Mugler Masterpack GmbH has taken a major step in modernising its packaging production by installing Germany’s first Side Seam Gluing Solution from Baumer hhs.
This innovative, non-contact gluing system—based on the high-performance PX 1000 application head—was installed in autumn 2023 on a MEDIA 68 folder gluer and has already delivered outstanding results.
Facing increasing labour shortages and cost pressures, Mugler Masterpack was searching for a smarter solution to improve productivity and reduce manual intervention. “We have to automate everything we possibly can and simplify our processes with intelligent solutions. The Side Seam Gluing Solution from Baumer hhs is exactly what we needed,” said Ulli Mugler, Managing Partner of the family-run business.
The new system replaces traditional glue disks, which have seen little innovation for decades. In contrast, Baumer hhs’s gluing solution ensures high-precision, clean adhesive application without contact—cutting glue consumption by up to 50%, eliminating manual cleaning, and drastically reducing downtime. It also enables faster job changeovers, helping to offset the skilled labour gap by simplifying machine operation and setup.
Despite being retrofitted into a 20-year-old machine, the system integrated seamlessly and has since run in three-shift operation without interruption. In addition to side seam gluing, Mugler Masterpack also upgraded its top gluing unit with modern PX 1000 heads and quality assurance tools such as the GDX 1000 sensors and Xtend3 controller—further boosting productivity and reliability.
“Our investment has clearly paid off,” Mugler said. “The improvements are visible in day-to-day operations. We’re moving closer to zero-defect production and increasing output without increasing headcount.”
Mugler Masterpack now plans to equip more of its machines—some of which run at speeds of up to 650 m/min—with the Baumer hhs system. This strategy is part of a broader initiative to future-proof operations through automation, especially as the company prepares for workforce transitions in the coming years.
Founded over 130 years ago and employing 250 people today, Mugler Masterpack operates two production sites in Saxony and supplies premium folding cartons to customers across Germany, Austria, France, and Switzerland. The company serves key industries including food, pharmaceuticals, hygiene, and automotive.
Baumer hhs’s partnership with Mugler Masterpack reflects the growing importance of intelligent automation solutions in packaging production—helping manufacturers stay competitive while meeting increasing demands for quality, sustainability, and efficiency.
