Taylor made solutions for your swab production: the machine concept which is able to grow with your needs

CB-1 Family

Up until now swab machines had – if at all – very limited modularity. Once you decided for a machine that was it. There was little to no opportunity to let the ma-chine grow with the needs in accordance with the growth of your business. The CB1 family addresses exactly this shortcoming, amongst many other benefits the family offers. You can start in the swab business with a very basic machine, the CB1 – BK Bulk and extend it to the most sophisti-cated machine, the CB1 – HP high perfor-mance with all available modules. Along the way you can add modules step by step

to the basic machine thus making the best use of your initial investment. The table matrix below shows all the possible com-binations and all modules currently avail-able; more modules are under develop-ment and are of course compatible with the CB1- family! You set the corner stone of your swab business and keep building in exactly the speed and requirements your business has. We are here to analyse and consider your current needs for the swab production and provide you with more information and advice. Please be in touch with us.

The last 45 years all European cotton swab machines had to rely on a cotton sliver weight of around 1.5 g/m. It was one of the big challenges of the manufacturers of this industry. Now, in 2014, FALU AG brings a radical change into this industry.

FALU AG based in Rüti, Switzerland, origi-nal inventor of the current swab manu-facturing process, introduces the interna-tional patented draft system enabling the usage of 3 to 5 g/m standard slivers, called FDM (FALU DRAFT MODULE).

The FDM offers several advantages. You simply rely on a standard sliver from the textile industry making you independent from producers of special 1.5 g/m slivers. This is less expensive. The sliver is pro-duced on a conventional carding machine without special equipment. The increased load makes the carding machine much more efficient with a better quality sliver. The heavier sliver is stronger and does not break any longer; in addition it moves, for the same production rate of swabs, up to 3.5 times slower than today. Consequently you can use even shorter fibres. The use

Falu is in the last development stage (industrialisation phase) of a new bio-degradable stick to form cotton swabs. The stick consists of natural fibres, re-cycled cellulose fibres and other biode-gradable material and can be manu-factured in any colour. The extrusion process allows the price to be very com-

CB1-BK Bulk CB1-B Basic CB1-HP High Performance

Flexibility upgradeable to CB1-B upgradeable to CB1-HP

Swabforming

- High productivity system (speed 2900 s/min) • • • - Active belt drive (speed 2600 s/min) • • •

Shaper Bar open (Falu) open (Falu) open (Falu)

half open half open half open

closed closed closed

Speed swabs/ minute

- Mechanical speed 3100 3100 3100

- Production speed 2900 2900 2900

Fixing of cotton on stick

- Heating bars • • •

- Cold glue applicator • • •

- Hotmelt N/A N/A •

Specialities*

- Baby Swabs / Safety swabs • • •

- Cosmetic Swabs N/A • •

- Medical Swabs • • •

Controller (PLC) Simens S7-1200: basic functionality Simens S7-1200: basic functionality Simens S7-1200: extended functionality

- control of machine

- various statistics

- machine data to central office via network

Dryer

- Standard N/A • •

- Linear extra dry N/A • •

- Industrial compact extra dry N/A N/A •

Capacity stick magazine 8 boxes 8 boxes 8 boxes

Falu Draft Module FDM • • • Quality Control N/A N/A • Layer Control to always ensure full packages N/A N/A • Packaging manual semi-automatic with turn table; fully automatic semi-automatic with turn table; fully automatic with automatic packaging machine with automatic packaging machine

N/A = not available * some combination of modules may not be available; talk to us for your special requests

Significant Improvement in the Production of Cotton Swabs: The Falu Draft Module FDM

Biodegradable Sticks: coming soon…

of 1 meter diameter coiler with a height of 1 m is now possible resulting in unin-terrupted cotton swab production for at least 8 hours. Last but not least the sliver weight can be standardized within your production process using the same sliver for normal swabs, safety (baby) swabs and cosmetic swabs, hence preventing excess stocks.

petitive for a biodegradable stick. Next to sticks made of polypropylene, paper and wood, this adds a 4th option for a stick which is completely biodegrad-able using sustainable resources only. Falu plans to launch this stick in the 2nd part of 2014.

Packaging machine for square or rectangular boxes SQB-2A

Packaging machine for round boxes RB-30A

Cotton swab production machine CT-3000 series

Production and Packaging of Cotton Swabs with Falu Equipment

The SQB-2A is a fully automatic cotton swab packaging machine for square or rectangular boxes to be combined with a FALU cotton swab machine. It has a capacity of up to 30 boxes per minute, covers a wide range of boxes and it assures high-quality finished products.

Every box typically contains from 100 to 300 swabs.

RB-30A is a fully automatic cotton swab packaging ma-chine for round boxes to be combined with a FALU cot-ton swab machine. The machine has automatic units for the dispensing of round boxes, lids and closing of the lids. It guarantees a reliable and gentle product handling and delivers high-quality finished products.

Depending on the size of the box, the capacity of the machine is up to 30 round boxes per minute.

The round boxes typically contain from 50 to 300 swabs.

FALU CT 3001/04 is a very reliable and proven work horse available in the market for more than a decade. It has a production capacity of up to 2’700 cotton swabs per minute and a stick magazine accommodating 8 boxes (a box contains up to 40’000 polypropylene sticks and up to 30’000 paper sticks). The machine can either be operated with a turntable offering the advantage of vast flexibil-ity or with dedicated packaging machines for all known packages in the industry.

