Case Study | NIPPON POLYSTAR CO., LTD.
2026/06/11
We've successfully developed a best-selling model!
Miki Pulley is a partner you can consult with while viewing the equipment
Nippon Polystar Co., Ltd.
Founded in 1964, Nippon Polystar has established a strong reputation as a leading brand in small-scale packaging machinery. Building on this trust, the company has distinguished itself by enhancing the value of its equipment to meet customer needs and streamlining the entire packaging process through the adoption of computer-controlled technology. Under the slogan “Always with a spirit of challenge,” the company has recently been expanding into new markets, with a focus on China and Southeast Asia.
〉Issues
Frequent malfunctions in the film cutting mechanism of the pillow packaging machine
〉Objective
We want to help protect valuable contents, enhance the appearance of our customers’ products, attract attention, and increase product value
〉Results
We changed the film feed drive method! By collaborating with Miki Pulley to rewrite the motor controller program and ensure machine stability, we successfully developed a best-selling machine that ships 30 to 60 units per year!
How can we reduce malfunctions in the film-cutting mechanism?
[What Is a Pillow Packaging Machine?]
A machine used to package products in bags. There are two types of pillow packaging machines: "vertical pillow packaging machines," which feed the packaging film perpendicularly from top to bottom, and "horizontal pillow packaging machines," which feed the packaging film vertically.
"Horizontal pillow packaging machines" are further categorized into "standard pillow packaging machines" and "reverse pillow packaging machines.
" A "standard pillow packaging machine" uses a method where the film is fed from the top to wrap around the product, creating a center seal. It enables individual packaging and high-speed packaging, and its key feature is that the display side faces upward, making it easy to inspect the product’s appearance.
"Reverse pillow packaging machines" use a roll of film mounted at the bottom. Products are placed on top of the film and wrapped from below to form a center seal. This method allows for multi-unit packaging and is suitable for packaging heavy items because the products are conveyed on a conveyor while being wrapped. Furthermore, since products are placed directly on the film, the machine remains clean and hygienic.
With the large machines we had been using, we had installed a controller-driven motor to feed the film, which inevitably led to frequent malfunctions at the cutting mechanism.
So we attempted an improvement where the film feed mechanism was driven mechanically, while an electronically controlled motor was placed at the cutting and sealing section. However, to do this, we needed Miki Pulley to rewrite the controller’s control program from scratch.
Nippon Polystar Reverse Pillow Packaging Machine PBF-300 MG
We have successfully developed a best-selling model that ships 30 to 60 units per year!
We fine-tuned the program for the prototype at Miki Pulley’s Technical Center. We went through this process over and over again, testing it on another prototype at the Nippon Polystar factory.
Thanks to Miki Pulley’s cooperation, the eg1 became our best-selling machine, shipping 30 units annually—and as many as 60 during peak periods. As the successor to the eg1, the third-generation eg1, which just went on sale in November 2019, features further improvements in functionality and usability. Of course, we continue to use Miki Pulley’s products in this model as well.
Nippon Polystar's third-generation EG1 reverse pillow packaging machine is equipped with Miki Pulley's "NSE (Loss Tensioner) Model"
One of the appeals of Miki Pulley is that you can consult with us while viewing the machinery at our factory
We decided to purchase from Miki Pulley not only because of the reliability of their products, but also because they take the time to listen to our needs on-site.
With other companies, it’s common to handle all communication with sales representatives over the phone.
But with Miki Pulley, we can discuss and consult while actually viewing the machinery at the factory, which makes things move much faster. We also find it very helpful that we’ve been able to maintain a long-term relationship with the same representative.If our contact person changes frequently, we have to explain the characteristics of our machinery from scratch every time. In that regard, at Miki Pulley, once we explain something once, they understand the implications and provide precise advice.
Recently, we’ve also received many ideas from Miki Pulley regarding the supply of control equipment to China through our local subsidiary, Shanghai Polystar, the establishment of new systems, and the training of local staff.
Miki Pulley products used in the PBF-300 MG reverse pillow packaging machine
CBW Model (Clutch, Brake, and Reducer)
RPM gauge
CS Model (Electromagnetically Actuated Clutch)
ZeroMax Continuously Variable Transmission (Transmission/Reducer)