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CorrugatedINDUSTRY

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APP Factory Visit DAJK Factory Visit

The 2014 Indonesia Corrugated Industry Summit was held at the Pullman Jakarta Central Park Hotel from September 22 to 24. The event was held by Reed Exhibitions, organizers of SinoCorrugated 2015. It was also co-organized by the Indonesian Corrugated Cardboard Industries Association (PICCI). A total of 47 corrugated equipment and consumables suppliers, together with 227 local corrugated box manufacturers attended the three-day event.

During the Summit, Mr. Kinardo Ang, President of PICCI, talked about the current status of the industry and made a number of predictions for upcoming industry development trends,

• Edoardo Silvestri, Sales Director of Fosber,noutlined his company’s "Simply Better" technology for the corrugated industry, giving participants an in-depth understanding of the company’s brand and technologies.

• Frank Sielhorst, Sales Manager of Erhardt+Leimer, presented a video that vividly showed the operational dynamics of the most advanced corrugated cardboard production line in Europe that broadened the horizon of local manufacturers.

• Ang Gee Leong, Sales Manager for Bobst Lyon Asia-Pacific, proposed some innovative, practical ideas on cardboard optimization.

• Jun Yi, Director for Asia of BOIX, delivered an address on Plastic versus Corrugated, which brought the afternoon session to a climax.

• Tuti Buntaran, Director of PT. Tosi Jasindo and a famous local trade agency gave a specific and comprehensive analysis on the current conditions and future trends of the corrugated packaging market in Indonesia. The talk was often peppered with warm applause.

The trade and business discussions that followed the speeches pushed the summit to new heights, where corrugated cardboard manufacturers from Indonesia had enthusiastic discussions on development and trade. Many buyers made clear their interest in making purchases. They also made arrangements to hold follow-up discussions, to explore cooperation possibilities. The cameras recorded many handshakes and hugs at the event as the discussions and exchanges progressed.

A reception took place at the hotel on the evening of September 22, featuring a series of vibrant performances. The interactive song-request segment saw the cardboard manufacturers’ sing and dance, sparking a merry sing-along within the entire audience. The reception ended with an announcement of winners in a number of categories that had been created expressly for the event.

Factory VisitAt the INDAH KIAT Serang Mill of Asia Pulp, Salim, General Manager of the Corrugated Cardboard Division, warmly welcomed the visitors and elaborated on the group’s operating models and local markets. The visitors were greatly impressed by what they saw and heard.The second stop of the tour was the DAJK offset printing and corrugated cardboard factory. Founded in 1996 and currently running three factories, DAJK specializes in offset printing and corrugated cardboard manufacturing. Last year, it purchased a 2.2m, 250m/min production line from Taiwan-based company Hsieh Hsu Machinery. The group is now expanding the facility to 300,000 sqm.

Johanes Jatar L, President Commissioner; Andreas Chaiyadi Karwandi, President Director, and

Timotius Harja Pradipta, General Manager of the company’s Corrugated Division warmly welcomed the Chinese visitors to the factory.The summit brought together top professionals for different ethnicities and religions to witness another milestone in the Indonesian corrugated industry.

The event had an international reach while retaining its distinctly Indonesian characteristics, thereby giving professionals from around the world the chance to exchange their views on technologies and development trends through speeches and discussions. This is sure to lead to breakthroughs in industrial innovation. In all, the Summit marks the dawn of an exciting new era in the history of the corrugated industry.

Erhardt + Leimer Mr. Faisal H. Basri Batubara Tuti Buntaran

2014 Corrugated Industry Summit














PICCI BOIX FOSBER

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APP Factory Visit DAJK Factory Visit














Erhardt + Leimer Mr. Faisal H. Basri Batubara Tuti Buntaran

2014 Corrugated Industry Summit














PICCI BOIX FOSBER

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Indonesia economy is quite independent to the world economy as 64% of GDP is contributed by domestic consumption which helps Indonesia to buffer external exposure. Average expenditure for food per capita 50.66%, in which 13 % is contributed by processed food (BPS, March 2013). The challenge is on the infrastructure (on of the most expensive one in the world, Logistic Index Indonesia 27%, while United States of America only 9,9%, Japan 10,6%, singapore event only 8%, Malaysia, 13% and Thailand 20%) and empolyees productivity also has serious problem (capability to do the job efficiently on economic scale). Demand for corrugated Packaging Material has reached US$ 176 billion and by 2019 Asia Pacific will represent 70% of worldwide corrugated market. While emerging market growth forecast to reach 30.2 billion sqm.

In 2011 Indonesia has become no 10 Top Corrugated Output in the world, moreover Indonesia 5 years growth (2011-2015) in no 4 in the world just behind China, India and USA with 2,35 billionsqm. Indonesia has new baby 4,5 million yearly. New Baby mean new retail business. Therefore the baby diaper business in Indonesia in the last few years is booming. It is being predicted that the Indonesian market for disposable baby diapers alone will grow at a pace of 14% a year, increasing from approximately 1.9 billion in 2010 to 3.7 billion in 2015. and all the big players enter the market, such as :

P&G is investing more than $100 million to build a plant for its baby care division and has started producing its "Pampers" brand diapers locally by this year. The plant located in Karawang, West Java. The plant will be ready to fullfill diaper demands for about 8 million babies in Indonesia.

Unicharm, Indonesia's largest diaper producer, has two factories and expects to start operations at a third in eastern Java next year. Unicharm Corp. spent $400 million for factories and sales offices in Indonesia, which had been relying on imports of Pampers.

Kao Corporation is building a second plant in Indonesia to help meet demand in the region. According to executives, the 140,000‐square‐foot plant will make laundry detergent and sanitary napkins initially and will ultimately make disposable baby diapers for the Indonesian region. It will be complete in 2014. The total investment for the project has been reported at ¥10 billion ($128 million).

Retail Trends in Indonesia• The market huge and changing• The shoppers Socially Shopaholics• The challenges - Raising competition and

raising cost of doing Business Corrugated has big market and though more than 70% is till basic corrugated box, but the other segment growth worldwide more than 6%, while the basic corrugated growth is decline by 3%. Corrugated has 4 main market segment

1. Basic Corrugated growth ww – 3%2. High Quality Flexo growth ww – 6.5%3. Litho Laminated growth ww – 6.5%4. Merchandise Display growth ww – 6.5%

Corrugated Material Trends LightweightingAverage substance weights continue to show reductions as producers look to improve yields as far as possible. This is driven by the need to reduce overall packaging weight and reduce transport costs. The majority of lightweight boards are being used in Western Europe, where finished board weights have been reduced by an average of 5gsm from 2009 to 2012, according to data from FEFCO. Paper weight is getting less and less. Fluting mostly now about 112 gsm down from 125 gsm. While Liner now mostly 150 gsm down from 200 gsm

HeavyweightingOn the other hand, the industry has seen the introduction of certain new heavyweight products, such as Billerud Flute semi-chemical fluting. Primarily targeted at replacing wooden packaging. The heavy duty sector is continuing to show growth, particularly in the chemical and automotive industries, as a result of growing demand as well as the 'greener' image of corrugated compared with

other materials.

New Packaging - Tea and Juice on the CupAt the beginning the tea was sold in the street on the plastic and giving a straw to the mainly driver in the street. Now it has been substitute with a cheap Tea Cup. It sold tremendously a lot. I have seen a printing machine 24/7 running one of the brand of this ice tea cup.

New Packaging – Food Contact PackagingWith the changing of life – most of woman now is not just a housewife, the woman also has job and will be to busy to prepare all the food in the traditional way, but of course they still has same passion to serve the family well. That is the reason that DS Smithe has innovated the ready one time baking – which make it easier to cooke, serve the cake and just thru it away once finish. No need to wash the cooking utiliities. Clean, fast and simple.

