The Corrugator, July - September 2022

Is Automation right for you? INDUSTRY UPDATES

Work smart. Why choose hard work when you can choose smart working?
Build quality into your processes by automa ng your workflow and grow your

business at the same me

We all want to simplify our workloads and the need to increase your headcount.
have processes that just work – every
me. It's painful to see mundane tasks l Reducing errors: With automated quality checks.
taking up so much of an operator's me, when they
could be working on more valuable, and from a staff l Increasing efficiency & throughput: By
perspec ve, more interes ng jobs. standardizing your processes and offloading tasks
with workflow so ware.
Why aren't businesses automa ng?
So, why are some businesses nervous to take the leap?
We'll be honest. Not everyone has embraced What are your apprehensions ?
automa on as we'd expect - despite its significant
Let's take a look at four of the main concerns
benefits, such as: businesses cite as a reason not to automate and
l Saving me and money: Handle more jobs without hopefully we can address any worries you might have,
too.

1. Automa on isn't necessary for our small company

Concern Consideration

“We’re a small enterprise. Our company is too small How much time does your business spend on
to take on the cost of automation, and administrative tasks every week? We’d advise
it simply wouldn’t be a worthy investment for us.” calculating the time spent, and how much money
We understand. You want to stay focused on the job this is costing your business.
at hand – without causing yourself,
your team or your customers more problems or
wasting money on expensive software.

2. Implemen ng workflow automa on is too complex

Concern Consideration

“There are so many tasks and aspects of my The first thing to think about is what tasks your
workflow that could be automated. I don’t operator performs. Do those specific tasks
know where to begin!” bring value to your business? Could the operator’s
Of course, you’re right that there are many tasks time be better spent elsewhere, on more
that can be automated. Depending on valuable, and interesting tasks which benefit from
how clever and quick you’d like your workflow to be, human handling and reasoning? Put
there are endless opportunities for each task through the flowchart below and write it
streamlining via automation. And really, this is in the box it lands in, to easily figure
exciting for futureproofing your business out a priority list for automation.
and continuously improving.

July - September 2022 | The Corrugator 47

2500mm

INDIA

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Is Automation right for you? Consideration INDUSTRY UPDATES

3. Automa ng will change our current workflow Which parts of the process can be improved by
creating standardized workflows and
Concern procedures? While you may find the concept of
change daunting, it’s li kely you can think
“We don’t want to completely change howwe work, of various examples where your workflowcould be
and our processes, to accommodate improved. Jot down a fewof your
automated software.” processes which get the job done, but which are
You’ve likely spent years honing processes and clunky, irritating and simply could be
you’re reluctant to start something when better! Then think about the ideal situation. How
you’ve no idea howit might pan out. It’s also would you like the systemto work? What
difficult to commit to change when the is your best -case scenario, which would improve and
process you have kind of works most of the time. enhance your existing processes
without causing disruption?
4. It's not the right me to make an investment
Consideration
Concern
While change often involves an initial cost, and some
We can’t justify making this investment right now.” adaptation and flexibility, the price
It can be difficult to rationalize parting with money, of doing nothing is far greater in our increasingly
when it seems like things are running challenging, competitive industry.
just fine. To see the monetary value in automation we
need to look at the costs it could Ÿ How much me is spent on non-value
eliminate, and the additional profit it could generate. administra ve tasks?

Ÿ What is the cost of customer complaints?
Ÿ How much money and me is spent on

over me?
Ÿ How much me, effort and money are spent on

recruitment?

Why automa on is the solu on

We hope this workbook has shown the value of automa on and given you the confidence to know where to start
your journey. In summary, here are the benefits your business will gain by automa ng:

l Take on more jobs – without increasing your headcount – therefore increasing your profitability.
l Reduce errors significantly by building quality into your workflow checks to maintain excellent standards and

reputa on and avoid reprints and complaints.
l Free up operator me and increase efficiency and throughput by standardizing and offloading mundane

tasks.

Source: Esko

July - September 2022 | The Corrugator 51



Automated Packaging Production & PACKAGING
Custom Corrugated Boxes

Packaging can be a deciding factor in whether types of machinery that can be used in the making of
or not your business achieves an impressive corrugated boxes, from the actual box making down to
return on investment. Businesses must strike the prin ng and gluing.
a balance between using high-quality and protec ve
materials, whilst also making sure there is s ll plenty Why use automated machinery for corrugated box
of room for profit. produc on?

Packaging can be a deciding factor in whether or not Meet demands
your business achieves an impressive return on
investment. Businesses must strike a balance between Automated box making machinery is ideal for
using high-quality and protec ve materials, whilst also businesses that have a variety of orders coming in on an
making sure there is s ll plenty of room for profit. almost constant basis. All you have to do is programme
Whether a brand decides to outsource their packaging your machine to a certain box size or shape using a
produc on and rely on third par es, or they want to user-friendly interface, and you can produce as large or
take control of their packaging in-house, automated small of a volume as you like to meet order demands. If
packaging machines can completely revolu onise the your business needs to reduce the produc on me of
process. How? They allow businesses to reduce waste, your packaging and op mise on produc vity during
minimise costs, and control their environmental busy periods, automated corrugated box machines can
impact. enable you to meet demands with no issue.

