Against a backdrop of tension over skills in flexible packaging, Bobst launches the new generation of its Expert K5 metallizer. Presented as the first autonomously operating machine in this field, the Expert K5 has been designed to automate critical tasks in vacuum metallization, thanks to AI-driven assistance functions.
AI-monitored metallization
The Swiss group, whose metallizers account for some 70% of the world's installed base, is targeting high-end film manufacturers and converters active in metallizing. The Expert K5 is the latest addition to an already well-established range, featuring enhanced automation with the proprietary Intelligent metallizing assistant (iMA).
According to Bobst, "the first and only full-width control system available on the market" . It allows simultaneous control of up to 50 evaporators, replacing manual adjustments with centralized console management.
The heart of the iMA system lies in the integration of sensors, HD cameras and algorithms, ensuring real-time monitoring of the line. It eliminates the need for constant manual intervention on aluminum evaporation temperatures for up to 50 evaporators.
Bobst's iMA system significantly reduces wastage
Bobst's iMA system also significantly reduces substrate waste. Optimization lengths are down to 5 km per roll, compared with 12.5 km on previous generations, representing a significant saving in substrate.
Compatible with the Bobst Connect platform, the new machine provides remote access for diagnostics and visualization of operations. Production data is catalogued to facilitate traceability and fault analysis. The operator interface has been redesigned to group all controls together, facilitating training on the machine.
In terms of materials, the Expert K5 is designed to handle a wide range of substrates: BOPE, MDO PE, CPP, paper and heat-sealable BOPP, with reel widths from 1350 to 4850 mm.
And a new option enables metallization of ultra-thin films (up to 6 microns) for paper lamination.
The machine is supplied as standard with the AluBond process, already proven to improve adhesion and barrier properties without the need for chemically treated films. As an option, AlOx GEN II technology enables transparent metallization on high-barrier BOPP.
"A real turning point for the flexible packaging sector"
Davide Garavaglia, manager of the rotogravure, vacuum, coating and laminating lines at Bobst, assures us: "This is the first metallizer on the market with such advanced automation, operating largely autonomously without requiring skilled operators. No other solution offers this level of intelligence and independence. This launch therefore marks a real turning point for the flexible packaging sector, decoupling human expertise from product quality and guaranteeing exceptional, reproducible coating performance and yields."
