Latest Global Trends in Conversion of Folding Cartons INDIA PVT LTD.pdf · Latest Global Trends in Conversion of ... World Wide Market Trends in the Folding Carton ... Latest Trends

Latest Trends in Conversion of Folding Cartons

© BOBST SA - 2008SGu 06.06

Latest Global Trends in Conversion of Folding Cartons

K. Venugopal MENONBOBST INDIA PVT LTD

PACKAGE 2008 SEMINAR , New Delhi, 9th August 2008


© BOBST SA - 2008SGu 06.06

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Don't know

None

Glass

Tin

Cartons

Plastic

Source - Karmasin Institute, Hungary

CONSUMER APPEAL:


© BOBST SA - 2008SGu 06.06

CONSUMER PERCEPTION OF CARTON PACKAGING

Source - Karmasin Institute, Hungary


© BOBST SA - 2008SGu 06.06

World Packaging Consumption (2004-2009)


© BOBST SA - 2008SGu 06.06.2008 - 5 Compass Session



World Wide Market Trends in the Folding Carton

Market requests completely different in high income countries or developing countriesRetailers and Brand owners are “dictating” the trendsCustomers looking for “Packaging solutions” not just for good cartonsAging population in western countries and impact of specific expectationsEnvironmental concerns every where in the world even in China and India

Results on major expectationsHot Foil stamping high demand…Micro flute & Litho laminatingFood RegulationsBraille requirementsComplex boxesSecurity packaging & Brand Protection



Market Trends in the Folding Carton ( Europe)

Key factors influencing Folding Carton demand in EuropeLimited Growth potential in the main markets Brand owners pursuing strategies of increased value added, convenience and consumer choice rather than additional volume.Packs substitution trends will have little impact on cartons used in primary consumer pack applicationsThe impact of light weightingCartonboard display outers and multi-packs with strong growth, impacts on increase of microflute containers.



Europe – Market Prospects per Sector ECMA

Pharmaceuticals and medical -> +4.2%Wines, spirits, beer and soft drinks -> +2.4%Paper, stationery and related goods -> +1.9%Cosmetics, beauty care -> +1.4%Cigarettes, tobacco -> -2.7%



Market Trends in the Folding Carton (Asia)China

The top carton packaging market mainly exists in the Tobacco ,Consumer durable, Personnel care industries.With the growth of GDP, Chinese total demands and quality requirement for folding carton is increasing High potential - Low consumption per capita (1/5th of dev. Countries)- 35 Kg / capita consumption for paper and paperboard

IndiaLow consumption per capita (1/20 of dev. Countries)- 8.5 Kg / capita consumption for paper and paper board

Folding Carton Growth in last 5 years ~15%Pharma -> Generic productsFMCGHygiene consciousness - Increasing



Market Expectations – Consumer point of viewRecyclingSustainable Packaging Environmentally friendly Attractive packaging, Appealing effects, SurprisingReduction of Packaging (primary –secondary)

Market Trends: Appealing point of view

Which Techniques are the most requested?

Special PigmentsPrinting TechniquesVarnish Hot Foil StampingHologramsDiffraction FoilsEmbossing / DebossingMicro embossingCFTSynthetic Materials,



Market Trends: Appeal















Flat Stamping







Examples

Sensuality Out of the standard

Not expected

Sweety



Examples Attractive & special

Visibility

Double wall protection





Litho laminated applications : ( Metalized board )



RFID



TECHNOLOGY EVOLVING IN AUTOMATIC FLAT BED DIE CUTTING :

SHEET REGISTRATION WITHOUT CONTACT BY CAMERA ( FRONT AND SIDE REGISTER)

WASTE SEPERATION ( BLANKING PROCESS )

PLASTIC PROCESSING ( PP / PET BY HOT PROCESS )




NEW DIE CUTTING TOOLINGS

EMBOSSING – THE REAL WAY



AUTOMATIC PILE TRANSFER ( APT ) – THE MODERN PRODUCTION FLOW MANAGEMENTPLASTIC PROCESSING ( PP / PET BY HOT PROCESS )



With multiple adjustment

Optimized register for all type of material

2

1

Traditional Register( Front / Side lay )



WHY CAMERA CONTACT LESS REGISTER:CORRECTS YOUR PRINT VARIATION

ELIMINATES THE SHEETER VARIATIONS WHEN PRINTED SHEET IN WEB BROUGHT TO OFFLINE DIE CUTTING

NO MORE STOPS FOR REGISTRATION

NO MORE CONTACT WITH SHEET FOR REGISTRATION – NO MARKS

TOP REGISTRATION REGARDLESS OF THE TYPE OF MATERIAL

EXTREMELY SHORT CHANGEOVER TIME



OPTICAL LATERAL REGISTER

Registration on the sheet edge (os or oos) or directly on the printOne device for all types of materials from paper to micro fluteEasy positioning of the camera with the Centerline marks