New Packaging – Beer in a Cooler Corrugated BoxNew Innovation has been made last year in UK by Miller Beer. It six pack beer also can be used as a cooler. It sells so well, as the young people can do picnic with this pack without any necessary to bring a cooler anymore. Simple and convenience.

Brown Box to Marketing Tools • Special Color to Color Separation (Opaque

ink to transparant ink)• Fast Moving in Retail (RRP and Display)

PrintingThe life style has change. Competition is very taft in the retail market, therefore more and more corrugated market is changing from brown boxes to the colorfull boxes. Fom the simple box to RRP (retail ready packaging), point of sale displays and merchandising units. These items are under pressure to provide the shelf appeal and brand exposure that brand owners are looking for. Paper mill also start to provide liner that can enhanced graphic properties allowing the reproduction of photorealistic images on RRP and POS (point of sale) applications in particular. The graphic liner is suitable for both offset and flexography. Demand from the FMCG sector continues to benefit from the trend towards the use of shelf-ready packaging ("SRP"), which can be readily converted from its initial role as a protective transit pack into a box or tray that can be placed on display in the retail store. SRP benefits retailers by reducing the manual work involved in loading goods onto store shelves and reducing the amount of damage to goods in store, while enabling products to be presented more attractively. SRP requires more sophisticated packaging manufacturing capabilities for cutting, printing and gluing the corrugated board

to form the more complicated box structures. The increased proportion of these higher value-added boxes, often requiring multi-passes within the production process, has contributed to capacity utilisation across the corrugated industry remaining higher than levels that would be indicated by the overall level of demand.

Retail Ready Packaging System of packaging and merchandising that allows goods to be moved direct to shelf with minimal handling, enabling products to be displayed effectively within then secondary packaging medium. Demand for higher quality, creative packaging. For this reason, the printing process also changing,

• Speciial color change to color separation• Ink change from opaque ink to transparant

ink

Common Practise• Ink is formulated generically• Pressman change anilox roller until the color

is as close as possible to the target• May also add extenders and bases to the

ink to correct color/strength. This can sometime backfire

Problems• Uses significant press time• Color may never be as close as it could be• Changing anilox roller influences graphic

quality

Better Practise• Ink is formulated specifically for the anilox

roll and substrate it will be printed on.• The ink is proofed prior to goingto press to

verify accuracy• Proofer must correlate with the press• Measure the drawdown and compare to

the reference• Adjust the ink recording the adjustment until

the ink within tolerence• Mix a full batch using the new formula• Ink is often within tolerance without any

adjustment on the press

Then we must make standarization of all the materials and equipments we use to make sure that the desire colors by the customers can be achieved in an economic way and always the same quality all the time. We have to do optimization of the printing machine as well as making a Fingerprint for all the parameters used in the printing process as well as the ICC Profile to give guidance what colors can be achieve with your each printing machine.






Corrugated TrendIndonesia, with a population of 240 million, is the world’s fourth most population and the largest economy in Southeast Asia. And it was estimated 30 millions of its population have strong buying power. It has 56.5% middle class income in 2010 (World Bank report, 2011; Bank Indonesia)






other materials.










ink





quality








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other materials.










ink





quality













Corrugated TrendIndonesia, with a population of 240 million, is the world’s fourth most population and the largest economy in Southeast Asia. And it was estimated 30 millions of its population have strong buying power. It has 56.5% middle class income in 2010 (World Bank report, 2011; Bank Indonesia)






other materials.










ink





quality








6

BoardRunner Non-Contact and Contact Extrusion

Features Valco Melton’s all electric model 900 glue valve.

The valve provides unparalleled high speed performance with over 250 million cycles before simple maintenance is needed.

The impact-resistant carbide plunger tip and engineered ceramic seat provide extreme durability.

The 900 valve’s powerful coil results in extremely accurate and repeatable glue patterns, in contrast to pneumatically activated extrusionsystems.

Easily switch from inside to outside gluing with no tools required.

The patented applicator heads allow for quick removal for changing number of beads and bead spacing.

BoardRunner Tri-Valve Non-Contact

Features three 524 series, all-electric glue valves (up to 4 valves per side).

The 524 series non-contact valves offer a ceramic tip/carbide plunger design for extended service life with less maintenance.

Can provide staggered pattern starts to match lead and trail tab angle, even in “auto-glue” system mode.

The non-contact method eliminates product skew that can be caused incertain contact gluing applications.

Features a tip-sealer design that prevents nozzle plugging during periods of down time.

Full valve and tip-sealer status can be viewed on Valco Melton’s OT-120 touchscreen control.

The Tri-Valve BoardRunner® with 900 valve attachment allows for inside/outside gluing from one side of the machine.

Flexibility to apply primarily top down, non-contact with the option to apply contact, bottom up when required

Flexoseal Glue System Options

Packaging Solutionwww.tosijasindo.com

[email protected]+62 21 75902726

The corrugated box manufacturing industry has long been focused on reducing waste as one of the key drivers of efficiencies. Like most box makers, you are probably focused on reducing waste in your facility. However, most people fail to realize the complex interdependent relationships that exist between quality, waste, product price, cost and production volume. What if “increasing” waste built value for your customers or increased your revenue and “decreasing” waste actually increased the cost of the box or even lowered sales? With so much at stake, it pays to take some time to more closely examine the tipping point between quality and waste.

What is Waste Anyway?There are actually two separate types of waste –

Corrugated Box MakersSaving Quality vs. Preventing Waste

internal and external. Internal waste is typically what the corrugated box industry refers to as “waste.” Internal waste represents any defective sheet or box that is produced and not shipped to the customer. However, if you don’t catch the defective product and it ends up in the hands of the customer, it is considered external waste. External waste is rarely, if ever, discussed unless brought up by the customer. The cost is only accounted for in the form of credits for defects returned. Some customers do not return many defective or problem products to the corrugated box maker, resulting in an inefficient and distorted feedback loop.

Misleading NumbersThrough our investigations, we have found that the costs tracked for external waste are more often larger than the internal waste figures. Furthermore, customer complaints, credits and feedback are a minority of the actual rate of defective product that customers are receiving. What this means is that some customers are bearing much of the direct costs (downtime, lost productivity, wasted products) associated with external scrap rates, while box makers are bearing much of the direct costs associated with internal scrap rates.

If customer complaints were, in fact, true indicators of the external scrap rates, this model would be useful for making operational decisions. However, discussions with end-users have shown that customers are not complaining about the vast majority of problems. Similarly, many box plants don’t complain about

every hiccup in their machines or every minor issue with their paper – that’s the norm and they are used to it. Because this feedback loop is broken, many corrugated box makers have a warped view (literally) of how much scrap they’re actually sending their customers.

OptionsTwo clear options are available to box makers for handling waste. First, do a better job of finding all defects before shipment and remove them from the production stream, increasing internal scrap rate and improving quality. Alternatively, send defects to customers in an effort to reduce internal waste, but increasing external scrap rates and decreasing quality. What are box makers expected to do? Is sacrificing quality worth the savings of reducing internal waste? What impact will this have on your business?

Possible SolutionThe secret to improving both internal and external waste is not only to identify the defective products and remove them from the production stream, but also to identify the root causes of the scrap production and address them. Investment in quality assurance systems for box inspection, operator training, as well as PM discipline and keeping equipment current can both identify scrap and reduce its root causes. If management is committed to solving problems on the floor that are causing waste, not only will less defective product be produced internally

(internal waste) but also less defective product will be shipped to customers (external waste). In addition, profits will improve and customer retention will increase, which directly improves the bottom line. Finding the problem quickly through quality assurance devices and not having them occur from the other improvement measures will decrease internal and external scrap rates and improve the ROI performance of the business.

End ResultIf investment in quality assurance systems, operator training, improvement in preventative maintenance programs and an upgrade program for production machinery can reduce the internal scrap rate, then the external scrap rate will be significantly reduced. Box makers will improve profits and keep happy customers who shouldn’t need to complain about the products they receive.Why pay the price of the traditional corrugated box manufacturing industry’s approach for quality, counting pennies and losing dollars.

