Why TOTANI?

Overview and Feature

The idea that pouch made of plastic film are quare has been changed significantly. In front of supermarket or convenience store, shaped package with fashionable and functional design is appealing to consumers strongly. Mainly shaped pouch suits market needs. Do you give up manufacturing shaped pouches only with the common sense that it costs too much to manufacture pouches with shaped design? Totani's Thompson die-cut unit for full shape uses Totani's original In-line Thompson method to solve the problem of manufacturing shaped pouches completely.

Totani expands the possibility of making shaped pouch.

Totani's original In-line Thompson method allows for the In-line high-speed die-cut which die-cuts film around pouch together with Thompson blade on one pouch making machine to make pouch with complex shape, thereby enabling rounded corner cut, notching at pouch top and shape-cut which changes pouch into various shapes.

Great! In-line high-speed die-cut

Unlike the existent die-set method, heavy and large shape-cut blade need not be prepared at each processing unit. The in-line Thompson method uses Thompson blades which are compact and are easily exchangeable. In this method, when pouch design is changed, Thompson blades have only to be exchanged. The design of shaped pouch can be changed within short period and at low cost.

Great! Advantage of Thompson blade

Totani's original <kiss touch> control can manufacture massive shaped pouches with Thompson blades. Totani upset the common sense that Thompson blade is nondurable.

Great! Mechanism of <kiss touch>

In-line high-speed die-cut method can manufacture shaped pouches together on one pouch making machine. Unlike the existent die-set method, several units need not be adjusted at each processing unit. Therefore, burdensome machine adjustment and material consumed in test at adjustment can be minimized.

Great! Time loss and material loss are reduced drastically

Applies to Totani's BH-60D model (High-speed. three-side-seal, automatic pouch making machine), BH-60DS model (High-speed. three-side-seal, automatic pouch making machine with standing pouch unit), BH-60DC model (High-speed. three-side-seal, automatic pouch making machine with zipper seal unit) and BH-60DSC model (High-speed. three-side-seal, automatic pouch making machine with standing pouch and zipper seal units). Shaped pouches which suit market needs, including three-side-seal type of pouch which is used to package of retort food and standing pouch with zipper, can be manufactured.

Great! Applies to many models

Totani changes the common sense of shaped pouch making from heavy and large shape-cut to lightweight and compact In-line Thompson method.

Great! Totani's original In-line Thompson method

Great! Originality of Thompson die-cut unit for full shape (1)

No die-set blade is required. Only low-cost Thompson blades can be used to process.

In the case of the existent die-set method which is used to cut shaped pouch, generally, rounded corner cut, notching in pouch top and shape-cut which changes pouch into various shapes require four types of die-cut blades for all processing units, including the final stage of guillotine cut. All the blades that are used to processing in four units cost about $7060 (*1), or, including spare blades, $14120. Also, as the blades used in the die-set method are large and heavy, their transportation and maintenance cost much.

In the case of Totani's Thompson die-cut unit for full shape, one set of Thompson blades, corresponding to design shape, has only to be prepared. High-speed shaped pouch making is enabled at about a hundredth (*1) of the existent cost. For example, under the same processing condition as above, the cost is about $706.

As Thompson blades are very thin, lightweight and flexible, compared with the die-cut blades used in the existent die-set method, they realizes complex, subtle and beautiful design.

(*1) It depends on processing shape.

Great! Originality of Thompson die-cut unit for full shape (2)

<kiss touch> control improves endurance of Thompson blade considerably. Totani upset the common sense that durability of Thompson blade is low. Totani realized 1,000,000 CMP (1,000,000 time die-cut = manufacturing of 2,000,000 pouches per minute)

Its secret lies in <kiss touch> control. Thompson blade which die-cuts pouch contacts with Base plate that receives the blade only several micrometers (1 micrometer = a thousandth of a millimeter). <kiss touch> control is explained simply below. A professional cook cuts one leaf reliably, quietly and lightly, without damaging a chopping board. Meanwhile, an amateur cook puts down a kitchen knife too deeply, and damages a chopping board or fails to cut a leaf.

Totani's original <kiss touch> control die-cuts around pouch together, softly and quietly to change the pouch into shaped design accurately, like professional cook. This <kiss touch> control prevents abrasion of blade extremely and rarely damages Base plate. Thus, Totani succeeded in considerably increasing durability of Thompson blade with drawback in durability. The height of Thompson blade can be adjusted in micrometers, thereby enabling extremely fine adjustment in accordance with abrasion of the blade.

<kiss touch> control requires high-precision processing of the entire machine including Base plate, as well as the technology to control vertical movement of Thompson blade. Totani used not only know-how of precision machining but also electronic control and sensing technologies to increase durability of Thompson blade considerably, which is difficult technically.

Great! Originality of Thompson die-cut unit for full shape (3)

Machine adjustments are simplified and material loss is reduced considerably, which reflects local input that, when there are many processing units, it takes much time to adjust machine due to stretch or misalignment of material.

In the case of the existent die-set method, accurate rounded corner cut, notching or shape-cut requires each adjustment at three units. For example, when rounded corner cut fails on pouch making machine, the machine must be stopped, be adjusted, be tested and then be operated. In this case, if the machine has many adjustment units, error occurs frequently due to stretch or misalignment of film in its operation, and it takes much time to adjust the machine.

Meanwhile, Thompson die-cut unit for full shape can die-cut around pouch together to change the pouch into any shape on one pouch making machine. Therefore, one unit has only to be adjusted. Due to brief adjustment and high-precision positioning, the machine need not be adjusted frequently, and test time associated with adjustment can be reduced. Also, defective products due to stretch or misalignment of material film are unlikely to be manufactured, and stable shape and beautiful finish can be acquired.

Great! Originality of Thompson die-cut unit for full shape (4)

Shape can be changed or corrected easily, which suits rapidly changing market needs.

As above, in the case of the existent die-set method, four types of die-cut blades must be prepared, including the final stage of guillotine cut. The blades cost much.
Also, it takes about two months (*1) to manufacture the blades, and pouch design or shape cannot be changed at once.

Meanwhile, in the case of Totani's Thompson die-cut unit for full shape, when pouch design or shape is changed, Thompson blades have only to be exchanged. It takes only two to three days (*1) to manufacture the blades. The blades can be manufactured at about a hundredth (*1) of the existent cost. Thompson die-cut unit for full shape applies to not only various shapes and designs but also various pouches, including three-side-seal type of pouch which is used to package of retort food and standing pouch with zipper sealing.

(*1) It depends on processing shape.


* The information on this site is subject to change without notice.

Page Top