Side registration without side guide

Easy and reliable position of the cameraExtremely short changeover timeLess device for a greater flexibility

Adjustment of the pressing forceLateral camera

Side camera



OPTICAL LATERAL REGISTER : ( NO More Mech Side lay )

Operative mode:1.The sheet stops at the front lays2.A movable tablet and two devices of running

wheels pinch the sheet3.The camera detects the position of the sheet (on

the edge or on the print) and calculates the lateral displacement for good registration

4.The movable tablet adjusts the sheet’s position with a linear movement in both directions (os and oos)

5. Lateral sheet correction ( lateral tablet movement ) of ± 10 mm

6. Tolerated variation of printing is ± 1,5 mm7. Once lateral registration done, the camera

checks the new position of the sheet

Side registration without side guide

No side guidesBetter registration regardless to the type of materialsBetter registration at any speed

>> Click to play the video



POWER REGISTER: ( NO More Mech Side Lay AND Front Lays )

The sheet is taken by the gripper of the POWER REGISTERFront sensors visualise the position of theFront Edge of the sheetSide sensor visualises the Lateral Positionof the sheetWith the simultaneous action of three linear motors, the sheet is directly positioned in the gripper barsLateral sheet correction of ± 13 mm in Both DirectionLengthways sheet correction of ± 6 mmTolerated variation of printing is ± 1,5 mm

>> Click to play the video

No contact guidesNo stops of the sheetNo marks on the sheet











Stripping / Blanking process

> Predictable and quick throughput for “Just in Time” deliveries



Why Trend for Blanking?

Need for “Just-In-Time” delivery100% Quality requirementLess manual handlingCost of labourCost of wasteCost of inventoryOptimized Production Process Order Delivery

Manufacturing Process must be predictable and quick



Less waste Less or no manual handlingLess manual laborQuick production flow (bottleneck)More organized department

0% 20% 40% 60% 80% 100%

Process duration

Withoutstripping

With stripping

With stripping &blanking

Printing Diecutting Manual handling Folding gluing

- 15%

- 25%

Stripping / Blanking process



Delivery of blanks



Blanking-Wrapping-Shipping











Trend: Synthetic Materials



WHY Synthetic Materials Packaging:

To emphasize end products it is sometimes necessary to use unusual materials.

See through packaging gives more appeal and sense of the product inside.

It gives an effect of expensive / quality / niche product.



Synthetic Materials



Synthetic Materials



Challenges in Synthetic Materials Converting Process:

Die Cutting Cold processCreases compressed by rules get stiff Creases have bigger bending stressRough cutting edge due to rupture of materialsCrease on some materials changes colorDifficult to Fold and Glue



Applications can be realized by cold or hot die-cutting and creasing process. (even. at high frequencies)

Hot die-cutting and creasing process allows :Maintain crease effect (eliminate material memory/recoil effect)

Better quality creases

More flexible creases, easier to fold

To avoid lightening of the crease when folded (PVC)

A maximum facility of folding in the machine

NB: characteristics differ depending on the material

Hot die-cutting and creasing process requires specific cutting and folding methods



Synthetic Materials Converting Process:

Cutting and CreasingSolid board Synthetic material



Revolutionary Heat Transfer: ( LOWER HEATING PLATE )Maximum heat transfer

Shorter time of heat exposure necessaryBroader range of material thicknesses can be processedTremendously increased variety of box types

Far higher production speeds possible than on heating chase system

Highest cutting and creasing quality at far lower temperatures85°C for PET / 95°C for PVC sufficientPP in 0.3 mm up to 0.6 mm processed with success



Cutting Tools for Synthetic Material:

The Lower heating plate allows:

Utilisation of standard wooden cutting diesStandard cutting rule height stays 23.8 mmMore economical solutionMore cutting stabilityLonger service life span



TECHNOLOGY EVOLVING IN FOLDING GLUING PROCESS :

COMPOSITE, REINFORCED,PARTITION BOXES POSSIBILITY -POLYJOINER

COMPLCATED BOXES IN ONE PASS - GYROBOX

BARILLE EMBOSSING for PHARMA CARTONS INLINE - ACCUBRAILLE

EASY GLUING OF UV / FILM / METALLISED CARTON – PLASMA TREAT

SMALL PHARMA LOCK BOTTOM JOBS – MINI CLB ATTACHMENT






BARILLE EMBOSSING INLINE - ACCUBRAILLE


PHARMA BOX WITH INSERT – LONGFORD INSERTOR




POLYJOINER : Main featuresMade up of a feeder and of an assembling sectionThe POLYJOINER module is designed to carry out functions perpendicular to the blanks running direction

It handles functions such as:Blank Joining Blank Superimposition Insertion of 1 or 2 partitionsBlank Alignment

> A product of the latest technological developments at Bobst, this unique robotized module will produce boxes with unusual dimensions or with highly sophisticated designs and will do so economically.