7 Tips for Better Box ManufacturingAlthough the dispensing equipment you select is of the utmost importance to ensure a quality adhesive pattern is applied precisely and without error, box makers often overlook the importance of preventative maintenance. Let’s be honest, it’s usually an afterthought. We have seen time and time again, problems relating to adhesive dispensing equipment that could have been avoided if the box maker would have just followed a few simple steps, every so often, to make sure their glue machinery was running at 100% efficiency. To help you avoid this unwanted downtime and make sure your glue patterns are always at their best, here are seven preventative maintenance procedures for better box manufacturing.

1 – Overtime, particles and coagulated glue can build up on filter screens causing restricted adhesive flow and excessive stress on the adhesive. Cold glue filters should be checked once per week after installation or after a change in the type or brand of adhesive. Depending on the amount of build up, adjust the frequency to accommodate your dispensing equipment.Remember,

opening the filter housing allows air into the system, so make sure you have the proper purge valve setup before you begin.

2 – Make sure glue pressure follows machine speeds. For box makers, the glue regulator is the most important adhesive delivery component in determining how much glue volume is applied at a given machine speed. If you experience too much glue on the joint when the machine slows down, or there is not enough glue when the machine speeds up, it could be the regulator. To test fluid regulators without an electronic pressure control, use the T-handle on old style regulators and the Auto/Manual switch on the new style regulators to manually check the function. If pressure does not increase or decrease, a simple repair is in order. Valco Melton regulator repair kits for corrugated box manufacturers provide a quick and inexpensive solution.

3 – Applicator heads and nozzles must be kept clean. Buildup over long periods of time and a lack of cleaning after the machine is down can cause added downtime. Likewise, worn applicator heads can cause poor pattern quality (ticking at the end of the pattern, buildup on the leading edge or even missing glue lines). Applicator heads are wear items, subject to the abrasiveness of paper and are susceptible to some chemical corrosion after prolonged exposure. Quick-disconnect fittings are another critical component to achieving quality adhesive patterns. Loose applicator heads are prone to leaking. To avoid issues, inspect the fittings to verify that the applicator head is properly secured to the valve. Replace quick-disconnect fittings as required.

4 – Check to see if the Electronic Pressure Control (EPC) speed-tracking curve is accurately setup. Doing so will help you to achieve optimum pattern volume at all machine speeds. If the EPC is not working properly, you are relying 100% on operator skill to monitor adhesive output. This requires constant adjustments in order to maintain proper adhesive volume. Without a functioning EPC, the amount of wasted adhesive can quickly become a costly problem.

5 – A slipping encoder can cause intermittent pattern length variations, which can mean a troubleshooting nightmare for maintenance departments. Encoders should be regularly inspected for smooth rotation, good wheel or timing belt condition and secure mounting. Box makers should also pay close attention to common problem areas such as incorrect belt tension, damaged encoder cables or loose cable connections. By adding simple encoder maintenance to your schedule you can prevent extended downtime and hassle.

6 - Glue hose lines back to the regulator should be inspected for kinks and flushed periodically to check for clogged sections. An inexpensive section of tubing can become a costly problem for corrugated box manufacturers if it causes a flow restriction, as this results in poor glue volume at high machine speeds. Don’t overlook the pump suction line. A damaged suction line could cause air pockets to get into the glue line. This results in skips in the glue pattern or no glue pattern at all. Signs of leakage are not always obvious; plan now to avoid problems later.

7 – Ensure there are no false triggers from tab scrap. Corrugated box manufacturers operating with tab-side installations are often plagued by flying tabs from the slotter. False triggers from tab scrap can be the result of broken or dull knives. Replacing worn out knives along with routine maintenance is recommended to combat false triggers from tab scrap. Additionally, a dual scanner setup using two photo eyes, along with control settings can help block false triggers.

Example: tab scrap glue application problem

corrugated box waste

BoardRunner Non-Contact and Contact Extrusion

Features Valco Melton’s all electric model 900 glue valve.

The valve provides unparalleled high speed performance with over 250 million cycles before simple maintenance is needed.

The impact-resistant carbide plunger tip and engineered ceramic seat provide extreme durability.

The 900 valve’s powerful coil results in extremely accurate and repeatable glue patterns, in contrast to pneumatically activated extrusionsystems.

Easily switch from inside to outside gluing with no tools required.

The patented applicator heads allow for quick removal for changing number of beads and bead spacing.

BoardRunner Tri-Valve Non-Contact

Features three 524 series, all-electric glue valves (up to 4 valves per side).

The 524 series non-contact valves offer a ceramic tip/carbide plunger design for extended service life with less maintenance.

Can provide staggered pattern starts to match lead and trail tab angle, even in “auto-glue” system mode.

The non-contact method eliminates product skew that can be caused incertain contact gluing applications.

Features a tip-sealer design that prevents nozzle plugging during periods of down time.

Full valve and tip-sealer status can be viewed on Valco Melton’s OT-120 touchscreen control.

The Tri-Valve BoardRunner® with 900 valve attachment allows for inside/outside gluing from one side of the machine.

Flexibility to apply primarily top down, non-contact with the option to apply contact, bottom up when required

Flexoseal Glue System Options





Corrugated Box MakersSaving Quality vs. Preventing Waste


















Example: tab scrap glue application problem

corrugated box waste

[email protected] +62 21 75902726



Packaging Solution




















A quick disconnect fitting tip

10How The Internet Changed The World

Asia has the highest portion in the internet shopping (estimated will be 39.7% by 2016)Indonesia on line business growth almost 200% within 5 year (from 2011 – 2016). The rapid growth in Asia-Pacific sales is a result of several factors. Three Asia-Pacific markets—China, India and Indonesia—will see faster B2C ecommerce sales growth than all other markets worldwide this year, while Japan will continue to take a large share of global sales.

Internet Shopping Internet shopping as a trend continues to expand rapidly, and is fuelled by the increasing use of smartphones and tech-savvy customers. This represents an opportunity for brand owners to introduce two different packaging types, one geared to traditional store display, featuring high quality graphics, and one designed for internet sale. This is, in essence, nothing more than a brown shipping container. Amazon.com Inc.'s Annual Revenues for the full year 2013 of $74.5BUSD. This was 21.9% above the prior year's results.

It changing the way how product pack. In the usual shopping – either paper of plastic bag will be used – but with internet shopping it is the ERA of Corrugated Boxes.

Amazon instead of giving business to the corrugated plants, they indeed also want to boost their business in the corrugating business as well. Have a look on their website, you can buy either simple boxes, double wall or even a paper roll (try to compare you selling price to the customer with their retail prices). Meanwhile as one of the main player in the corrugated industry also doing the same retail corrugated boxes online (see their website you will see that they also selling standard corrugated boxes that can be ordered online)

NEW TRENDNow you can shop from the subway on your way just click which products you want to buy make an online payment and collect the goods on your way home or just ask for a delivery service.

Corrugated Shipping Boxes- 8x8x8 Bundle of 25 boxesby IndyBoxes 11 customer reviewsPrice $ 17.25 & FREE SHIPPINGIn StockShips from and sold by TheBoxery- Factory Fresh (we never sell used)- Strong Industry Standard 32 ECT shipping boxes- Stored in a smoke-free warehouse

5 new from $3.01

6x6x6 Corrugated Shipping Box Bundle/25by Corrugated 21 customer reviewsPrice $ 13.29 & FREE SHIPPING on orders over $35In StockSold by JNE Packaging LLC and Ful�lled by Amazon. Gift wrap available.Want it Monday Sept. 15? Order within 13 hrs 49 mins and choose One-Day Shipping at checkout.- 6x6x6 Corrugated Shipping Box Bundle/25

600 mm x 10 m Corrugated Cardboard Paper Roll-10 Metresby Clobe Packaging 12 customer viewerPrice: 4.99In StockDispatched from and sold by Clobe packaging4 new from 1.95- 600 mm W de Single Face Corrugated Paper Roll 10 Metres In Length

SK4 Cardboard Boxes1.27 1.03 0.84

A4 Printer Boxes SK5 SK1 Cardboard Box

How The Internet Changed The World




“The internet’s biggest impact on SMEs has been as a great leveller, making it possible for a small firm to be a global company from day one, with the reach and capabilities that once only large companies could possess,” says Charles Roxburgh, a director at the management consultancy McKinsey, which has been researching the impact of the web on the global economy.