What is packaging automa on? Consistent quality

Packaging automa on can refer to machinery used at Corrugated box making machinery leaves no room for
any stage of the packaging process, from produc on to human error. Automated machinery is programmed to
packing and sealing. This ar cle will focus on cut boxes in highly specific shapes and sizes
automated packaging produc on and the various consistently. Businesses don't have to worry about any
poten al inconsistencies in the size or quality of

July - September 2022 | The Corrugator 53







Automated Packaging Production & Custom Corrugated Boxes PACKAGING

corrugated boxes used for shipping their products. quickly, to suit the needs of each product/consumer
Having a standardised packaging produc on process and maintain a smooth supply chain overall.
means you ensure your products are posted safely and
reliably, without risk of boxes being the incorrect size Types of corrugated box making machinery:
due to being restricted to the sizes of pre-made
packaging. Box making

Reduce environmental impact Corrugated cardboard boxes should be as tailored to
your individual products as possible, if you want to
Businesses must take into account the impact they're ensure there are no damages or extra costs when
having on the environment, if they want to be shipping. Inves ng in automated machinery means all
respected in their industry and by consumers. Instead you have to do is programme the machine to a certain
of pre-ordering tons of packaging materials to pre- size or shape and leave it to produce as many or as li le
empt orders that come through, make your own boxes as you require.
corrugated boxes as and when they're required with
an automated machine. Box prin ng

Kolbus AutoBox offer a wide range of box making As well as being able to automate the produc on of
machinery to enable businesses of all sizes to take your corrugated boxes, you can use machinery for
control of their packaging produc on and design. branding your packaging materials too. Box prin ng
Their most famous machine, the AutoBox, allows machines can be added into your produc on line to
complete customisa on, with over 100 varia ons of ensure that your packaging impresses consumers upon
boxes to create and print. Automated box making arrival. Packaging is a great way to reinforce your
machinery is user-friendly and can hugely reduce your branding and add a personal touch to your packages
business' wastage. By having set measurements and that customers will always appreciate.
shapes for your boxes and only producing boxes as
orders come in, li le to no packaging material is Box gluing
wasted in the process.
To further op mise your business' supply chain, you
Op mise efficiency can invest in box gluing machines. These machines take
over the assembling process of your packaging and
It perhaps goes without saying, but automated make sure every corrugated box is securely glued.
corrugated box making is far quicker than relying on a Op ng for automated or semi-automated machinery
workforce to get the job done. Box making machines allows brands to maintain speed, quality, and efficiency
allow brands to manage their own packaging throughout the en re packaging process.
produc on without having to compromise on speed or
quality. Machinery can be depended on to produce Source: Manufacturing Tomorrow
large volumes of packaging both accurately and

July - September 2022 | The Corrugator 57





2950266

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Perfecting Packaging PACKAGING

Ad d re s s i n g P r i n n g C h a l l e n ge s fo r Digital prin ng on corrugated board en ces PSPs
Corrugated Board to leave behind tradi onal analog systems for a
number of reasons including short-run
Prin ng on corrugated board is a growing interest capabili es, faster turnaround mes, and
for Print Service Providers (PSPs) entering expanded offerings. Without the need to change
package prin ng. Currently, there are two types plates for file change digital quickens the en re
of methods for corrugated prin ng with digital order process.
technology -pre-prin ng and direct prin ng. In

this ar cle, we discuss direct prin ng onto Avoiding makeready allows print providers to go
corrugated board. straight into produc on, increasing the ability for
display, packaging, and temporary manufacturers
Direct prin ng with digital flatbed devices is to create prototypes and respond to clients'
commonly used for prototype crea on. Flatbed demands. Patrick Donigain, specialist and
vendors address challenges for direct prin ng marke ng senior, Canon Solu ons America,
onto corrugated board with load/unload believes that efficient produc on of variable data
mechanisms, color gamut, image quality, and and image packaging offers new short-run
material hold down to en ce PSPs to u lize their opportuni es that can be highly lucra ve.
newest digital technologies over analog.
Transi oning to digital prin ng for corrugated
Financially Favorable

