Packaging production systemsFlexible solutions

for luxury packaging

BOXline

Rigid cardboard boxes with magnetic closures

Book-style boxes with sharply defined edges

Rigid boxes made of board, paper and cover material

Presentation boxes with flap lids and embossed designs

Gift, party and motto boxes

Elements for slipcases and inlays

Slip-on lids or shoulder boxes

Decisive benefits

� Reproducible high-precision� Premium quality� Cost-effective even for small runs and limited series

� Flexible handling of repeat orders� Short order lead times� Fast make ready

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Design and consulting services

Packaging design from our technology partner

August & Christine Marie – Luxury packaging by KOLBUS –an inspirational range of stunning solutions for luxury pack -aging designed for highly automated production on KOLBUSpackaging lines. Our strategy is simple and comprehensive.We aim for sustainable use of cardboard and paper, un -compromising quality through series production and market-oriented and customer-specific design and production.

Our background is impressive: in-depth engineeringknow-how has generated a new method for producing luxury packaging using paper and cardboard.

The type of packaging and the exact use to which it will beput will vary. More important is the wide variety of potentialdesigns. One striking example is packaging for luxury winesand spirits; other solutions include large and small boxessuitable for a huge variety of products. The design portfolioof boxes with an attractive look-and-feel includes lay-flat orcollapsible boxes, and packaging with sophisticated closuresystems. Packaging made on our systems is attractive tohandle and it opens or closes with a distinctive and surpris -ing sensation.

The packaging is made of grey cardboard between 1,5 and 4 mm thick, so that the boxes are extremely rigid and stable.Precision-made, lined and covered on highly automatedKOLBUS packaging lines, the boxes are ideal as packagingfor luxury consumer goods. During the design process, thefocus is on high-value and high-quality packaging that canbe produced in large volumes and with the highest precisionwith very short order lead times.

The way is open for special decorative techniques, such asfoil embossing or partial application of print coating, to em-phasise the packaging design and character. Graphic designelements and the choice of cover material can strikingly emphasize the quality look of packaging.

Our services range from individual consulting and ideas topractical development of packaging solutions and researchon products and manufacturers

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Rotary board cutting machine PK 170

For precision cutting of grey cardboard or similar mate rials in two passes with linear cutting speed of 120 m/min, strip feeder 220 cycles/min.

BenefitsHigh-precision, accurately angled cutting of boards at topspeeds using the rotary board cutter for lengthwise andcrosswise cuts.

FeaturesExactly parallel cuts with optimal cutting quality. Easy opera-tion with steplessly adjustable feed and cutting speed. Thestrip hopper for cutting blanks is quick and easy to attach.Slippage-free board feed thanks to pull-in rolls made of an effective rubber/steel combination.

Board cutting

1st pass/slitting 2nd pass/crosscut

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Video: Rotary board cutting machine PK 170

https://youtu.be/e56C_7U-YsQ

BOXline – modular KOLBUS pro -duction system delivering flexiblesolutions for the production of luxury packaging

KOLBUS has developed an innovative, fully automatedproduction line for high-quality luxury packaging. The rigid boxes are produced on a system with automated,toolless format changes.

Grooving machine NM 101

For cutting precision grooves in cut-to-size boards at up to 65 cycles/min.

Benefits� Production of sturdy, versatile box components thanks to

optimal smooth grooving cuts, through to a minimal last board/paper layer, combined with precision, ultra-thin application of glue for lining and counterlining.

� Optional positioning aid with digital display of knife positions

� Up to 0,1 mm exact positioning� Machine for large formats� 100% accurate angles, sharp edges and ultra-smooth

grooves

Features� Groove cutting with angled knives� Up to 65 cycles/min, speed harmonized with the speed

of the downstream casemaker� Special grooving knives can be set at any angle from

90° – 130°� Grooving knives can be adjusted off the machine� Double magazine� Parting device

Board grooving

BOXline

The boards are grooved or cross-grooved according to design specifications

[A] Box line

[B] Box lid line

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Video: Grooving machine NM 101

https://youtu.be/xk3PPIfdhcU

Depending on production requirements:

DA 260 casemakerAlternatively: DA 270 or DA 290

Magnet inserter SW.M 400

For fully automatic production of box lids, book cases, files, posters, calendar and board game components atspeeds of up to 40 cycles/min.

BenefitsOur DA 260 casemaker is a professional machine engineeredto exacting specifications. Easy, one-man operation and fastand simple set-up contribute to the DA 260’s high productivity.

FeaturesInput and output zones are at an operator-friendly height and ergonomically efficient. Make-ready is quick and easywith semi-automated settings. The operator always has aclear view of the entire machine. The machine is also ideal for small-batch or custom products using multi-section andthin boards.

To make boxes with sophisticated magnetic closures, the magnet inserter automatically mills the blind holesfor the magnets, applies the glue and inserts the magnetsor steel studs.

BenefitsWith magnetic closures you get the reassurance of a soft, butclearly audible, clunk as the magnets connect. It's especiallyimpressive with high-end, reclosable luxury packaging.� Fewer process steps – no separate hole punching,

no extra label application � Lower material costs with steel studs� Perfectly laminated layers over magnets/studs so

no blemishes on box cover

Features� Gluing station with nozzle system and integrated

premelter� Separation from magnet hopper� Feeder system for up to 4 magnets or steel studs� Simple adjustment for format changes� Milling station

Line the boards and continue processing

Manufacturers decide whether the lining or the counter -lining is applied first. It depends on whether the inside oroutside surface of the box is in the foreground later.