2016

Asia-Pacific

North America

3.7%22.6%28.2%39.7%

2.3%

3.5%

Western Europe

Eastern Europe

Latin America

Middle East & Africa

11How The Internet Changed The World






Corrugated Shipping Boxes- 8x8x8 Bundle of 25 boxesby IndyBoxes 11 customer reviewsPrice $ 17.25 & FREE SHIPPINGIn StockShips from and sold by TheBoxery- Factory Fresh (we never sell used)- Strong Industry Standard 32 ECT shipping boxes- Stored in a smoke-free warehouse

5 new from $3.01

6x6x6 Corrugated Shipping Box Bundle/25by Corrugated 21 customer reviewsPrice $ 13.29 & FREE SHIPPING on orders over $35In StockSold by JNE Packaging LLC and Ful�lled by Amazon. Gift wrap available.Want it Monday Sept. 15? Order within 13 hrs 49 mins and choose One-Day Shipping at checkout.- 6x6x6 Corrugated Shipping Box Bundle/25

600 mm x 10 m Corrugated Cardboard Paper Roll-10 Metresby Clobe Packaging 12 customer viewerPrice: 4.99In StockDispatched from and sold by Clobe packaging4 new from 1.95- 600 mm W de Single Face Corrugated Paper Roll 10 Metres In Length

SK4 Cardboard Boxes1.27 1.03 0.84

A4 Printer Boxes SK5 SK1 Cardboard Box

How The Internet Changed The World




“The internet’s biggest impact on SMEs has been as a great leveller, making it possible for a small firm to be a global company from day one, with the reach and capabilities that once only large companies could possess,” says Charles Roxburgh, a director at the management consultancy McKinsey, which has been researching the impact of the web on the global economy.



2016

Asia-Pacific

North America

3.7%22.6%28.2%39.7%

2.3%

3.5%

Western Europe

Eastern Europe

Latin America

Middle East & Africa

12

BOARD PRODUCTION

The success of any package is linked clsoely to its appearance. A global market leads to stronger competition with similar products offered to potential buyers. The appearance of the packaging is the only possibility to make a product stand out from others. Plastics, metal, glass, wood, cartonboard and corrugated are suitable materials and lamination, printing and labelling can give additional value to packaging.

Corrugated offers several unique advantages compared to other materials-it’s high in strength while low in weight. High volumetric efficiency is achieved through good stacking strength. It is flexible in box design, low cost (even in small volumes) and environmentally friendly. Corrugated offers excellent protection for the product whether used as simple shipping containers or as consumer presentation packages. Unfortunately, corrugated does not always exhibit a flat top surface-resulting in printing issues such as dot gain variations, density variations, trapping variations and varnish variations.

During the corrugating process, starch is applied to the peaks of the flutes and bonds them to the liner. As the starch dries it shrinks, stretching the liner into the valley between the flutes. The more starch applied, the more water has to evaporate, the more the liner will be stretched, the more starch applied, the more water has to evaporate, the more the liner will be stretched, the more washboarding will appear. There is a relationship between the amount of starch used and washboarding.

The moisture content of the air, the paper and the strach influences the quality of the finished product. High atmospheric humidity, high moisture content in the paper fibre and high moisture content in the strarch will swell the board and reduce the amount of starch applied. There is a linear relationship between water content and washboard effect-the higher the water content, the lower the washboarding effect is. However, there is a limit in applying water to the process. The water needs to evaporate during drying, thus slowing down the process and occasionally damaging the board surface. Side effects like cockling or honeycomb may appear when the water content is too high. Because every corrugator differs in size, age, components, format, and many other parameters, it is essential to find the optimal settings to control the process and to keep the process

constant. Process variations and the washboard effect can lead to high costs because of waste, idle machine time, discussions with customers, additional bad quality rebates and loss of image.

A simple number, quantifying the washboard effect in a repeatable, easy to understand marner is needed. As in other applicating such as colour or density control, this number can be used in customer contracts. Agreements about the quality can be easily defined.

To meet this requirement PERET has developed the CORRCHECK-Corrugated Checker. It’s a carrera based, hand-held tool that measures the surface of corrugated in a non-contact manner. In a few seconds, the microscopic undulating surface is analysed over approximately 40mm taking more than 6,000 depth measurements. The resulting

Cockling and Honeycomb effect due to excessive moisture

CORRCHECK-the ideal measurement tool for corrugated board High end application: WBE>0.007 is visible

washboard effect number-WBE-is displayed with a resolution of 1 µm.

The CORRCHECK enables you to measure your board directly as it comes off of the corrugator. There is no need to prepare samples for measurement. Simply place the device onto the surface and start to measure. If the resulting WBE is higher than allowed corrective actions can be taken immediately. Preliminary testing in real world applications are showing an excellent correlation with the visual appearance of the board. Depending on the application and the corrugated composition, different tager WBE numbers are typically used. An objective measurement tool for the washboard effect will allow you to define your quality parameters upfront, as it done for most other production parameters.

The CORRCHECK offers new parameters for the corrugated industry. It is now possible to offer consisntent, high quality products to packaging buyers. As in any other production environment, there is but one simple truth-quality means measure, measure and measure.

Packaging Solution



Packaging Solution

SMS C300 is a modified tapioca starch product, applied in a corrugated board adhesive formulations.

SMS C300 is suitable for use on single facer and double backer for all types of corrugated board and

glue kitchen

Easily Dissolvedcharacter as peak viscosity during dissolution is low

Stable Viscositygives a more consistent operateon the machine and a better board quality

Good Water Retentionwhich leads to better bonding strength

Less ConsumptionLess Consumption of glue due to better distribution allowing good bond strength with less glue

CORRCHECK – NEW MEASUREMENT TECHNOLOGY FOR CORRUGATED BY DIPL.ING. LUKAS PESCOLLER OF PERET GMBH

BOARD PRODUCTION

CONTROL THEWASHBOARD EFFECT








Washboard effect and fluting defects on packaging could be seen as a message

about the quality of the product itself.

Relationship between amount of starch and washboard effect




BOARD PRODUCTION








Cockling and Honeycomb effect due to excessive moisture

CORRCHECK-the ideal measurement tool for corrugated board High end application: WBE>0.007 is visible




Packaging Solution



Packaging Solution

SMS C300 is a modified tapioca starch product, applied in a corrugated board adhesive formulations.

SMS C300 is suitable for use on single facer and double backer for all types of corrugated board and

glue kitchen

Easily Dissolvedcharacter as peak viscosity during dissolution is low

Stable Viscositygives a more consistent operateon the machine and a better board quality

Good Water Retentionwhich leads to better bonding strength

Less ConsumptionLess Consumption of glue due to better distribution allowing good bond strength with less glue

CORRCHECK – NEW MEASUREMENT TECHNOLOGY FOR CORRUGATED BY DIPL.ING. LUKAS PESCOLLER OF PERET GMBH

BOARD PRODUCTION

CONTROL THEWASHBOARD EFFECT








Washboard effect and fluting defects on packaging could be seen as a message

about the quality of the product itself.

