By The vision of a sustainable future is one where fault-free folding cartons and corrugated boxes are produced by highly automated printing and converting lines controlled by centrally stored data and digitally connected throughout the entire value chain.
As we continue to move away from manual intervention to reduce waste-creating errors and speed up production, flatbed die-cutting technology must be optimized to allow for higher productivity and cost-efficient manufacturing of fibre-based packaging, so converters can respond with confidence to the market trends of today and tomorrow.
Overview of Packaging Market Trends
The packaging market is driven by a number of trends that influence the manufacturing of folding cartons and corrugated boxes.
Corrugated cartons going from production to delivery.
The continued growth in e-commerce, the accelerating demand for sustainable packaging, and the request for faster time-to-market mean converters are facing unprecedented pressures to deliver high quality at top speed in shorter runs with less waste, whilst also being equipped to handle new types of board with more recycled content.
The Impact of E-commerce
E-commerce has changed packaging dynamics. The global market in 2022 is estimated to be worth $63.6 billion, having seen a sharp rise with annual growth rates of 20 percent between 2017 and 2021, according to the Smithers Report, The Future of E-commerce Packaging to 2027. However, this level seems to be calming down from the manic days of the pandemic to around 12.5 percent in 2022. Growth is predicted to continue, and even though this will be at a steadier rate of just under 10 percent CAGR, it still presents huge opportunities for printers and converters.
Sustainability in Packaging
In addition to that, sustainability is also at the forefront of every brand owner’s mind as they pledge to lower their impact on the planet. Many are turning to fiber-based solutions in response to consumers’ concerns over plastic waste and to comply with new legislation, which is increasing the demand for sustainable packaging solutions and putting more pressure on the supply chain. Shorter production runs and often changing designs are the order of the day, requiring greater agility and higher productivity from the converter.
Fast and Cost-Efficient Production
Advancements in Die-Cutting Technology
Today’s die-cutting technology, whether it is part of an inline box-making solution or presented as a standalone machine, is built to offer exceptional cutting capabilities with minimal waste. Blanks must be precisely cut and in full register in order to pass inspection and avoid being discarded.
Automated die-cutting for precise and efficient packaging.
Featuring a host of solutions that automate each function, from feeding to final stacking, large format converting lines that combine flexo printing with flatbed die-cutting are ideally suited to producing e-commerce solutions. They come with integrated 100 percent quality control inspection that closes the loop from artwork design to the final product, thereby reducing costly production recalls and consequently waste.
Innovations in Die-Cutting
Some of the latest innovations in this space include more advanced feeder technology that reduces board compression by up to 15 percent, making it possible to handle lighter board types that lower the total weight of paper in each packaging unit, which minimizes the environmental footprint and cost.Meanwhile, automated setup functions can control and correct all parameters to cut down on the number of boards required to initialize each job and the time it takes to begin producing sellable output. There have been new solutions available that can die-cut a much wider range of board thicknesses so folding cartons and corrugated boxes can be converted on the same machine for greater production flexibility.
Folding cartons
For folding cartons, a new automated cutting plate adjustment where a motorized micrometric system can center the thin cutting plate to the die has been developed to ensure the perfect match between the cut and creasing positioning. This removes the need for operators to perform the more usual manual alignment and allows settings to be stored for repeat jobs.
Digital Connectivity in Packaging Production
The Future Vision
As mentioned, the future vision of packaging production calls for the entire packaging value chain not only to be automated and digitalized but also fully connected to give clear visibility of all processes to converters and brand owners alike. Remote job setup will become the norm using data from artwork PDF files to further shorten setup times.However, efficiency is not everything; quality must be high and consistent, which is why every detail matters. Tooling is an often overlooked and underestimated part of die-cutting but by investing in high-performance tooling from certified die-makers, converters can ensure that their flatbed die-cutter reaches its true potential.Furthermore, tools can be connected with machines via a chip so that job data can be exchanged in seconds, significantly reducing machine downtime during setup.
Monitoring and Maintenance Benefits
Another advantage of full connectivity is the ability to constantly monitor each machine so preventative maintenance can be put into action to avoid potential issues that can affect efficiency and uptime. Only by having complete oversight of the production floor through connectivity and data analysis can converters eliminate bottlenecks and eradicate waste to optimize their operation.
Final Word
In conclusion, on-board automation shortens make-ready requirements and fulfills faster time-to-market expectations while connected and digitalized solutions deliver controlled and sustainable operation leading to zero-fault production. This will be powered in part by innovative and versatile die-cutting solutions.
Machine Dalal platform is preferred by buyers and sellers from the global print industry to get directly connected with each other and trade their machinery.
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