt. A conveyor with rollers inclined to idle roller moves them leading them up to the Robopac machine, which places them in rotation to achieve the full wrapping with the application of stretch film.

Saving of time and materials

The feedback from Tucker Rocky was immediately very positive and Robopac machines have made in full their duty. Numerous advantages were immediately reported by the customer:

- a consistent saving of time in the tyre packaging operations, which means greater productivity;

- the tyres are more protected and therefore subject to minor damages ;

- the opportunity to easily apply a label on the stretch film involves improvements in terms of shipments, allowing the monitoring of each batch;

- the greater ease in handling and carry the batches guarantees improvements in logistics;

- packaging with stretch film is extremely more flexible than the cardboard;

- An aesthetic improvement of the batches was obtained, plus the savings on the cost of packaging materials;

- the new solution provides significant advantages in the storage and disposal of consumable materials, represented today by the stretch film reels.


Further developments

Considering the effectiveness of new solutions installed, the client company required then other five machines with a larger diameter (1200 mm), also in view of the recent merger of Tucker Rocky with a new important company that produces large tyres. Currently Robopac has already been engaged to explore more options for make the whole process even more powerful, improving the general logistics by inserting lines even more automated, always by mutual agreement and in close cooperation with the client, with the common goal of becoming more efficient and faster. The new system should provide a motorized infeed conveyor that leads tyres to the car. Once packed with stretch film, the conveyor will bring them back to the operator, who will apply the label and record the load. A lateral work plan allows to properly house printers and scanners. Where appropriate, it may also be provided a side output to 90° to bring the tyres packed towards the central transport system.

The Compacta S series

The machines Robopac Compacta S series have proved on this occasion robust, easy to use, extremely flexible. Thanks to the different diameters of the rotary shroud, the range of these machines covers comprehensive countless categories of products, the most varied shapes (in this case, circular) and sized. Compacta S is a machine that combines the construction solidity to the automatic wrapping operations of the first level. The versatility and the ease of use - combines with high quality that distinguishes it - places this Robopac product at the top of its category.

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