Relationship between amount of starch and washboard effect




14

The dynamics of the retail arena are having significant consequences for packaging. Strong cost pressure leads to innovative packaging solutions to reduce a product’s total lifecycle cost. Retailers are forced to think in new ways about the role of packaging and how it can be used to achieve new things, increasing its performance and blurring the lines between packaging, store furnishing, and marketing communication. And the environmental effect of packaging material is increasingly being considered, with fiber-based materials standing out because of their recyclability and renewability.

As the significance and role of packaging grow, retailers will have to give it more attention. The ones that can best understand and execute on the full potential of packaging solutions will be best placed to win in the marketplace of today and tomorrow

The purpose of retail packaging is expanding. From the original purposes of containment and

protection, retailers and brand owners began to see the significant potential for packaging as a platform for communicating with consumers. Today, it is used to get attention, communicate brand and product characteristics, highlight promotions and more. It is estimated that as much as 70 percent of all purchase decisions at mass merchandisers are made at the point of sale. As the fight for limited shelf space intensifies,using packaging to its full potential will become even more important.

In general, one of the most important aspects for a buyer of packaging is its expected effect on sales. After all, if packaging can lift sales by just one percent, it has a much larger impact on the bottom line than any cost optimization can deliver. Second, a retailer tends to consider indirect costs of packaging handling. For example, shelf-ready packaging can reduce replenishment costs with 1 to 2 percentage points of sales—a significant number considering most retailers earn low

single-digit margins. Online is a trend in both grocery and non-grocery retail. For grocery, most European countries still have an online share of at most a few percent. However, in the United Kingdom, the European leader in online grocery retail, it is estimated that 20 percent of total grocery sales will take place online in 10 years’ time. Amazon, the world’s largest online retailer, has recently taken its first steps into grocery retail with Amazon Fresh, offering free same-day delivery in selected regions in the United States.

Stora Enso helped a leading Finnish retailer reduce waste and increase efficiency along the entire fruit and vegetable supply chain through the development and deployment of HeviStrong packaging solutions.

Retailers within grocery have five key themes to consider in retail packaging in 2016 and beyond• The success of discount retailers• Increased private-label penetration• Intelligence in packaging solutions• The shift of retail to online channels• A greater focus on sustainability

Discount grocery retail is a major success across most of Europe. As a result of their continuous focus on cost, discounters are some of the leading adopters of innovative packaging. Examples include shelf-ready packaging, pallet presentation, bundled packaging, and use of lighter materials. In the future, a key challenge for discounters will be to make these cost-efficient solutions more attractive in the eyes of consumers.

Private-label penetration is increasing across Europe, but currently has large variations between countries. Originally used as a lever in negotiations, private label is now adding functions to the assortment and supporting the retail brand. Overall, the difference between private-label and brand packaging is getting smaller. Retailers are also more involved in developing and sourcing packaging. In response to these developments, brand owners are accelerating their differentiation efforts, for example with complex, eye-catching corrugated board constructions at the point of sale.

The packaging converters must delivers value in several ways:• Proactively suggesting innovative packaging solutions to build brand value, support sales, and optimize performance to reduce total cost

• Supporting customers to achieve their profitability and sustainability targets by enabling less weight, less waste, less unused space, and less impact on the environment

• Helping customers make their supply chains more sustainable by using renewable raw materials and Stora Enso’s recycling organizations to take care of their recycling needs.

Stora Enso Packaging Solution















Retail Packaging2016 and Beyond

15





























Retail Packaging2016 and Beyond

16

Firstly, an important distinction: although they are often referenced in the same breath retailready and shelf-ready packaging - RRP and SRP respectively - undertake totally separate functions, explained Asda packaging services corrugated director, Brian Gibbs. And as the one-time co-chairman of the Efficient Consumer Response (ECR) working committee that developed the retail-ready concept and established the functional guidelines for its implementation some two decades ago, Mr Gibbs knows better than most that these differences are far from being merely a matter of semantics.

'Shelf-ready is a transit packaging solution for collation and distribution that might end up by chance on shelf. Retail-ready packaging adheres to the 'five easies' and can only be achieved through considered design. It starts with the customer and works back through the supply chain, whereas SRP originates at the end of the production line.' The 'five easies' (for anyone unfamiliar with the collective) summarise the key criteria that a retail-ready pack is required to fulfil, ie to be easy to identify back of store, easy to be placed on shelf, easy to open (by the store staff), easy to shop (customer), and easy to dispose of post use. It is a classic win-win formula that benefits the entire supply chain, not least the retailer by accelerating the progress of items from goods inward to on shelf: a 50 metre one-way trip that can seriously impact upon margin should it incur unnecessary time and personnel costs.

And it is a format that the corrugated sector is particularly adept in delivering, claimed the Confederation of Paper Industries (CPI) director of packaging affairs, Andy Barnetson. 'A well-crafted RRP

RRP solution for Waitrose own-label prawn skewersDS Smith provided this flexo printed RRP

solution for Jimmy's Iced CoffeeA poor example of retail ready

packaging

solution not only reduces retailer cost and time in shelf management, but also acts as an eye-catching, practical brand ambassador. 'The continuous improvement in retail-ready packaging is testament to the extent to which the corrugated industry is listening and is taking an innovative approach towards identifying ways in which we can be the most effective, whether that is via product design or production efficiencies. The thinking is what makes the process better.' Ready reckoningNo format is so successful that it can't be improved upon, not least through the development of new flute specifications that are better engineered to minimise shadow effect when printed and allow for the inclusion of more userriendly perforations.

Whilst DS Smith's R flute, for example, has a similar amount of fibre as a standard B flute, it also has a lower calliper that makes it thinner but still provides the requisite amount of strength and stability.

Additionally forming a more receptive base for solid colour is the knock-on effect of being able to produce a flatter board through using more flutes per square metre of surface area. A case in point is the high quality flexo-printed retail ready pack produced by DS Smith South-West in R flute for start-up brand Jimmy's Iced Coffee, now equally at home on the shelves of high-end retail outlets, such as Fortnum & Mason and Harvey Nichols, as it is in the chill section of Waitrose or as an on-the-go pick me up from a BP service station.

'We've been really pleased with the results as the pack has gone down very well with our buyers, and it is certainly enhanced our appreciation of the importance of secondary packaging and its role in the product development process,' said brand owner, Jim Cregan. 'We wanted to make the product clearly identifiable so it was very important for the product to be presented on the supermarket shelf in the best possible way.'Belying anecdotally reported reservations to the contrary, 'Waitrose doesn't particularly like having trays in the chill cabinet but prefer products to be stacked individually as it looks tidier,' noted Mr Cregan when the new pack was first introduced last year. The UK's sixth largest grocery retailer is now actively exploring

opportunities for its application, said packaging development manager, Jonathan Couper. 'The in-store experience for the customer and their interaction with the packaging, and so the brand, is key, and we have not wanted to put any potential barriers in the way of this.

'In principle, however, Waitrose are not against the use of RRP, in fact in certain areas we are keen to exploit them more as there are clearly big benefits for both our customers and the business when they are used in the correct context.'The retailer is currently finalising its own RRP guide to provide better support for its suppliers: 'with robust principles that will mean that we deliver a genuine benefit for all the stakeholders,' added Mr Couper.

Hopefully, these will ensure there is no obvious disconnect between the RRP solution and the primary packaging it helps to display - often reflective of when the development of the corrugated tray has been something of an afterthought, noted corrugated sector specialist consultancy Packology's managing director, Robert Herridge.

'Not on my watch and not as far as Asda own brand is concerned,' said Mr Gibbs. 'Part of the brief from Asda brand implementation to primary pack designers is not to put essential information below the 30 mm lip that is incorporated on all of our RRP packs.'

Further developments in store 'Other improvements may be more a matter of thinking inside of the box, quite literally so,' said Mr Herridge. 'However comprehensively it fulfils the 'five easies', there willl often be an interval of time during which a retail-ready tray stands empty on the shelf. Indeed, with so many RRP applications now in

use, the overall effect of a fixture stacked with boxes at varying stages of requiring replenishment can be quite off-putting to consumers.