61 July - September 2022 | The Corrugator



Perfecting Packaging PACKAGING

board comes down to return on investment (ROI). sheets from one point to another, but also doesn't
“Digitally printed board is more economical—at damage the board or flutes in the process.
certain run lengths—then running the same job
on a corrugated press,” says Larry D'Amico, direct Fujifilm's Inca Onset X Series of printers features a
of sales, Durst Image Technology US, LLC. The cost dual or single robo c handling system for handling
of offset or flexographic plates that require press corrugated boards and is fi ed with an
makeready me compared to digital alterna ves appropriate specialized head effector. “The head
can be financially favorable for a short-run job. effector features suc on cups that are distributed
equally over vacuum bars on the underside of each
According to Michael Maxwell, senior manager, head effector, and they enable substrates to be
Mimaki USA, Inc., the volume of corrugated loaded and unloaded reliably,” says McConnell.
boards printed in an analog environment can
exceed the benefits of digital, however, small runs The Inca Onset X Series can be purchased or
and prototyping are be er served through a upgraded to speeds from 2,000 to over 10,000
digital process. “By assessing the cost-effec ve square feet per hour (sf/h). Fujifilm also offers the
quan es for digital versus standard processes, Acuity F flatbed with a High Flow Vacuum to hold
print providers can serve customers in both areas corrugated boards that produces just under 1,700
for short and long runs,” he advises. In addi on, sf/h.
improvements in prin ng processes like LED
curing make it possible to adopt digital without Durst prin ng systems offer a combina on of tools
concerns regarding heat. to lay corrugated board flat. “Our skis are
pneuma cally controlled and digitally posi oned.
Concerns for Corrugated We offer three different levels of ski material
depending on the flute thickness,” shares D'Amico.
While digital prin ng to corrugated board offers a Its systems also include 12 individual vacuum
higher ROI with fast turnaround mes, it is s ll a pumps to provide power and control while
developing technology. However, flatbed device elimina ng the need for taping. The Durst Delta
manufacturers offer solu ons to address SPC 130 prints on corrugated up to 100,000 sf/h.
challenges.
While op ons for load/unload mechanisms exist in
Load/Unload Mechanisms the corrugated market, some prefer a hand-feed
approach, be er suited for lower volumes.
Corrugated board doesn't lay flat because it is a “Feeding by hand, our changeover from job to job
naturally inconsistent surface, which is sensi ve is a few seconds. Our customers prefer to not have
to heat. This is a concern for equipment with the addi onal setup me that is required with
printhead technology millimeters from the most feeders and stacking mechanisms,” explains
substrate and must be overcome during loading, Mark Swanzy, COO, Xanté Corpora on.
imaging, and unloading. Load/unload
mechanisms like suc on cups, skis, and vacuums Oversized tables with mul ple origin points aid
offer a solu on to secure the corrugated material. operators that manually load/unload corrugated
board. Maxwell says Mimaki's JFX200-2531 offers
Becky McConnell, product marke ng manager, an oversized table with mul ple origin points to
graphic systems division, Fujifilm North America improve the me between prints by enabling
Corpora on, believes that because board operators to prepare a job in one print zone while a
distor on can happen due to the nature of different job is prin ng in the other print zone.
manufacturing, it's cri cal to have a material Mimaki's printer speeds for corrugated range from
handling system that not only manages to move 250 to 600 sf/h.

July - September 2022 | The Corrugator 63







Perfecting Packaging PACKAGING

Color Gamut Flood white or white layering can be used as a
base or to enhance the final color. However, he
In the packaging segment, it's integral to achieve a cau ons that white ink is expensive, even
wide color gamut with low ink consump on. ICC compared to a paper-lined board.
compliant color profiles op mize color gamut.
Eric Carlomusto, inkjet demonstra on manager, Image Quality
Agfa Graphics, says users can emulate Pantone
libraries the majority of the me. Agfa's Je Tauro Image quality and resolu on is higher on white
prints corrugated board at speeds of 1,485 to coated board than uncoated boards. “Uncoated
2,960 sf/h. The UV ink creases printed media brown corrugated board has a much smaller
without cracking. It's capable of 200 percent gamut because of the white point and ink
stretch—flexible for most corrugated absorp on,” says Ken Parsley, product manager,
applica ons. Mutoh America, Inc. The Mutoh ValueJet 1638UH
has a top speed of 220 sf/h and a media retaining
Extra ink channels are also used for be er print system standard to assist with difficult media.
quality at high speeds. For example, Donigain says
white ink for specialty applica ons allow presses High-quality litho-like print quality requires a
to achieve a large color gamut on standard white top, kemi-board, or kra liner board.
corrugated materials. Ink channels that support Schlimme recommends only prin ng directly to
light cyan and light magenta also allow for smooth kra or virgin paper surfaces for lower quality,
print quality. lower resolu on applica ons. Addi onally,
unlined or uncoated kra boards don't support
“White ink capabili es are important for vibrant high-resolu on prin ng, fine lines, or small text.
colors or brand color matching,” explains Mark
Schlimme, direct of marke ng, Screen Americas. Smaller text can be problema c on flexographic
Corrugated board is absorbent, which can affect presses with ink bleed, plugging, and a lower LPI
color and the show-through of the fluted surface. screen. “Our print quality is up to 1,600×1,600