Special Boxes – Polyjoiner Solution

Composite boxes

Two-part display boxesReinforced detergent boxes

Boxes with one or two partitions



Polyjoiner equipment












WHY GYROBOX:

THIS REVOLUTION ENABLED TO PROCESS COMPLICATED BOXES WHICH WOULD HAVE REQUIRED TWO PASSES ON A FOLDING GLUING MACHINE TO BE PROCESSED IN ONE PASS

THIS ALSO OPENED UP NEW AVENUES IN DESIGNS WHICH OTHERWISE WOULD NOT HAVE BEEN IMAGINED TO BE PROCESSED IN AUTOMATIC FOLDER GLUERS



Gyrobox Module:



Examples of Gyrobox Samples:



Type of box



Type of Box



Type of Box



Type of Box



Type of Box



Type of Box



Type of Box



Type of Box



Type of Box



Type of Box



Type of Box



Type of Box



Type of Box



TYPE OF BOX



TYPE OF BOX



Type of box






BARILLE EMBOSSING for PHARMA CARTONS INLINE - ACCUBRAILLE






Market Trends: Pharma - Braille

Braille requirements on pharma packagingEuropean Directive 2004/27/C

Directive to be transposed in all EU by Oct. 30, 2005

Sept. 1st 2006 all medical packaging must incorporate Braille in Germany and most of European countries already introduce by 2007

Latest in 2010, all the countries of EU should have introduced the Braille



Situation Braille embossing creates various productions challenges with existing methodsCustomers feel that it would be more cost efficient to emboss Braille on the folder gluerPlus: Evidence of Braille embossing coming on high quality food packaging (chocolate / biscuits) and now wine labels

ActionSurveys at many top reference Pharma packaging producers across EuropeIn 2007 BOBST has come up with the…



Braille Regulations

Accubraille*New Solution or rather Revolution for applying Braille embossing directly on Folder Gluer.

* Bobst Patent



The Result…

A new module is developed for Mistral and Alpina to emboss Braille in the folder gluer, bringing,Productivity:

Faster make ready of your die cutter ( Die Cutting press down time reduced by almost 40% )Less stop on the die cutter (cleaning of embossing tools)Less feeder challenges on folder gluer

Cost savings (tools on die cutter) @ 20%Quality:

Definition is excellent with rotary processNo crushing during feeding on Folder Gluer

Flexibility: Allows the Braille to be applied close to cut & creased edges



Video












What is Plasma?



The 4th State of Matter

Plasma is a form of matter that has higher energy than the correspondingsolid, liquid and gas.

Plasma can carry a lot of energy and is highly reactive



Industrial applications

Plasma Openair® is usable under atmospheric conditions



Plasma in the packaging industry

Openair® plasma systems employ the beam of ions and free electrons to :

1. Clean the surface and remove the contaminents (dust, moisture)

2. Increase the surface tension by activating the polymer structure (wettability)

3. Make the coatings and adhesives stick better



Materials

Coated blanks: Varnish coatingsLaminated blanks: PP; OPP; metallisedFull Plastic Sheets: PP; PET; PVC

Full plastic boxes



Metallised , UV varnished or laminated boxes savings :

Reduce the need for Mulitple adhesive gradesNo need of ‘’Milling’’ to remove top varnish/fil layer on glue flap.Reduce the glue investment by using cold glue ratherthan hotmelt

Only if one side carton stick to a polymere varnish or metallised laminationIf 2 sides are polymere, the hotmelt is required

If cold glue, the standard lower gluing unit can be usedPress : no UV varnish cut out = no special blanket(stripping blanket)Press : reduce the press down time for blanketadjustmentDiecutters : no need to have perforations on the glue flaps



Middle range Plasma device PT 3 (1 to 3 jets)

Straight-line full plastic boxes (2 jets)Carton coated crash-lock boxes (3 jets)

Basis• Delivered with one, two or three jets depending on the needs• 2 universal + 1 glue pot bracketry for the jets• Folder-gluer machine interfaceOptions•Autotransformer

Delivered with 1 jet, upgrade up to 3 jets












PROCESSING SMALL CRASH LOCK BOTTOM, MAIN CHALLENGES :

FOLDING OF SIDE PANEL SMALLER THAN 30 MM AND OPEN BLANK WIDTH OF 118 MM POSSIBLE

FOLDING OF SMALL COMPOSITE FLAPS

SMALL LOCK BOTTOM BOXES EXISTED IN PHARMA AND THE ONLY OPTION WAS MANUAL GLUING INVOLVING LABOUR

MINI LOCK BOTTOM DEVICE PROCESS THESE LOCK BOTTOM JOBS AT OPTIMUM SPEEDS TO GET BEST PRODUCTIVITY.




© BOBST SA - 2008SGu 06.06

Thank you for your attention

www.bobstgroup.com

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Latest Global Trends in Conversion of Folding Cartons INDIA PVT LTD.pdf · Latest Global Trends in Conversion of ... World Wide Market Trends in the Folding Carton ... Latest Trends