Barca de Mexico Brings Technology to the Forefront

Jose Ignacio Barragán Ocampo stands beside the newest machine installed at his corrugated packaging plant in San Juan del Río, Querétaro, Mexico. The equipment, a J&L Mark 5 XT Specialty Folder-Gluer, folds, glues, and ejects completed boxes at speeds that would have been difficult to imagine a year ago. The machine is now fully operational. The process of bringing it to the floor, however, started much earlier.

For years, Barca de Mexico relied on manual folding for several of its product lines. This method was sufficient for simpler box styles, labor was consistent, and the team managed the workload well. But as demand changed, a particular box design began to have higher levels of demand: the 4-cell auto bottom. The design, used for packaging items like beverages and other goods that require internal compartment, is more complex to assemble than standard designs, and presented a unique challenge.

Manual folding and gluing of these boxes took time. According to Ocampo, the main challenge was “the processing time that was invested to arrive at the final product needing a greater number of people to carry out the process.” The team was able to fulfill orders, but the process required considerable labor, which limited overall capacity. As the volume of 4-cell boxes increased, it became clear that continuing with manual work would either lead to production delays or require additional staffing.

EXPLORING THE OPTIONS

This created both a problem and an opportunity. The issue was clear: the plant needed to process complex boxes faster and more consistently. The opportunity was to make an investment that could improve the plant’s long-term capabilities. Ocampo began looking at automation options.

On a visit to a corrugated packaging facility in Chicago, IL, Ocampo was joined by a regional sales manager from Alliance Machine Systems International. While walking through the plant, Ocampo saw a specialty folder-gluer in operation. The machine was running at high speeds and appeared to be handling the folding and gluing process well. Ocampo took interest, but he did not rush to a decision. While the potential was obvious, the question remained whether the same machine could handle the specific product mix at Barca de Mexico. Simple designs are not difficult to automate, but the 4-cell auto bottom includes several folds and glue points that must be executed in a very particular way.

Barca de Mexico already had experience working with Alliance. The company had previously supplied the plant with several stackers and load formers. Another stacker is scheduled to be delivered soon, marking the third Accustak machine installed in that plant. The working relationship between the two companies was positive, but adopting a specialty folder-gluer represented a more complex step.

J&L folder-gluers have a long history in the corrugated equipment sector. In 1997, the original J&L company merged with Thermoguard Equipment Incorporated to form Alliance Machine Systems International. Over time, the machines were refined through successive updates. The current model, the Mark 5 XT, includes various improvements, adjustments to performance, and handling of specialty packaging designs. This machine seemed right for Barca de Mexico, so they took the next step and reached out to Alliance.

Barca de Mexico began a formal evaluation process by consulting with Alliance’s Sales Engineering team. The first step was to review the specific box formats the plant needed to run. The teams identified dimensions, production volumes, and material types. From there, a machine size was selected. The team then developed a layout to fit the equipment into the existing facility footprint.

Because the 4-cell auto bottom box was central to the investment decision, Alliance engineers developed a detailed illustration showing how the machine would process the design with specific sheets of corrugated material. The illustration broke down each folding step and clearly marked glue points. This helped confirm that the equipment could handle the required structure and gave the plant team a clearer picture of what to expect.

TIME FOR TRAINING

Once Barca de Mexico and Alliance had finalized the design and specifications, the machine was built to order and shipped to Mexico. At that point, the focus shifted to training. No one at the plant had operated a specialty folder-gluer before. Successful use of the machine would depend on how well the team understood both the mechanics and the day-to-day operation.

Alliance field service engineers arrived at the plant to supervise installation and lead the first two weeks of operator training. These sessions covered start-up routines, safety procedures, basic functions, and troubleshooting. Later visits were scheduled for more advanced training, focusing on changeovers, maintenance tasks, and fine-tuning of box setups.

The learning process took time. The team responded well to the training, and as time went on grew more accustomed to the machine and how it works. Building familiarity with the system helped the operators not only run the machine correctly, but also avoid mistakes that could result in downtime or wasted product.

More than six months after installation, the J&L Mark 5 XT is running as expected. It processes the 4-cell auto bottom design reliably and at speeds well beyond what was possible with hand folding. The transition has allowed Barca de Mexico to meet higher production demands without expanding its labor force or sacrificing lead times. Operators continue to improve their efficiency.

PLAN ON PARTNERSHIP

The working relationship with Alliance played a central role in the project. Because Alliance was already familiar with the plant layout and the types of equipment in use, technicians could tailor the machine and support plan without starting from scratch. The training sessions were structured around the knowledge level of the team, and support was available beyond installation. These factors helped minimize disruption and build confidence in the process.

According to Ocampo, now, more than six months later, the J&L Mark 5 XT is still running smoothly, and the team is happy to report that they have “adjusted excellently, with increasing experience.”

The machine solved a specific production problem and gave the plant more flexibility. It did not replace the need for experienced operators, but it changed the way labor is applied. Workers now oversee a higher-output system rather than manually assembling each box. This shift has improved both consistency and throughput. It also helped protect against other risks. Manual folding of complex boxes introduces variability. As demand increases, the margin for error narrows. By automating the most difficult fold patterns, Barca de Mexico has reduced the likelihood of quality issues and gained more predictability in production planning.

Barca de Mexico’s decision to invest in a specialty folder-gluer was based on a specific production need, but the results have extended beyond that original purpose. It has improved the plant’s ability to meet complex orders, reduced dependence on labor-intensive processes, and opened the door to further improvements.

The project is also a case of long-term partnership supporting long-term goals. Alliance provided the machine, as well as a system of support that closely followed the plant’s operating realities. The installation of the J&L Mark 5 XT stands as an example of how targeted investment can resolve real constraints and open the door to new markets for corrugated plants.

Headquartered in Spokane, WA, Alliance Machine Systems International, LLC is a global leader in the manufacturing of automated paperboard packaging equipment for the production of corrugated boxes. Learn more at alliancellc.com.