Gone are the days of ultra-long runs of 100 000 pieces and more,’ she says. ‘Today, brand owners and packaging buyers want less packaging per job so they can change box styles or designs more easily without being left with redundant stock.’
That puts pressure on converters to make shorter runs economically viable. Equipment downtime and lengthy makereadies are harder to absorb when production schedules are fragmented across more SKUs and smaller orders. ‘Well-maintained equipment is essential to ensure maximum uptime,’ Nikki notes.
Material changes are creating additional challenges. Lightweighting, long established in the European corrugated market, is spreading as multinational brands standardise packaging specifications across regions. At the same time, greater use of recycled liners requires converting equipment and tooling capable of handling less robust board without jams or disruptions.
Accuracy is critical. ‘If a blank corrugated sheet is not cut, creased and scored accurately, it will cause problems in downstream gluing,’ says Nikki. ‘Creaser tooling and profiles need to be in pristine condition, with regular operator checks to maintain optimum performance.’
Automation is also becoming more important, particularly as skilled labour becomes harder to find. Systems that reduce setup times and simplify operation can help converters manage shorter runs and more complex designs without sacrificing productivity.
MBM is responding with developments including its Armadillo modular knife system, designed to improve cutting accuracy and robustness on rotary die cutters, printer slotters and flexo folder gluers. The company has also seen growing interest in its Knife Management System, which keeps tooling organised close to the machine and helps operators identify missing or replacement parts before they cause unnecessary downtime.
