Traceability and zero defects? How to overcome the new challenges of converters
May 14, 2025
By Raul El Fakdi, Slitting BU Director and Jordi Prat, Slitting Technical Sales Director, Comexi.
Industrial automation has revolutionized the flexible packaging industry, enabling companies to improve efficiency and reduce errors in their production processes. However, the implementation of these solutions not only responds to the need to optimize production times, but also to ensure the safety of workers and the quality of the final product.
A clear example of this positive impact is the case of Plásticos Sierra del Oro, which recently automated its production line with Comexi technology. Their experience demonstrates the tangible benefits of this technological investment and how it has transformed their daily operations.
Plásticos Sierra del Oro is a packaging converter for a wide range of sectors, especially food, and is continuously expanding into other markets such as PETFOOD. It offers flexographic printing, lamination, micro/macro perforation and plastic film slitting services. Since its foundation in 1995 in Murcia, Plásticos Sierra del Oro has relied on Comexi as a technological partner, integrating its machinery in all stages of production.
Challenges prior to automation
Before installing the automated system, Sierra del Oro faced several challenges on its production line. Manual handling of loads by operators was not only physically demanding, but also created ergonomic risks. In addition, the pressure on the operators was high, which affected their attention to critical aspects of the process.
Another major challenge was the reliability of data collection within the plant. Automation has made it possible to obtain accurate data on production efficiency directly and without human intervention, speeding up analysis and improving decision-making to increase productivity.
“The main reason for installing automation was to eliminate load handling by our rewinding team, improve the quality of data collected in the factory, and increase line productivity. The person in charge of the machine works with less pressure and fatigue and improves attention to key aspects of the process,” explains Miguel Angosto, Assistant Manager of Plásticos Sierra del Oro.
Choosing Comexi: experience and trust
After evaluating several options, the company chose Comexi for its experience and evolution in the sector. The relationship between the two companies, consolidated over more than twenty years, has made Comexi a fundamental strategic partner. Sierra del Oro had already taken an important step in terms of quality and capacity with the acquisition of several high productivity double-turret slitters. The next logical step was to automate the tasks that were still done manually.
“We analyzed different options, and Comexi’s was the one that convinced us the most. Our common path began more than twenty years ago, and it has helped us to consolidate our position as a reference in the sector”.
An efficient design process and comprehensive support
One of the highlights for Sierra del Oro was being able to count on a turnkey solution, carried out in close collaboration with Comexi’s technical and commercial team.
“The design process was very efficient thanks to the collaboration between our team and Comexi’s team, the support was excellent in all aspects. We believe that the success of the project has been greatly facilitated by the fact that it has been carried out by a single company that has perfect knowledge of the operation of all the elements involved”, emphasizes Miguel Angosto.
ERP integration and improved traceability
Automation has also enabled more efficient integration with its ERP, which has optimized data management in the plant. This integration has eliminated manual data entry by operators, reducing errors and streamlining the production process.
“The integration with SAP has allowed us to improve the quality of the data collected in the factory, and we have eliminated manual data collection by the operator, which speeds up the process and reduces errors,” concludes Miguel Angosto.
Key benefits of automation
Investment in automation has proven to be a successful strategy for packaging companies, bringing significant benefits:
- Increased productivity: effective operating time is maximized, allowing lines to run at higher throughput.
- Zero errors: Automation avoids manual reel handling and drastically reduces the risk of errors.
- Reduced labor costs: Optimizes the distribution of personnel, focusing them on higher value-added tasks.
- Improved ergonomics and safety: The risks associated with handling loads are reduced, protecting the health of employees.
- Improved quality control and traceability: Thanks to automation and integration with the ERP, errors are minimized, and quality standards are improved.
- A single supplier for the whole solution: The choice of Comexi as a single supplier facilitates the integration of the solution, ensuring an efficient and coordinated after-sales service.
Automation as a key to competitiveness
The implementation of automated end-of-line systems not only improves the efficiency and quality of the production process but also reduces costs and enhances worker safety. As demand grows in the flexible packaging industry, automation is positioning itself as a strategic necessity for all companies wishing to remain competitive.
The case of Plásticos Sierra del Oro illustrates how a well oriented investment in technology, accompanied by the support of a reliable partner such as Comexi, can radically transform the operation and guarantee a more profitable, efficient and safe future.