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Perfecting Packaging PACKAGING

dpi, which is printed with a 1.2 picoliter dot and printers compared to flexographic presses. Pinch
allows for detailed graphics and small point text,” rollers and vacuum belts should use low pressure
says Swanzy. Xanté's press speeds are dependent to avoid crushing boards. He explains,
on sheet size—24×28-inch sheets print up to “corrugated crush can affect the structural
3,328 sf/h while 48×96-inch sheets print at up to integrity and is a concern on most corrugated
7,872 sf/h. flexographic presses, which can be difficult to
control.”
The desired image quality also affects the press'
print speeds. Schlimme explains, “while Screen's According to Roger Walkley, product manager,
Truepress Jet W3200UV HS can print excellent Inca Digital, mechanical systems that push boards
process color image quality to kemi-board at down risk injury to the machine as well. “Without
speeds over 1000 sf/h, it's realis c to expect that sufficient vacuum the board can pop up,
the physical handling requirements will limit an damaging an unguarded system,” he says. Fla er
operator to something between 800 and 1,000 boards present fewer problems for mechanical
sf/h.” interven on. The Inca Onset X3 prints up to 9,688
sf/h while the Spyder X prints 1,615 sf/h.
According to Donigain, six to 42 picoliter droplets
and ac ve pixel placement compensa on assures Other Concerns
image sharpness, density, and uniformity around
the en re flatbed. Package prin ng includes prototypes, packages,
and POP standees. It also correlates with food-
Material Hold Down related applica ons, which hold specific
requirements for ink. According to D'Amico, the
Flatbed presses with industrial strength and zone applica on, smell, or chemical composi on of
vacuum beds hold boards in place for prin ng. “If digital ink may make it unusable for food
the corrugated boards are exposed to variable applica ons. Aqueous-based inks eliminate the
humidity or changing temperature, however, the smell associated with UV inks. “We are looking at
board can pop and buckle,” explains Schlimme. He low migra on inks suitable for digitally printed
suggests a higher quality board to eliminate the boxes that come in close contact to food,” he
need for tape down. adds.

Other solu ons to hold down corrugated boards Print providers that intend to offer packaging for
include vacuums. Donigain says for short-run food products must ensure the ink doesn't
corrugated packaging and temporary point of contain UV reac ve chemistries. To find ink
purchase (POP) displays, vacuum configura ons formula ons, print providers can use material
allow for dynamic, versa le large format prin ng safety data sheets provided by inkjet press
applica ons. The Canon's Océ Arizona 6100 Series manufacturers.
features a High Flow Vacuum system that handles
warped corrugated boards and plywood sheets Due to various paper layers and moisture in the
without tape or physical means to hold boards material, prin ng to corrugated board is a heat
down. Canon's press speeds for corrugated sensi ve process. LED curing systems reduce the
boards range from 200 to 1,000 sf/h. heat to stabilize the shape and dimensions of the
material while conven onal systems omit heat.
While vacuum belts are used to help warped “swissQprint offers a new LED curing system that
boards lay flat and feed smoothly through the reduces the heat drama cally,” says Carmen
prin ng path, Swanzy warns that corrugated warp Eicher, VP of marke ng, swissQprint.
can be much more problema c with digital

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Perfecting Packaging PACKAGING

swissQprint printers are intended for small and packing 1,500 brochures or sell sheets in a
outputs in the corrugated industry. Despite being box is a very different task than staging even 25
capable of 2,217 sf/h, Eicher says the sets of POP standees or ready-for-retail pallet
performance in the corrugated sector realis cally wraps,” he explains. In fact, poor handling during
starts at 1,100 sf/h in produc on mode to wrapping, packing, and shipment can ruin print
produce adequate quality. In quality mode for jobs if large materials are mishandled or
high-quality results, the output is about 600 sf/h. improperly stacked.

The Future of Corrugated Ready-for-retail packaging is becoming more
relevant as big box retailers seek more localized
While digital flatbed devices offer a number of and regionalized products. This creates a need for
benefits to print providers, tradi onal analog s ll shorter runs. “It's becoming increasingly
tends to be a more favorable op on. Parsley important to offer services and solu ons across
explains that while high-end machines have the the full spectrum of a product's branding,”
produc on capability packagers need; there is suggests Schlimme. Print providers with clients
room for improvement in ink for image quality on who already request small format folding carton
uncoated stock. packaging or labels can offer clients ready-for-
retail packaging or in-store standees and displays.
Donigain believes digital's print quality surpasses
analog quality for low- and mid-volume But retail packaging isn't the only market taking
produc on, but achieving high levels of quality at advantage of short-run prin ng. Eicher points out
analog print speeds is difficult and represents an that designers and marke ng agencies prefer
area for improvement. However, speed is seeing and touching mock-up samples rather than
expected to improve as single-pass technology 3D CAD simula ons, allowing corrugated to enter
advances. industries in need of prototypes. Because
producing prototypes with analog can be
D'Amico also sees one-pass technology entering expensive and me consuming, digital
the market with speeds ten mes or more what prototyping is a lucra ve business for print
the scanning systems produce. Once these providers.
products become widely adopted, he believes
they will make a significant impact on the Steady Demands
corrugated market.
The use of corrugated board in digital print
Prepara on and Trends con nues to grow as customers demand smaller
runs and personaliza on for popular corrugated
Before purchasing equipment, print providers applica ons like packaging, POP displays, and
should fully understand the work they are prototypes. Before digital technology can make
producing to obtain the technology that best fits major strides in the packaging segment,
those applica ons. This includes understanding challenges regarding prin ng to corrugated board
the en re workflow—how the files are received like color gamut and image quality must be
and how the boards are finished. “It is cri cal that addressed.
all phases of producing the work must be
understood before you consider a digital printer,” Source: Digital Output
says D'Amico.

