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Sonoco Alcore

Case Studies

Solving V-buckle and Sag Issues 

Who: Multi-site metal producer in Europe.

Product: Aluminum coated products. 

Problem: This producer uses different cores for different calipers and experience sags and v-buckles in the aluminum, costing up to €30K per roll and damaging the aluminum. 

Solution: We visited the producer’s sites and performed testing at our Core Competency Centre to optimise cores for each site.

Result: The customer avoided v buckle and sag issues, saving €30K per damaged roll as well as 5-10% cost savings on core spend through our optimisation project. 

V-Buckle Cost Savings Generated

Who: Metal customer in Eastern Europe.

Product: Aluminum.

Problem: The customer required both outside diameter stiffness and sufficient wall thickness to prevent v-buckles when winding thin aluminum sheets.

Solution: Our core specification focused on outside diameter stiffness and wall thickness parameters.

Result: Our customer prevented further v-buckle issues and saved up to €30K per roll by not wasting damaged material. 

Case Studies

Our Products at Work

Hi-Radius Core

Our Hi-Radius core has a smooth, rounded edge on the unwinding end, which allows the producer to avoid using plastic caps. This solution is especially effective if our customer is spinning and texturizing the yarn in-house.

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Sonoco Alcore will purchase Mondi's existing core equipment and then replace it with newer state of the art technology equipment. In addition, Sonoco Alcore will manage 28 employees responsible for core production on site.

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