Finishing & Screen Printing
BOBST flexo folder-gluer gives Dansun Packaging leading edge in corrugated production
Wednesday 26. May 2021 - With a clear focus on achieving packaging excellence, just in time delivery and strong market competitiveness, Chinas Dansun Packaging has invested in a new state-of-the-art FFG 8.20 Discovery folder-gluer from BOBST.
Established in 2003, Dansun Packaging occupies a 50,000m2 site, incorporating plant and warehousing facilities, within the Hefei Economic and Technological Development Zone. It employs 410 people and manufactures more than 100 million m2 of corrugated board each year for markets including food, electronics, home appliances and chemicals.
“Market competition is fierce and as a result we are always seeking to strengthen our business by investing in our people and equipment,” said Larry, general manager at Dansun Packaging. “Our focus is on ensuring sustainable development of the company for future success through pertinent investments and waste reduction strategies in order to achieve competitive advantage in the industry.”
Larry added: “Dansun provides a full range of services and complete packaging solutions to customers. We are committed to continuous improvement so that we can be sure to meet customers increasing demands for timeliness, flexibility, reliability and diversity of supply, as well as boosting our own position in the market.
“As part of a programme of investments in our site, equipment, warehousing technology and customer workflow systems, we chose to purchase a BOBST FFG 8.20 Discovery in 2017, followed by a BOBST palletizer in 2019. We were sold on the FFGs ability to meet the supply needs of our major customers, thanks to its high speed, fast job changeover, easy operation and reliability.
The BOBST FFG 8.20 Discovery offers unparalleled flexibility and heightened efficiency to the production line. It is a high-speed box-making solution that is able to process up to 18,000 boxes/hr across a wide range of corrugated flute types, including single and double wall boards. Designed to be intuitive and bring additional value to the supply chain, the flexo folder-gluer combines automation, accuracy and quality in one machine to offer superb return on investment. It also boasts ultra-quick setting up times, or order changeover during the run, of just two minutes with Rapid-Set.
The flexo folder gluer was fully operational at Dansun Packaging within a month and today, production capacity is more than 3.5 million/sqm. BOBST also provided training to operatives as part of the installation package.
Larry said: “With the BOBST FFG 8.20 Discovery, we have a machine that allows us to increase throughput while maintaining quality and efficiency along the line. We are seeing significant benefits since it was installed and are impressed with its performance.
We have seen a reduction in ink loss – reduced from 2kg/change order to 300g/change order – a massive boost to Dansuns sustainability drive; an increase in output thanks to the machines high speed, and an average speed from 140 to 275 cases per minute. Start-up losses have also reduced from three boxes per changeover to 1.5 boxes and unit labour cost output has reduced by 22%. In combination with the palletizer, we have been able to increase production line speed even further and reduce carton waste and defects.”
“These are substantial results that enable us to meet our customers lead times and quantities at short notice, while still delivering consistent quality,” added Larry
For Dansun Packaging, there are a number of machine features that have stood out for the team. Job parameters can be stored on the system and easily retrieved, meaning make-ready times are reduced significantly, along with job errors and waste. These are further enhanced by the ability to change printing plates during production. Meanwhile, automatic palletizing increases productivity and reduces carton loss and the process defect rate. In addition, the quick-change function of the doctor blades and uniformity of ink application, as well as a unique ink washing device, reduce ink consumption.
Larry said: “We have always worked well with BOBST and our relationship is mutually beneficial. We always find the team to be professional and reliable and the technology and services they bring to the packaging industry is first-class.
“The purchase of the BOBST FFG 8.20 Discovery flexo folder-gluer has been an important one for Dansun and our customers. It has taken our production to another level and, thanks to BOBST service and remote maintenance solutions, the machine is still running smoothly four years on. Our customers trust in us to be able to deliver the high standards of packaging they require on time, every time.”