Schlimme agrees and says that finishing and
delivery of printed boards is cri cal. “Wrapping

July - September 2022 | The Corrugator 71





The Citroen Oli Suggests The Future INDUSTRY UPDATES
Is Made Of Cardboard

Citroen has showcased the Oli, a rolling concept which is made of
cardboard and suggests 'less is more'

The Citroen Oli concept has made a big around 23 minutes. Its top speed is limited to 68mph in
impression on the car world. Rather than being the name of efficiency, though, so don't expect a
some high-tech two-tonne gadget-fest, Citroen thrilling drive – although having just cardboard and
says the Oli's manifesto is 'less is more' with a focus on fibreglass between you and the outside might raise
simplicity and lightness to achieve sustainability. The your adrenaline.
quirky French brand decided to make the car – which
isn't directly previewing a produc on model – out of It sits on wheels that Citroen says are made of a blend
unconven onal materials. Most striking is the use of of aluminium and steel, to keep weight down. Citroen
recycled corrugated cardboard sandwiched in a has worked with Goodyear to develop a sustainable
honeycomb shape between fibreglass panels to keep tyre, too, which is said to be good for 50,000 miles. It's
weight down and improve efficiency while s ll being made of sunflower oils, rice husk, pine tree resins and
strong enough. natural rubber to replace the synthe c petroleum-
based rubber compounds used in common tyres.
The Oli is definitely… interes ng to look at – we
weren't sure whether it was coming or going when we The Citroen Oli is also the first car to wear Citroen's new
first saw it, but the most unconven onal silhoue es in logo. It harks back to Citroen's original logo from 1919,
the brand's history have gone on to become their most and is another way the brand is looking back to look
iconic. Take, for example, the Citroen 2CV, DS and even forward. As Citroen CEO Vincent Cobee points out, cars
the latest Ami – these are cars that look unlike anything have become much heavier and complex over the years
else on the roads to this day, and have made their due to safety and legal requirements, but perhaps the
places in automo ve history. answer is to look at simplifying cars for the future
in a way that strikes a be er balance between
For that reason, rather than using 'dynamic lines' in its sustainability, safety and u lity.
design, Citroen decided to go against the grain and use
ver cal and horizontal lines for the Oli, giving it that Scan this QR code to watch its
flat windscreen and flat 'pick-up bed' – the French launch video
carmaker is proud to point out it's done something
'other vehicle makers wouldn't dare to do'. Citroen Source: Car Thro le
says there's also a prac cal reason for the ver cal
windscreen – it uses the least amount of material
possible, given that a ver cal windscreen has the
shortest distance from top to bo om.

There are other novel ways the carmaker has worked
to improve the Oli's recyclability. The simple seats are
made of a mesh that allows for more natural light
throughout the car and are made of 80% less parts
than a tradi onal seat.

Removable Bluetooth speakers are also in place
instead of a built in sound system, which has us
wondering why it's never been done before. These
weigh much less than a built-in setup and can be taken
with you when you want to listen to music outside the
car – simple, but genius!

The Oli's 40kWh ba ery is capable of an impressive-
for-the-size 248 miles between charges, thanks to its
lightweight setup. Charging from 20% to 80% will take

July - September 2022 | The Corrugator 74

ADVERTISERS’ INDEX

Name of the Company Page No. Name of the Company Page No.

AGSP Impax Corp. Cover Gate Fold Linux Machines Incorpora on 92
AGSP Impax Corp. 82 & 83
Amylodex Pvt. Ltd. 6&7 Mark Engineering Services 106
Arjun industries 56
Bilansh Brand- Sarita Group Chemicals 42 MetaChem Paints & Adhesives Pvt. Ltd. 60
BKG Rolls 14 & 15
Dongfang Precision 10 Nexxgen 32 & 33
Dicar (Saurashtra Systopack Pvt.Ltd.) 85
Emba 26 NP Machinery 101
Erhardt + Leimer (India) Pvt. Ltd. 36 & 37
Flotech Machineries Pvt. Ltd. 88 & 89 Pap-Tech Engineers & Associates 8
Ganesh Dietech
Gromotech Agrochem Pvt Ltd Back Cover PRINT PACK IPAMA 90
Guangdong Fosber Intelligent Equipment Co., Ltd 24
Gum Corru Puredex 30
Gum Corru Inside Back Cover
Hotron Heaters Pvt. Ltd. 44 & 45 Pushpa Enterprises 81
InSun Co 50
InSun TaoKwong 68 Radiant Electro Heat 55
J S Machines 58
KD Labs 59 Radiant Hea ng Systems 54
Keshaka Works 48 & 49
Kohima tools 62 Sanjay Adhesives 64
Lian Tee 100
103 Shree Guru Kripa 52
18
Shree Krishna Engineering Works 98 & 99