'I wonder if there isn't some kind of opportunity for the application of a smart technology so that when the box has served its purpose, a message is automatically sent to the back of the store, rather than being left unattended until the shelf stacker next monitors that particular aisle?'

The Faraday Centre's commercial manager, Andrew Revel, also focuses on the need to keep things neat and tidy within the fixture. 'A real opportunity lies is producing something that is a high-quality item that not only combines the cost-saving, efficiency and sustainability benefits of existing formats but also has consumer appeal in terms of both how it works and how it presents the products. 'Take that to its logical conclusion and rather than looking at something that is in a box or else that is presenting one line, why couldn't you look at fixture-based retail-ready packaging for certain brands or categories where you could replenish an entire section or indeed the entire fixture rather than individual products. You could achieve standardisation across your retail formats that would create conformity and acceptance with the consumer.

'Whilst the breadth of choice between competing brands would seem to militate against such an eventuality within the average supermarket, it could be a potential solution for the expanding number of smaller convenience outlets (C stores) stocking 1,000 rather than 40,000 SKUs, and where a smaller footprint has a direct correlation to pack size. 'Although the same concepts

of RRP apply, there will be some slight differences: not just fewer brands or SKUs due to restricted shelf space, but less storage facility at the back of the store meaning that RRP boxes will tend to go straight from lorry to shelf,' noted Mr Barnetson. A fully stocked fixture that could be wheeled in and out could be the solution. Adding value to the RRP propositionWhilst the adoption of the more futuristic smart technologies currently under development, such as inductive inks, printed electronics, augmented reality and near field communications, is more likely to be driven by brand owners and retailers via primary packs, the indications are that corrugated RRP could be the next application to be targeted by digital print.

With the much heralded Landa nanographic presses now primarily focusing on folding cartons, there is a real opportunity for Sun Automation's CorrStream digital inkjet system to take a lead in the short-run corrugated market, said global product manager (digital), Sean Moloney. 'Whilst all of the digital activity in this sector has up until now been concentrated on producing point of sale and display material, the CorrStream is the first system to compete head on with flexo in printing corrugated trays for on-shelf usage.'On a cost basis, we can meet analogue systems in terms of speed, width and substrate; handling print runs of up to around 10,000 off with our wider 66 series machine (1345 mm). Even though our ink costs are currently more expensive, we gain in terms of not needing plates, reduced set up nd downtime.

'Whilst there is scope for improving the basics of RRP in terms of cost efficiency: flute specifications, design, pallet heights and doubleloading on wagons, etc, when it comes to what more can be done to encourage customers to buy from the package itself then that is where digital is coming into its own. Corrugated is following in the slipstream of what has been happening in say labels and flexibles. What you are able to do with digital print allows many more options to the brand owner and the retailer, we are looking forward to enabling box makers to take full advantage of that. RRP is nowhere near yet where it can be in the future once people introduce digital into their box plants.'In addition to the 66 series, CorrStream will

be available in two other widths: 783 mm and 557 mm (running at 75 m/min), which prospective adopters will be able to inspect at first hand when Sun Automation opens its dedicated worldwide demo centre in Bristol this April. In the meantime, Sun Automation is taking letters of intent now, and the first systems are on coursed for commercialisation by the end of the year.

'We're going to show customers how to use this equipment from the point they receive the artwork through to the printed sheet. There is much more to digital than simply turning on a machine and putting a piece of cardboard through,' said Mr Moloney.With the average batch quantity printed at an integrated sheet plant below 6,000 off, the CorrStream is being positioned as a single-digit percentage point cost-competitive alternative to conventional print. It does, however, have a further key capability to bring into contention, albeit not yet, he said.

'Although the opportunity for applying variable data and delivering a customised solution is obviously going to be a big driver in the future, right now all the big corrugated manufacturers are far more focused upon reducing cost and improving margin. All they can see in the current market - and there is no sign of it going away - is systems running up to seven or more colours on the back of increased set-up costs because batch quantities are reducing. Supermarkets want more colour and vibrancy in store. 'We've worked hard to be cost competitive at the start; we can overlay that with all the advantages of variable data, etc, in due course. Those attributes that are specific to digital will come into play when the customer is ready,' concluded Mr Moloney.

Retail-Ready PackagingRetail-ready packaging has been the making of corrugated, elevating its status from dull but worthy basic brown box to one with standout shelf appeal. So what's next for the format, asks Des King.























17




RRP solution for Waitrose own-label prawn skewersDS Smith provided this flexo printed RRP

solution for Jimmy's Iced CoffeeA poor example of retail ready

packaging




















Retail-Ready PackagingRetail-ready packaging has been the making of corrugated, elevating its status from dull but worthy basic brown box to one with standout shelf appeal. So what's next for the format, asks Des King.























18

Kiwiplan has been providing software solutions for the corrugated industry for more than 30 yeras. The seamlessly integrated ‘Order to Invoice’ solution was designed specially for the industry by corrugated industry users. It has been generally accepted that the Kiwiplan products collect a huge amount of invaluable historical data across the more than 20 modules in the suite of products. This data can be a powerful tool to enable the user to find inefficiencies in production, track genealogy of paper for chain of custody intiatives and to give true pre and post production costing, to name just a few of opportunities.

The challenge was to provide a platform to enable this investigation, trust the integrity of the data , provide it in a format that was expandable to unlimited plants across an enterprise and also deliver it in a format that is easy to understand yet informative for CEO’s through to shop floor supervisors. Some challenge maybe, but Kiwiplan has never been one to resist such a challenge. More than five years ago, the Data Analysis and Reporting Tool (DART) product was released to the market. The initial scope was limited to part of the MES solution, but in more recent times this has been expanded across the MES spectrum and now also includes sales and order processing, quotation, estimating, costing and more. As well as being an invaluable source of reporting and analytical information, DART has several other key value adding strengths:

• Long term data archive-data storage is becoming a key requirement for the purpose of audits or general reporting. The DART warehouse can be utilised as an offline archive that can be easily accessed when audits are required or reports for longer periods needed. This means there will be no impact to the performance of the production environment as the data is automatically replicated offline and overnight.

• True data integrity checks-many reporting and data cubing solutions will present reports and views, which are pleasing to the eye, but can you trust what you are seeing? Most just report the data, but do not check the validity or accuracy of the information that is being represented. Kiwiplan has built in functionally that will check the data and if there are concerns about the accuracy of any part, this will be reported and can be viewed directly from within the DART product.

Therefore, it can act as a potential training/data cleaning tool.

• Third party data-often a customer runs part of the Kiwiplan solution and part of another third party system. To get the report/view you want out of the data cube, you have to create it from your own database. With DART, this is no longer a requirement. Data can be supplemented from a third party system which allows much greater flexibility to report what you want to report, as opposed to being restricted to what is in your database.

DART has become a core product in the Kiwiplan suite of products and this has been promoted partly due to the increasing importance of initiatives like:

• Pre and Post costing- knowing the true cost of production compare to the estimated cost has always been relevant and important, but with the cost of raw material and labour increasing resulting in margins being squeezed, it has never been more important to be able to analyse the costs. With DART this can easily be interrogated so changes to the manufacturing processes can be reviewed or lessons for future potential sales opportunities.

• FSC/PEFC initiatives- chain of custody initiatives has become part of the norm for corrugated plants today. Your customers expect a plant to have either FSC or PEFC certification. Often this is expected with no premium payment for the product supplied to the customer. As a result, it is a requirement that is often considered as a pure cost. The implementation in itself is often considered as a pure cost. The implementation in itself is often manageable, but the issues arise when being audited to prove traceability of the source materials and products. With DART being seamlessly integrated into the other Kiwiplan modules, views can be created which will instantly display the genealogy of an order back through production and all the way to the source rolls. This saves time and a huge amount of paperwork.

