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Sonoco Alcore

Case Studies

How we’re helping our customers


PrinTex

Who

Man-made fibre yarn producer with locations in France and Germany

Problem

Our customer used a wide variety of cores with various outside ply parchment designs to identify the different yarn and filament types produced for its various customers. This meant they had to keep over 400 pallets of stock to ensure they had the outside ply designs needed when one of their customers placed an order.

Solution

Instead of using various outside ply designs and parchment papers, our PrinTex core has a white outside ply in which we can print a variety of different colours, numbers and symbols. We can also print a variety of designs on the outside of the ply, including letters, numbers, stripes and symbols. Additionally, our production process ensures the ink does not bleed into the yarn.

Result

Our customer can maintain minimal inventory-reduced by 85% in this case. We also eliminated the cost of parchment paper.


Hi-Radius Core

Who

Polyester yarn manufacturer

Problem

Our customer used a standard core with plastic winding caps and experienced yarn breaks during unwinding, which forced them to downgrade the yarn type from A to B and sell it at a lower price. They also could not unwind all of the yarn.

Solution

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 texturising the yarn in-house.

Result

The customer is now 100% break-free, and back at yarn type A, delivering over a six-figure cost savings and increased efficiency. Additionally, they eliminated plastic cap cost and can now unwind to the end of the core, so no product is wasted.


Delta Core

Who

Yarn producer in Spain

Problem

Our customer, who draw-twists yarn for foreign markets, used metal cops to wind the yarn. They had to collect the metal cops and return them to Spain, limiting their ability to export and increasing costs.

Solution

Our Delta Core paper cop solution eliminates metal cops in polyester and polyamide yarn production and is 100% recyclable.

Result

The customer now can maximise exports without worrying about the problems associated with metal cops. Furthermore, the metal cop supplier was located in India, requiring large order quantities and long delivery times. The switch to our Delta core paper cop also generated significant cost savings with JIT delivery, eliminating collection costs and removing plastic sleeves from the production process.


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.

Read the case study

Mondi

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.

Read the case study

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