Bastos Group Automates Its End-of-Line Packaging for Paper and Cardboard in Portugal with Innova

At Innova Group, we adapt to every challenge presented by each client and every industry. Whether handling heavy loads or fragile and lightweight products, packaging systems must be tailored to meet each customer’s specific requirements. This was the case in the paper and cardboard sector with Portuguese paper distributor Avelino Bastos (Bastos Group), which needed to automate its end-of-line packaging and improve load protection. Avelino presented us with a very specific challenge in terms of load securing and stability, considering the fragility and deformability of this type of product.

 

With this objective in mind, Innova recently installed an automatic packaging line at Avelino Bastos consisting of vertical strapping systems and a rotary arm stretch wrapper, along with accessories specifically designed to meet the securing and compacting needs of these products. The installation was carried out at its production plant in Caldas de São Jorge, Portugal. Avelino Bastos Lda is a leading Portuguese company in the distribution and commercialization of paper, cardboard, and related products, dedicated to offering sustainable, high-quality packaging solutions to both domestic and international markets.

 

The automation challenge at Avelino Bastos

 

Avelino Bastos was undergoing a growth phase and needed to automate its end-of-line packaging to respond to increased production and improve logistics efficiency. Until then, the company relied on a semi-automatic end-of-line process, with manual strapping of loads and a semi-automatic stretch wrapper, resulting in longer packaging times and greater labor involvement in the logistics area.

 

The main objective was therefore to optimize resources through automation: reducing packaging times while improving overall efficiency and final packaging quality. By upgrading its packaging systems and transitioning to automation, the company also aimed to increase load stability and securing during transportation and handling.

 

The paper and cardboard industry presents various packaging challenges, as products come in many different formats, including pulp and paper reels, paper boxes, stacked sheets, and more. Many of these formats consist of lightweight and fragile loads that can deform or become damaged during transport if not properly secured. For this reason, moving to an automated system was one of Avelino Bastos’ key objectives in improving its logistics and product commercialization.

 

Innova’s solution: a line adapted to paper protection

 

To meet these objectives, Innova’s technical team designed a customized packaging line integrating the following systems:

 

FV | Pro vertical strapping system

The first stage of the line consists of an automatic vertical strapping system designed to secure the cardboard load to the pallet base. This application provides increased stability and load compacting, which are essential to prevent shifting or deformation during transportation.

 

The strapping machine is equipped with Innova’s ODEN strapping head, manufactured and patented by Innova. It stands out for its lightweight, compact, and precise design, reducing maintenance times and ensuring greater reliability in strap tensioning. This in-house developed strapping head combines energy efficiency with consistent and uniform strap application, even on delicate loads such as those handled by Avelino.

 

AWS | TechLite rotary arm stretch wrapping system

The load then moves to the AWS TechLite automatic stretch wrapping system, especially suitable for lightweight and unstable loads such as Avelino Bastos’ paper and cardboard products. The rotary arm wrapper also includes Innova’s patented ROPING GRIP wrapping finish system, which adds greater pallet stability. This wrapping finish is applied in the form of a film rope that reinforces the base of the load.

 

The automatic stretch wrapper installed at Avelino includes two key accessories for paper loads: a top press system and a top cover applicator. The automatic top press holds the load firmly during the wrapping process, preventing product shifting or deformation. Meanwhile, the automatic top cover applicator adds a protective film cover to shield the load from dust, moisture, and other environmental conditions during storage or transport.

 

• Pallet conveyor line

The packaging installation is completed with a pallet conveyor system consisting of an infeed line, a pallet centering device, and an outfeed line with an accumulation area. This setup enables a continuous and automated flow from the end of palletizing to the end of the packaging process.

 

Results: automation, precision, and safety

 

With the installation of this new packaging line, Avelino Bastos has achieved complete optimization of its end-of-line operations, reducing wrapping times and manual intervention while improving load compacting, stability, and final presentation.

 

Thanks to Innova’s solution, the company now operates with a fully automated, flexible system that adapts to its production pace, providing the reliability and safety its products require.

 

At Innova Group, we are proud to have collaborated with a leading company in the paper and cardboard sector such as Avelino Bastos, contributing our expertise and technology to strengthen its production process and support its growth. This project also represents another example of how Innova responds to the needs of each industrial sector by adapting and developing our solutions to deliver maximum performance and load protection in any production environment.

 

Thank you, Avelino Bastos, for trusting Innova for your automation project!