• True enterprise reporting-many times, reporting is restricted to a plant-by-plant basis, but with DART, trends across the enterprise can be reviewed. Company KPI’s and OEE can be established, reported and then analysed to see where potential

improvements are possible.• Rollstock usage/loss-a key cost in any corrugated

plant is paper and in all plants, paper is ‘lost’ between the rollstone and the take off of the corrugator. Some call this ghost waste, but there are many terms for this.

With DART you are able to analyse:• What was received;• What was planned to run on the corrugator;• What was loaded on the rollstands;• How much was planned;• How much was run;• How much was produced through the dry-end;• How much was wrap waste occured;

Armed with this information it is easy to see where waste is occuring and a focus on improving the problem area can be made and progress then easily tracked.

Satisfied UsersBrian Sorensen of Peterson Packaging has been an avid user of Kiwiplan DART for several years. Mr. Sorensen states, “We were impressed with the ease and flexibility with which views could be created that gave us the information that was of value to Peterson. Not just what Kiwiplan thought would be of value. It was also important from a cost perspective that we were able to create the views ourselves as opposed to having to pay a specialist to bring each idea to realisation.”

Richie Goldberg of President Container rapidly realised that DART was not a reporting tool. Its real value is when you bring it into the everyday facric of your company. Mr Goldberg states, “We needed an casy to understand, fast analytical tool to enable us to see what was happening in our plant, make decisions on the correct path forward and then be able to track progress on a daily, weekly, monthly and annual basis. In no time at all, DART has become a critical tool in the development and success of our organisation from the shop floor to the management.” In the short time that DART has been offered by Kiwiplan, its true value has been realised by existing and new Kiwiplan users alike. DART is flexible, fast and only limited by the imagination of the individual.

DARTData Analysis & Reporting Tool

by steve whillis, kiwiplan europe

REPORTINGACCURATE

www.kiwiplan.com Of�ces Worldwide

SIMPLY A BETTER SOLUTION

You have the bestmachines and the bestpeople ...

... now is the time toinvest in the best software.

The premier software solution provider to the corrugated industry

Kiwiplan has been providing software solutions for the corrugated industry for more than 30 yeras. The seamlessly integrated ‘Order to Invoice’ solution was designed specially for the industry by corrugated industry users. It has been generally accepted that the Kiwiplan products collect a huge amount of invaluable historical data across the more than 20 modules in the suite of products. This data can be a powerful tool to enable the user to find inefficiencies in production, track genealogy of paper for chain of custody intiatives and to give true pre and post production costing, to name just a few of opportunities.

The challenge was to provide a platform to enable this investigation, trust the integrity of the data , provide it in a format that was expandable to unlimited plants across an enterprise and also deliver it in a format that is easy to understand yet informative for CEO’s through to shop floor supervisors. Some challenge maybe, but Kiwiplan has never been one to resist such a challenge. More than five years ago, the Data Analysis and Reporting Tool (DART) product was released to the market. The initial scope was limited to part of the MES solution, but in more recent times this has been expanded across the MES spectrum and now also includes sales and order processing, quotation, estimating, costing and more. As well as being an invaluable source of reporting and analytical information, DART has several other key value adding strengths:

• Long term data archive-data storage is becoming a key requirement for the purpose of audits or general reporting. The DART warehouse can be utilised as an offline archive that can be easily accessed when audits are required or reports for longer periods needed. This means there will be no impact to the performance of the production environment as the data is automatically replicated offline and overnight.

• True data integrity checks-many reporting and data cubing solutions will present reports and views, which are pleasing to the eye, but can you trust what you are seeing? Most just report the data, but do not check the validity or accuracy of the information that is being represented. Kiwiplan has built in functionally that will check the data and if there are concerns about the accuracy of any part, this will be reported and can be viewed directly from within the DART product.

Therefore, it can act as a potential training/data cleaning tool.

• Third party data-often a customer runs part of the Kiwiplan solution and part of another third party system. To get the report/view you want out of the data cube, you have to create it from your own database. With DART, this is no longer a requirement. Data can be supplemented from a third party system which allows much greater flexibility to report what you want to report, as opposed to being restricted to what is in your database.

DART has become a core product in the Kiwiplan suite of products and this has been promoted partly due to the increasing importance of initiatives like:

• Pre and Post costing- knowing the true cost of production compare to the estimated cost has always been relevant and important, but with the cost of raw material and labour increasing resulting in margins being squeezed, it has never been more important to be able to analyse the costs. With DART this can easily be interrogated so changes to the manufacturing processes can be reviewed or lessons for future potential sales opportunities.

• FSC/PEFC initiatives- chain of custody initiatives has become part of the norm for corrugated plants today. Your customers expect a plant to have either FSC or PEFC certification. Often this is expected with no premium payment for the product supplied to the customer. As a result, it is a requirement that is often considered as a pure cost. The implementation in itself is often considered as a pure cost. The implementation in itself is often manageable, but the issues arise when being audited to prove traceability of the source materials and products. With DART being seamlessly integrated into the other Kiwiplan modules, views can be created which will instantly display the genealogy of an order back through production and all the way to the source rolls. This saves time and a huge amount of paperwork.

• True enterprise reporting-many times, reporting is restricted to a plant-by-plant basis, but with DART, trends across the enterprise can be reviewed. Company KPI’s and OEE can be established, reported and then analysed to see where potential

improvements are possible.• Rollstock usage/loss-a key cost in any corrugated

plant is paper and in all plants, paper is ‘lost’ between the rollstone and the take off of the corrugator. Some call this ghost waste, but there are many terms for this.

With DART you are able to analyse:• What was received;• What was planned to run on the corrugator;• What was loaded on the rollstands;• How much was planned;• How much was run;• How much was produced through the dry-end;• How much was wrap waste occured;

Armed with this information it is easy to see where waste is occuring and a focus on improving the problem area can be made and progress then easily tracked.

Satisfied UsersBrian Sorensen of Peterson Packaging has been an avid user of Kiwiplan DART for several years. Mr. Sorensen states, “We were impressed with the ease and flexibility with which views could be created that gave us the information that was of value to Peterson. Not just what Kiwiplan thought would be of value. It was also important from a cost perspective that we were able to create the views ourselves as opposed to having to pay a specialist to bring each idea to realisation.”

Richie Goldberg of President Container rapidly realised that DART was not a reporting tool. Its real value is when you bring it into the everyday facric of your company. Mr Goldberg states, “We needed an casy to understand, fast analytical tool to enable us to see what was happening in our plant, make decisions on the correct path forward and then be able to track progress on a daily, weekly, monthly and annual basis. In no time at all, DART has become a critical tool in the development and success of our organisation from the shop floor to the management.” In the short time that DART has been offered by Kiwiplan, its true value has been realised by existing and new Kiwiplan users alike. DART is flexible, fast and only limited by the imagination of the individual.

In the short time that DART has been offered by Kiwiplan, its true value has been realised by existing and new Kiwiplan users alike, DART is

flexible, fast and only limited by the imagination of the individual.

Kiwiplan ArticleIndonesia contact [email protected] +62 21 75902726

A total of 139 foreign exhibitors from 15 countries – China, Taiwan, South Korea, Thailand, Malaysia, the Philippines, Vietnam, Indonesia, Germany, Italy, Holland, Sweden, Switzerland, Canada and the U.S.A - were present at TOKYO PACK 2014, and reported numerous new leads gained from exhibiting at the show.

A total of 3,422 overseas visitors from 45 countries also registered for the exhibition, jumping almost 40% from the 2,031 who attended the 2012 show. The official Packaging Insight Japan Tour - a one-day orientation program held on 6 October and designed by TOKYO PACK exhibition owner-operator the Japanese packaging industry association Japan Packaging Institute (JPI) and EP Resources Pte Ltd, Singapore, to help foreign visitors gain the maximum benefit from their visit to TOKYO PACK - was also fully booked, and included the participation of a 42-strong delegation from Thailand.