After the successful introduction of the CB1 family, the production of this machine will be discontinued. How-ever companies who wish to optimise on the basis of one model within their production will be able to do so and still purchase machines from the CT 3000 series in the near future. Spare parts will of course be available as for any other Falu machine for a long time to come.

Cotton packaging machine for card bord boxes SV-2-S

Packaging machine for polyethylen bags

The cardboard box presents the swabs in the most ap-pealing fashion pointing out the quality of the product. The printing on the box offers various designs.

The boxes are packed by the FALU SV-2-S, a fully auto-matic cardboard-box packaging machine to be combined with a FALU cotton swab machine. The cardboard boxes are also an ideal and space saver package for cotton swab. The packaging machine has a capacity of up to 36 boxes per minute; every card board box typically con-tains from 50 to 300 swabs.

FALU BV-2A is a fully automatic bag packaging machine to be coupled with a FALU cotton swab machine. The cotton swabs are automatically packed into bags which are subsequently sealed by an integrated welding sta-tion. The packaging machine has a capacity of up to 26 bags per minute.A bag typically contains from 60 to 300 swabs.

FALU BV-2M is a semi-automatic bag packaging ma-chine to be combined with a FALU cotton swab machine. After the bags are placed at the machine by the opera-tor, the machine fills the cotton swabs automatically into the plastic bags; the bag is then sealed by the operator at a separate welding station. The packaging machine has a capacity of up to 20 bags per minute.

FALU BV-MV, a semi-automatic bag packaging solution based on a jig, is especially suited for emerging markets. This packaging solution is to be combined with a FALU cotton swab machine with a round table. With the as-sistance of the jig nice looking polybags can be produced easily and efficiently with low capital investment.

Standard Swabs

Cosmetic Swabs

Baby Swabs /Safety Swabs

Medical Swabs

Medical Swabs

Round boxes Square boxes Card bord boxes Polyethylen bags Blister packages

Dancing Shaft of Cotton Pad production

Cotton Pad Packaging Machine RB-2

Cotton Pad Production Machine WR-2100-S family

Cotton Pad Production Machine WR-600 family

45 YEARS OF WORLDWIDE EXPERIENCE• Proven and reliable machinery Made in Switzerland• Branch leaders work successfully with FALU for many years• Efficient and reliable After Sales Service• Life long spare parts supply for FALU machinery• Well trained engineers are available at short notice• Since 2012 Falu also includes Bellini & Meda Machinery and Technology

Falu AGJoweid Zentrum 5CH-8630 Rüti(Switzerland)

T +41 55-225 51 51F +41 55-225 51 59sales@falu.com

FALU WR-600 is a semi-automatic cotton pad production machine ideally suited for the emerging market. Purpose of the machine is the semi-automatic production of vari-ous shapes of cotton pads. Depending on the size of the cotton pad, the machine has a capacity up to 960 pads per minute. The final product is filled by an operator into the package (for example into polyethylene bags).

Purpose of the machine FALU WR-2100-S is the fully au-tomatic high speed production of cotton pads and has to be combined with a fully automatic packaging machine (i.e. FALU RB-2 or OPTIMA).

The capacity reaches a maximum of 6’000 pads per minute, depending on shape and package size.

FALU RB-2 is a fully automated bagging and packaging machine for cotton pads and related products.It fills the bags automatically with cotton pads and seals them. It enables the use of a wide range of bags. The ma-chine has to be connected to the Interface of the cotton pad machine FALU WR-2000 and 2100-S series.It has a capacity of up to 52 bags per minute, depending on the bag size.A bag typically contains between 25 and 140 cotton pads.

Production and Packaging of Cotton Pads with Falu Equipment

www.falu.com

The continuous unwinding of the cotton tape and the cyclical feeding into the cutting area of the Falu stance WR-2000 causes considerable oscillations of the cotton tape. Today, various methods are being applied to dampen these oscillations. All of them cause additional stress to the tape.

In conjunction with the latest stance WR-2100-S Falu has developed a new way to con-trol the tape oscillation with much reduced stress to the cotton tape.

This unit, a dancing shaft, can be retrofitted to the WR-2000, which considerably re-duces the breaks of cotton tapes during the manufacturing process, allowing cotton tapes with reduced strength / weight to be produced with excellent process stability. The dancing shaft increases overall process stability, reducing micro stops during pro-duction hence enhancing productivity.

Why moisturise a dry pad with liquids from a bottle if you can pick an already wet pad from a box or a can? Pre-moisturised pads address the desire for convenience of the consumer and are expected to show significant market growth in the future.

FALU KPD is an automatic packaging machine for the production of moisturised pads working in combination with a FALU WR-600 cotton pad machine. The output of the machine is approximately 15 containers per minute. The machine fills the containers with the preselected number of pads and moves them forward to the next station where the pads are moisturised and the can is sealed and closed.

Automatic Packing Machine for pre moisturised Pads: the KPD

Falu offers quite a range of cotton pad production equip-ment. Whatever your needs are, we have the right solu-tion for you. Shapes of and patterns on the pad are almost without limits. The pattern of cotton pads can be easily changed with the use of an embossing cylinder, available as separate tool. This additional unit enables, prior to confection, to emboss

cotton pads with any desired design. Embossing makes the pad look more attractive and improves its stability. FALU cotton pad machines can produce pads in differ-ent formats, with or without stitched edges. The cotton pads can be made of the following materials: 100% cot-ton, 100% rayon or any desired combination of cotton and rayon. Talk to us, we will find the solution to your needs.