Unveiling the Mysteries of Efficiency in Corrugated Packaging Operations

Article by HP

Production efficiency refers to maximizing output while minimizing input, including time, labor, and materials. Efficient operations ensure that resources are utilized optimally to produce high-quality products in the shortest possible time. Corrugated packaging production is no different. In fact, OEE (Overall Equipment Effectiveness) is a key performance indicator measured and tracked by many converters as a means to increase productivity and profitability. Yet, as simple and logical as it may sound, the concept of efficiency encompasses multiple dimensions that require a strategic approach to fully realize its benefits.

Key factors contributing to production efficiency include speed, quality control, resource utilization, and workforce efficiency. Let’s examine those factors in the context of corrugated packaging printing:  

Production speed is not just the pace at which the press runs, it’s a combination of press throughput and cycle time. While analog presses’ specs refer to high thousands of sheets per hour, the actual production or overall cycle time is challenged due to setup and changeovers. Digital single-pass presses' linear speed is lower compared to HQPP Flexo, however, seamless job setup and changeovers, show a competitive cycle time and not just for very short runs. For example, in a recent conversation with HP PageWide C5x0 Press customers, they indicated that the setup of the digital press is not comparable in any way to Flexo. While it takes them 20-30 minutes to be able to start a print run on the analog equipment, with digital it takes only 1-3 minutes.

Maintaining consistent quality throughout production is essential for efficient operation. The cost of non-quality should be measured and reduced to a minimum. For most analog presses installed to date, the processes to achieve quality, color-to-color registration, and color consistency over time can be laborious and not necessarily repeatable. These processes should be automatic as much as possible, to eliminate human errors and to enhance repeatability. Digital technology ensures consistent print quality from the first box to the last, minimizing variations and maintaining a high standard across all production runs. This high level of accuracy reduces the likelihood of defects and rework, ensuring that every print meets quality standards. HP C5x0 customers emphasize the simplicity of computer control of color (once it’s agreed upon a sample) instead of mixing, QCs, and corrections required when working with analog ink. The fact that the press is 4 colors has not impacted any of their end users, they never lost or had to walk away from a project.

Resource utilization by in large refers to material and the need to use materials judiciously to minimize waste and reduce costs. Bear in mind that materials are not just corrugated boards, it is also the tooling required for the printing process, the amount of ink, primers, and other fluids used for preparing the press, printing, and cleaning after the print process. HP’s digital post-print single-pass press uses a proprietary bonding agent technology that eliminates the need for priming sheets before printing and supports high color saturation on coated and uncoated liners. More so, the press reduces most of the water consumption required for press cleaning between jobs compared to HQPP Flexo. A fact that not only optimizes resources but contributes to sustainable production.

Last but not least, people make a difference. Investing in employee training and fostering a culture of continuous improvement and engagement drive effective operation and task handling. HP PrintOSx provides operators with tools to enhance efficiency, such as a dedicated view of scheduled tasks, guides, and preventive maintenance instructions. C5x0 operators also have access to remote support engineers, who can assist in real-time, reducing press downtime and enhancing operator knowledge and sense of achievement.

All the parameters discussed above are interconnected. Achieving the desired color and quality impacts setup time, which affects production speed. Inefficient operators can affect cycle time and quality, while a lack of training can lead to resource wastage.

When considering plant operations with efficiency improvement as a general target (not just per-press optimization), a digital single-pass printing press can yield significant results. By producing only what is needed, when it is needed, digital single-pass presses support lean manufacturing principles and positively impact overall material flow within the plant. Producing per order rather than per forecast enhances plant efficiency by reducing production volatility and uncertainty. Minimal inventories lower operational costs and enable quick adaptation to changing customer demands. Digital presses excel in switching between different product types and sizes without significant downtime.

Efficiency is a critical driver of success in the corrugated packaging industry. Improved efficiency translates to cost savings, better resource management, and enhanced customer satisfaction. Embracing digital single-pass printing technology is a strategic move that can significantly enhance the efficiency of your corrugated packaging plant, positioning your business for success in a competitive market. As it supports production cycle time, quality control, resource utilization, and workforce efficiency, digital single-pass presses offer a comprehensive solution for achieving superior operational efficiency.

For more information please contact Adi Shorer, HP