SK Packaging 72 & 73

Sond Engineering Works 102

SUN-UP (India) Machinery Co. Pvt. Ltd 2&3

SUN-UP (India) Packaging Machinery Co. Pvt. Ltd Inside Front Cover & 1

Super Cut Engineer Pvt Ltd 70 & 71

Super Shear Line 78 & 79

Ubique Packaging Systems Pvt. Ltd 94 & 95

Vijay Chemical 65

Vijay Maru Print Pack Machineries (VMPPM) 76

WICMA 75





Closed-Loop Corrugated Case Reuse INDUSTRY UPDATES
Process Delivers Savings Through Cycles,
Material Input Reduction

Wiring Solu ons Plus (WSP) supplies wiring harnesses to manufacturer REDARC Electronics in
suburban Adelaide, South Australia.

Last year, the two companies piloted a closed-loop expected five years of use, this will prevent was ng
corrugated case reuse system to see how much (if any) 9,114 cases and over 20 km (13 miles) of tape.
material input savings they could achieve. Prior the
trial, WSP's products were packaged in single-walled While there were fears that BoxLatches would take
corrugated cases that were taped closed before being more me, in prac ce they were faster than tape and
sent to REDARC. These weak cases were o en knives for closing and opening boxes, saving WSP a
damaged during transport under the strain of the projected $568 per year in staff costs.
heavy wire contents. Upon receiving at REDARC, cases
were opened, and flaps removed with knives, then REDARC benefits from reduced task me and lowered
unloaded on the line before being disposed of a er a risks from blades damaging products or injuring staff.
single use. Both WSP and REDARC have invested in a set of Clip &
Stack products that are used to hold back box flaps as
With 42 cases shipped per week by WSP to REDARC for items move along the assembly line, improving access
50 weeks per year, even this small volume of to the contents while being faster and safer than
corrugated was seen as wasteful. Supplier BoxLatch, rubber bands or tape. Open boxes are also now safely
whose clip products stabilize corrugated and provide stacked to save floorspace.
for reuse, partnered with the two companies on a
year-long trial to see what savings and circulatory Clean, empty cases are collapsed, with BoxLatches and
could be achieved. Clip & Stack packed separately at end-of-line for reuse.
No tape was stuck to conveyors and no bands were
Today, by using BoxLatch products, WSP's cases are wrapped around rollers. Maintenance people were
now kept in good condi on as they move through happy with this benefit, the company says. Cases and
produc on, enabling their reuse like plas c totes, but BoxLatches are then returned to WSP, where they start
at a frac on of the purchase cost. Two BoxLatches are the cycle again.
used to secure the base of the box to carry an 11-kg
(24-lb) load, while one is used to close the top of the This case study illustrates that closed loop corrugated
case. Tape is no longer needed, saving WSP $115 per case reuse works with even a small number of cartons
year. and provides a significant ROI on the cost of BoxLatch
products. The more cycles the cases are reused, the
The wire supplier also decided to upgrade its cases to a higher the return.
double-walled variety at a marginal cost to allow for
reuse and improved product protec on, which meant Source: Packworld, by Ma Reynolds from BoxLatch
cases are cycled a modest seven mes before disposal.
This has cut costs from $1.20 to 0.30¢ per use. Over the

July - September 2022 | The Corrugator 00







How to reduce the impacts of single-use INDUSTRY UPDATES
plastic products

Single-use plas c products (SUPPs) may So how can we phase out SUPPs and what are the
epitomize convenience, but with the damage alterna ves?
they cause through produc on, distribu on and Here are some recommenda ons from UNEP and the
li er, they are a major threat to environmental and Life Cycle Ini a ve's meta-analyses of life cycle
human health. The open burning of plas c waste, assessment studies on SUPPs:
consump on of plas c-contaminated seafood and Opt for reusable alterna ves
crea on of harmful microplas cs are just some
reasons why SUPPs should be phased out. Elimina ng Priori zing reusable products is not only cri cal for
plas c product pollu on is an important component of environmental health, but it can also be cost-effec ve.
the United Na ons Decade on Ecosystem Restora on. Businesses that allow consumers to bring their own
bags, cups or containers can save on SUPP-associated
The UN Environment Programme's (UNEP's) recent supply and storage expenditure, while customers can
report From Pollu on to Solu on shows there is avoid poten ally paying extra for shopping bags or
currently between 75-199 million tons of plas c waste containers.
in the ocean, and in 2016 some 9-14 tons of waste Co on and non-woven polypropylene shopping bags
entered the aqua c ecosystem. It is es mated that by
2040, this will have almost tripled to 23-37 million tons
per year. Plas cs are the largest, most harmful and
most persistent of marine li er, accoun ng for at least
85 per cent of all marine waste.

But experts say, simply binning SUPPs and switching to
single-use products made of other materials is not the
solu on. “It is the single-use nature of products that is
the most problema c for the planet, more so than the
material that they're made of,” says Claudia Giacovelli,
Programme Officer of the UNEP Life Cycle Unit. “The
best solu on may not be the same in all socie es but
taking a life cycle approach can help in se ng the base
towards the right decision.”