Magnets are used to close the box lid which will later be joined with the box itself.

[A] Box line

[B] Box lid line [B] Box lid line

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Lining unit SA 260

For fully automated lining of box lids, book cases, files,posters, calendar and board game components at speedsof up to 40 cycles/min.

Benefits� Ergonomically optimal arrangement of feed and

unloading areas� Separate drives – absolutely minimal downtime,

far less wasted material, easy handling� Practical combination of automated manual

adjustment processes� Twin-roll gluing system for thin, even glue application� Pull-out gluing unit for cold and hot glues

Features1. Linked with an SW.M, in a box production line� Single case feed� Turning unit for single products� Single case output

2. Linked with a DA 260� Board prestacking conveyor for automatic feeder � Counter stacker with conveyor output

The reverse side of the board is covered; the cut-to-sizeboard is now completely covered, including the magnetsif these are being used.

Highly automated mechanical production delivering industrialquality for luxury packaging

Building on the know-how gained in almost 90 years ofdeveloping automated casemaking machines for book production, KOLBUS engineers have developed machinemodules which can be linked inline to produce a widerange of rigid boxes from board and paper. These produc-tion lines for luxury packaging are engineered for versa -tility and impressive quality with fast, toolless formatchanges. With this ability to deliver consistent, industrialquality and to match the demands of digital printing, KOLBUS is creating new options for packaging manufac-turers and their end customers in the consumer goods industries.

Production adapts to changing markets and manufacturersneed no longer commit to large minimum order volumesfor imported packaging. This in turn will open new marketsfor small artisan suppliers closer to customers.

BOXline

[A] Box line

[B] Box lid line

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SW.E 500 corner puncherSW.H 500 box machine

For the production of consumer-goods packaging fromcross-grooved precut boards with punched corners

A new way of making boxesThe system delivers boxes with wrap-around lids, slip-on lids or shoulder boxes with precision angles and clean, sharpedges and corners. The boxes are made from cross-grooved,precut boards.

In the SW.A 500 infeed and aligning device the precut boards are separated and precisely oriented.

The SW.E 500 corner puncher with four corner knife holderspunches the basic shape for the inside tray while board trans-port is briefly paused. No punching die is required and swarfremoval is automatic.

[A] Box line

BOXline

The box sides are erected and cold-glued in place pre -cisely positioned by the grooves. The box is dried in theholding unit and the finished box is then transported outof the line.

Simplicity for the manufacturer. Sophistication for the customer –the modular box production linefrom KOLBUS

New options for producers of packaging and brandedgoods. The modular system means flexibility and rapid response to changing market situations.

The four corners are punched out creating a base andfour outer sides. The previously cut grooves ensure thatthe sides of the completed box will be exactly at right angles to the base.

The SW.H 500 box finishing module consists of:� Cold gluing unit for gluing the grooves� Erecting unit for the side walls� Holding unit for glue drying� Delivery via transport beltAll the units are linked to configure the automated produc-tion line.

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The SW.G 500 box processing line with the SW.Z 400 blank placing modulewhich can be easily replaced bySW.B 400 box placing module. With side glueing module SW.BS 400

For industrial production of high-end gift boxes with magnetic closure

Automated production of wrap-around boxes with magneticclosure using luxury materials and printed substrates.

The SW.G 500 box processing line positions and glues onthe finished box components or the flat-packed folding boxwith the wrap-around lid.� Gentle handling of lined wrap-around lids with magnetic

closures � More automation and short order lead times� Flexible production� Consistently high quality� Fast format changes make ready� SW.L 400 puncher round and shaped holes integrated

(SW.L 400M) or stand alone.

[B] Box processing line

The box lid and the prefinished tray section (or a pre -punched element for a collapsible box) are glued firmlytogether. Magnetic inserts create a high-end closing system ideal for luxury packaging.

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The box tray is precisely positioned on the glued wrap-aroundlid by the SW.B 400. The station SW.BS 400 is for uprightglued sides and press to box side. Alternativ the SW.Z 400 isused to position flat-pack folding boxes or other componentson the lid section. Finally the finished boxes are output on atransport conveyor.

Both these placing modules are on castors; they can be swapped around by simply rolling the required module intoposition.

Video: BOXline drupa 2016 | 40 finished boxes per minute

https://youtu.be/H8BnZ_BJRYg

Box types and configurations [Examples]

Rotary board cutter PK 170

Grooving machine NM 101

Casemaker DA 260

Magnet inserter SW.M 400

Lining machine SA 260

Feeding station SW.A 500 or aligning device SW.RCorner puncher SW.E 500Box machine SW.H 500

Box processing line SW.G 500 with placing module SW.B 400

Box line SW.G 500 with placing module SW.Z 400

Puncher SW.L 400

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Flap lid box with pop-up tray section and magneticclosure

Wrap-around lid box(incl. window) with collapsible boxsection and magneticclosure  

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Box with handle and magnetic closure 

Lidded box Shoulder box Slipcasewith removable inside box

Cube box as 2-part lay-flat boxwith magnetic closure

KOLBUS GmbH & Co. KG | Osnabrücker Straße 77 | 32369 Rahden | Germany info@kolbus.de | www.kolbus.com + www.luxury-packaging.eu | Tel. +49 5771 71-0

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The modules making up a KOLBUS BOXline are fitted withaxial servodrives based on Siemens SIMOTION D and areequipped with the KOLBUS 3·60, type AFS 702, ready for remote diagnosis. Line control is via the Copilot® system withuser-friendly touchscreens.

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