Case Study: Hansa-flex ag
Automating End-of-Line Logistics with Mosca
A Strong Partnership
For the past year, HANSA-FLEX AG has used an end-of-line solution from Mosca GmbH in Geisenfeld, Bavaria. This system automatically straps pallets, then weighs and labels them to streamline shipping. The main feature is Mosca’s fully automatic KZV-111 pallet strapping machine, which brings together advanced conveyor and strapping technology with automated data processing. Mosca’s SoniXs technology makes sure HANSA-FLEX AG’s pallets are securely sealed before shipping.
Every day, about 250 pallets leave the HANSA-FLEX South Central Warehouse in Geisenfeld, each weighing around 881 pounds. To manage this workload more efficiently, HANSA-FLEX chose to automate the pallet securing process, which had previously been done manually.
Before automation, operators used handheld tools to strap the packages. Automating this step speeds up the process and reduces physical strain on staff. The new line also handles weighing and labeling, assigns packages to the right logistics provider, and sends data to both the company’s ERP system and the service provider for processing and billing.
Once strapped, the package moves through the rest of the line until it is ready to ship. One conveyor has four load cells that weigh each package automatically as it arrives. The system then creates a shipping label, prints it, and attaches it to the package. At the same time, the label data goes to both the HANSA-FLEX ERP system and the logistics provider for processing. Finally, a turntable directs the package to the correct forwarding station.
HANSA-FLEX AG
IN WITH THE NEW
Mosca stood out in early talks with HANSA-FLEX for its technical know-how and comprehensive package of machines, conveyor systems, belt material, and services. Working closely with Mosca, HANSA-FLEX staff designed an H-shaped processing line centered around the KZV-111.
Large boxes are strapped to pallets and brought to the start of the line by forklift. Automatic conveyor units, a turntable, and a centering unit move and align the boxes before sending them to the KZV-111. The system uses light barriers to detect package size, guides the package between the pallet’s wooden gaps, and straps it twice. A contact strip helps prevent pressure damage to the carton. Mosca’s ultrasonic technology ensures strong, secure seals with high tear resistance.
HIGH PERFORMANCE FROM
MODERN MACHINE TECHNOLOGY
The KZV-111 has proven its value thanks to several useful features. It can strap up to 500 packages twice a day. The strap tension is fully adjustable; HANSA-FLEX currently uses 30 percent tension, but the machine can go higher if needed. "Mosca has given us plenty of room for improvement in our current use," says Daniel Beran, team leader at HANSA-FLEX.
After a year, the machine’s easy operation stands out. "The KZV-111 from Mosca integrates seamlessly into our daily work," says Daniel Beran. "The machine is easy to understand and hardly prone to errors. It only takes 15 minutes to train an employee with no prior knowledge. That's a big time advantage." The success of this line supports HANSA-FLEX AG’s plans to automate additional End-of-Line processes. Another fully automated line is already running at the Bremen site, handling smaller packages with its own automated conveying, labeling, and sorting system.
CUSTOMER SATISFACTION
CONCEPTUALIZATION, PRODUCTION & MAINTENANCE FROM
ONE SOURCE
The whole process is now automated, quick, and efficient. "Before the new packing line was commissioned, three of our employees worked full-time to get pallets ready for dispatch. Now one or two colleagues can do it in half a day," says Felix Kaufmann, Head of Central Warehouse South at HANSA-FLEX. "The increased level of automation has made our entire process leaner. Many manual operations are no longer necessary, which means that the work is less physically demanding for our colleagues."
"Mosca's flexibility is an important plus point, even when it comes to service. If a fault does occur with the machine, the service team and our direct contact are always available and provide us with quick and uncomplicated solutions."