July - September 2022 | The Corrugator 82

How to reduce the impacts of single-use plastic products INDUSTRY UPDATES

are increasingly common, as are reusable and portable sustainable, such as by using renewable energy and
plas c and stainless steel bo les, cups, and tableware. recycled materials.
Reusability is also increasingly viable for personal
hygiene products, through products like silicone Sourcing locally and avoiding air-freight transported
menstrual cups and cloth nappies. goods is another way to reduce the environmental
impact of products over their life cycle. Finally, end-of-
Turn 'single-use' into 'mul -use' life impacts must be considered, so that products can
be recycled or discarded in an environmentally friendly
The more any product is reused, the lower its manner when they can no longer be reused.
environmental impact. When consumers can't avoid
SUPPs, they should mi gate their environmental Geographical and social context ma ers
impact by reusing them when possible instead of
immediately disposing of them. For example, durable A garbage container overflowing with li er. Areas must
single-use plas c bags, bo les, cups, tableware, and develop tailored approaches to phasing out single-use
take-away food packaging can be reused or products based on local contexts.
repurposed.
As more areas propose bans to SUPPs, policymakers

Single-use alterna ves made of other materials are must consider geographical and social contexts when
not intrinsically be er, meaning that they should be iden fying appropriate alterna ves. Factors such as
reused when possible too. Such as, a paper shopping produc on requirements, expected use, reusability,
bag may need to be used four to eight mes to have a likelihood of li ering, local waste management
lower environmental impact than one single-use infrastructure and educa on can all impact how
plas c bag. environmentally friendly proposed alterna ves are.
Design products with circularity and end-of-life
considera on Shi ing to reusable op ons and bolstering recycling
and waste management infrastructure must take
Consumers should not shoulder the en re burden of priority. In the interim period, areas with li ering
decreasing the impacts of SUPP. Guided by problems should avoid using lighter products because
policymaker and retailer ac on, products should be they are more likely to be li ered, even though they are
designed to be both lightweight and durable to generally less resource-intensive to produce.
maximize reusability. Produc on should be Ul mately, elimina ng SUPPs is only one way to reduce
environmental damage.

As Giacovelli notes, “Countries are encouraged to
promote ac ons that lead to keeping resources at their
highest value in the economy, by consuming less and
replacing single-use products with fit-for-purpose
reusable alterna ves for a healthier planet.”

Source: UN Environment Programme's (UNEP's)

July - September 2022 | The Corrugator 83





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3 Ways Change Leaders Prevent, Minimize INDUSTRY UPDATES
and Manage (or Create) Resistance to Change

If leaders don't handle the change process can be uncomfortable, but discovery and curiosity are
effec vely, it will likely turn into a how-to-create- also part of the human equa on. We are born with
resistance 101 guide. innate curiosity. Children are endlessly curious
creatures, eagerly seeking to explore and make sense
A key a ribute of change leadership is one's ability to of new things. If they feel safe and comfortable, a
prevent, minimize and manage resistance. As an changing environment is fun and exci ng.
emergent manager more than a decade ago, I was

leading a high-profile change project. Excited by the Here are three focus areas that will help leaders to
opportunity to fight resistance, I set the wheel of make sense of this organiza onal phenomenon -
change in mo on. I believed it was human nature to resistance to change:
resist change. I donned my shiny armor for the ba le.
1. An cipate and prevent resistance
Thankfully, a er a few years of driving complex
change, my viewpoint has changed. Resistance is no The best prepara on for a ba le is to avoid it. Where
longer a ba leground for me, but rather an insigh ul viable, sensing and mi ga ng the problem is be er
leadership clue. than all the fixing efforts. Here are two ps:

Let's first describe some of the key triggers for l Do the change management appropriately: During
resistance (to change): change, people will ask ques ons, such as "What is
happening, and what does this mean for me?" It's
1. Not understanding what's happening important for leaders to communicate early,
2. Being uncertain of what it means for the person, involve the key players in the change process and
have a solid plan.
how it will affect them, etc.
3. Being fearful of the unknown and comfortable with l Pay a en on to concerns at the beginning: Change
is a lived experience. It has a past, present, and
familiarity hopefully, a future. There might be pockets of
4. Feeling proud of their current way of doing things emo onal dips when people remember a previous
5. Seeing many past changes with no bad experience. Suppor ng people to climb out of
these dips requires skillful change leaders who
posi ve outcome listen and take ac on to ease their minds and
hearts. Would employees, colleagues or team
Change begins at an individual level; it is personal. For members resist if they felt at ease?
the change to succeed, it relies intrinsically on people's
willingness to adopt it. People's emo onal and 2. Welcome resistance as a signal rather than a barrier
intellectual transi on into the change affects their
willingness. It goes without saying that resistance will Here are useful ps to see through and beyond
surface if leaders don't support this transi on. resistance:

Is it human nature to always resist change? I say this is l Unearth the root cause: The true nature of the
a cliché and therefore my answer is no, it is not human resistance might differ from what's on the surface.
nature. A er all, people have reasons to resist. Change

July - September 2022 | The Corrugator 87



3 Ways Change Leaders Prevent, Minimize and Manage (or Create) Resistance to Change INDUSTRY UPDATES

When a child cries, we ins nc vely seek to her grief, then work with Mary to revitalize her 20 years
understand the cause. Are they feeling unsafe, in of spark.
pain, hungry or scared? If they are old enough, we

ask them. When an employee is dragging their 3. Create condi ons for social networks and
feet, they might feel that the ground is falling from rela onships
underneath them. Individuals may resist change
due to the fear of what they must give up. Perhaps Challenging mes call for a greater focus on wellness
their iden ty, pride or status. An effec ve change and resilience. Change is a social phenomenon and
leader listens, acknowledges the fear and takes here are two sugges ons to advance resilience through
ac on to help people find their foo ng. social se ngs:

l Discuss the issue and be personal: One of my l Harness informal networks and rela onships:
clients — a large healthcare provider — was Building informal networks and social
upda ng its appointment booking process from a opportuni es at work will nurture bonds and
manual system to an efficient tech solu on. Mary rela onships. Within these networks, people feel
was the leader of the booking team. She hadn't safer to lean in, raise their opinions and express
been sick in 20 years. But when the change was their concerns.
introduced, she was signed off with stress. I met
her when she returned to work. She frowned, l Involve shining personnel: Middle managers are
gazing at the booking folders. "I worked for years o en key players of change programs, as they are
to build this great system," she lamented. "Erasing close to the teams. Investment in developing
this process feels like they are dele ng me." middle managers as change champions is a great
way to boost morale.
This was such a revela on. It was not about the new
system or the technology, yet the fear of loss. Loss of Source: Entrepreneur, by Gulcan Telci
existence. The immediate step was to acknowledge

July - September 2022 | The Corrugator 89







4 Affordable Technology Upgrades to Improve INDUSTRY UPDATES
Existing Equipment Performance

Modernizing your
factory's produc on
equipment can be a
significant investment in
your manufacturing
opera ons, improving
equipment performance
while keeping up with
the latest innova ons
brought about by the
Industrial Internet of

Things and other
industry changes

Older produc on equipment can pose a pla orms and other tools that connect with the
dilemma. On one hand, it represents a Internet of Things (IoT). By adding affordable sensors,
significant investment and con nues to be a you can modernize and take advantage of the resul ng
crucial part of the opera on. But on the other hand, it data prolifera on and manufacturing throughput
may no longer be supported by OEM equipment and improvement without the big price tag.
may lack interfaces with the technology or system
controls you use. Surpass original equipment reliability

Fortunately, there are ways to address deficiencies in A er safety, one of your top manufacturing and
older factory equipment, and they don't have to break technology goals should be improving machinery
the budget. Manufacturing and technology reliability. Even equipment that is built to last according
moderniza on can improve safety, efficiency, to the top standards of the day may become outdated
throughput and produc vity levels, and with the right as reliability standards evolve and new technologies
approach to an equipment refresh project, you can make it possible to keep closer tabs on performance. If
make a posi ve impact on the bo om line at a frac on you choose a control pla orm carefully, you can
of the cost of a total equipment refurbishment or improve reliability.
replacement project. Here's how:
Generate data for con nuous improvement
Invest in safety
Automa on tools and sensors can monitor machine
There's a lot technology can tell you about efficiency, throughput, up me, down me and other key factors,
but it's always a good idea to put safety first. Purchases such as environmental condi ons. It's also possible to
like safety controllers, safety relays and safety sensing deploy advanced con nuous process or batch mode
equipment are a good investment, even for older applica ons that deliver large amounts of data on a
equipment that isn't part of your long-term macro level. These tools can help you con nuously
produc on plans. Keeping operators safe should improve opera ons. These are a lot of improvements
always be the top priority. to consider, to be sure. The good news is that it's not
necessary to make all these upgrades at once. Instead,
Integrate new technology into older machinery you can priori ze according to which upgrades are
more likely to have an immediate impact and fit your
Legacy machinery can be brought to modern budget.
standards with technologies like controllers,
environmental sensor arrays, safety technology, Source: Advanced Tech
Supervisory Control and Data Acquisi on (SCADA)

July - September 2022 | The Corrugator 93





RCBMA held an educational FCBM NEWS
seminar on 29th September 2022

On 29 September 2022, RCBMA held an educa onal 3. Nego able Instruments Act
seminar at Hotel Grand Safari, Jaipur exclusively for its 4. Building a successful organiza on
members. Four experts invited as speakers shared
their exper se on following topics for prac cal The seminar got a good response from 50+ members
benefits for today's corrugator: who a ended in person and around 10 members
through online mode. The highly interac ve sessions
1. Savings through Cost calcula on, planning were followed by Q&A, followed by dinner.
and waste reduc on

2. Govt schemes for benefit of Entrepreneurs

July - September 2022 | The Corrugator 96