JAPAN – On display for the first time at Tokyo Pack 2014, Rengo Co Ltd has developed an award winning transport and display tray for strawberries in conjunction with Ja Zen-Noh Tochigi. Designed as a substitute for the standard plastic containers commonly used in Japan to transport the fragile fruit, the new corrugated tray from Rengo holds 10 strawberry punnets suspended and cushioned by corrugated ribs, to prevent spoilage in transit.

Tokyo Pack 2014Connecting the Japanese Packaging Industry with the World

When stacked, each tray has a rigid corrugated flange that ‘locks’ into the side-folds of tray above, leaving ample head-space between layers. This mechanism both supports the upper trays and also provides strength to the column of trays, preventing them from slipping and possibly collapsing into the lower trays, crushing the product.Since strawberry farmers rarely have box-erecting equipment, the trays have been designed to be easy and quick to assemble from flat-pack at the farm.

Simple, but attractive two-colour red and green direct print onto the outer top linerboard, while a brown pattern for the interior tray supports resembles traditional wood containers and gives the illusion of a more expensive three or four colour flexo print job. This allows the tray to do double duty as both transport container and point of purchase display.

When the strawberry punnets have been sold, the cartons are easily dis-assembled into flat packs and are 100% recyclable.The company was awarded the Japan Packaging Institute’s prestigious President’s Award in the Japan Star 2014 contest and displayed with the winning packs at Tokyo Pack 2014.

The 25th edition of the biennial TOKYO PACK, Asia’s largest packaging show (7th – 10th October, Tokyo Big Sight), saw visitor numbers hit 1 7 8 , 6 9 8 , significantly higher than the 175,870 that visited in the last show edition in 2012. Exhibitor numbers also grew by more than 7% from the last show edition to 654 companies, of which 99 were first-time exhibitors at TOKYO PACK.



ETERNA LEAD EDGE FEEDER

Allows consistent and precise feeding of wide range corrugated board with various board quality.

Unique polyurethane wheel surface with grid lifter and air cushion ensures smooth feeding of warp boards with consistency and register accuracy.

Front gauge position back and forth adjustable to accommodate variation in gripper margin

Fine vacuum suction adjustment through invertor adapts to wide range of stock

DIECUTTING SECTION

Safety door and diechase safety locking system to ensure safe operation.

Complete lost sheet control throughout the entire machine.

Centerline system compatible to Centerline II for quick change over and short set up time.

Air cushion underneath the cutting plate for easy cutting plate STRIPPNG SECTION

Heavy duty double action stripping system to ensure positive stripping

Centerline system compatible to Centerline II for quick stripping die set up.

Motorized upper frame suspending hoister.

Quick lock stripping pins used for quick set up of simple stripping work.

DELIVERY SECTION

Front, back and side joggers to ensure neat stacking

Non-stop delivery ensures continuous productivity

Batch counter output

21

A total of 139 foreign exhibitors from 15 countries – China, Taiwan, South Korea, Thailand, Malaysia, the Philippines, Vietnam, Indonesia, Germany, Italy, Holland, Sweden, Switzerland, Canada and the U.S.A - were present at TOKYO PACK 2014, and reported numerous new leads gained from exhibiting at the show.

A total of 3,422 overseas visitors from 45 countries also registered for the exhibition, jumping almost 40% from the 2,031 who attended the 2012 show. The official Packaging Insight Japan Tour - a one-day orientation program held on 6 October and designed by TOKYO PACK exhibition owner-operator the Japanese packaging industry association Japan Packaging Institute (JPI) and EP Resources Pte Ltd, Singapore, to help foreign visitors gain the maximum benefit from their visit to TOKYO PACK - was also fully booked, and included the participation of a 42-strong delegation from Thailand.

JAPAN – On display for the first time at Tokyo Pack 2014, Rengo Co Ltd has developed an award winning transport and display tray for strawberries in conjunction with Ja Zen-Noh Tochigi. Designed as a substitute for the standard plastic containers commonly used in Japan to transport the fragile fruit, the new corrugated tray from Rengo holds 10 strawberry punnets suspended and cushioned by corrugated ribs, to prevent spoilage in transit.

Tokyo Pack 2014Connecting the Japanese Packaging Industry with the World

When stacked, each tray has a rigid corrugated flange that ‘locks’ into the side-folds of tray above, leaving ample head-space between layers. This mechanism both supports the upper trays and also provides strength to the column of trays, preventing them from slipping and possibly collapsing into the lower trays, crushing the product.Since strawberry farmers rarely have box-erecting equipment, the trays have been designed to be easy and quick to assemble from flat-pack at the farm.

Simple, but attractive two-colour red and green direct print onto the outer top linerboard, while a brown pattern for the interior tray supports resembles traditional wood containers and gives the illusion of a more expensive three or four colour flexo print job. This allows the tray to do double duty as both transport container and point of purchase display.

When the strawberry punnets have been sold, the cartons are easily dis-assembled into flat packs and are 100% recyclable.The company was awarded the Japan Packaging Institute’s prestigious President’s Award in the Japan Star 2014 contest and displayed with the winning packs at Tokyo Pack 2014.

The 25th edition of the biennial TOKYO PACK, Asia’s largest packaging show (7th – 10th October, Tokyo Big Sight), saw visitor numbers hit 1 7 8 , 6 9 8 , significantly higher than the 175,870 that visited in the last show edition in 2012. Exhibitor numbers also grew by more than 7% from the last show edition to 654 companies, of which 99 were first-time exhibitors at TOKYO PACK.



ETERNA LEAD EDGE FEEDER

Allows consistent and precise feeding of wide range corrugated board with various board quality.

Unique polyurethane wheel surface with grid lifter and air cushion ensures smooth feeding of warp boards with consistency and register accuracy.

Front gauge position back and forth adjustable to accommodate variation in gripper margin

Fine vacuum suction adjustment through invertor adapts to wide range of stock

DIECUTTING SECTION

Safety door and diechase safety locking system to ensure safe operation.

Complete lost sheet control throughout the entire machine.

Centerline system compatible to Centerline II for quick change over and short set up time.

Air cushion underneath the cutting plate for easy cutting plate STRIPPNG SECTION

Heavy duty double action stripping system to ensure positive stripping

Centerline system compatible to Centerline II for quick stripping die set up.

Motorized upper frame suspending hoister.

Quick lock stripping pins used for quick set up of simple stripping work.

DELIVERY SECTION

Front, back and side joggers to ensure neat stacking

Non-stop delivery ensures continuous productivity

Batch counter output

Rengo acquires a 90 percent share in PT Indoris PrintingdoRengo announces that Thai Containers Group Co., Ltd. (TCG), a joint venture between Rengo and SCG Paper Public Company Limited (a subsidiary of The Siam Cement Public Company Ltd.), has completed the acquisition of a 90% stake in PT Indoris Printingdo, a manufacturer of corrugated packaging and folding cartons which operates outside of downtown Jakarta.

HP and KBA collaborate to develop digital inkjet solutions for corrugated packagingHewlett-Packard (HP) and Koenig & Bauer AG (KBA) are collaborating to develop new roll-to-roll inkjet solutions for the high-volume corrugated packaging market. KBA will be bringing its experience in paper handling, manufacturing scale and wide knowledge of the packaging market to the joint initiative, while HP will contribute its inkjet and IT technology as well as digital press go-to-market capabilities. The US$2.5 billion corrugated package printing market has been pushing the industry’s growth worldwide due to brand globalization, population growth and a resurging economy. In parallel, trends such

News...!

as stock keeping unit (SKU) proliferation, micro-segmentation and shorter product lifecycles are driving demand for the shorter run lengths enabled by digital print.

KIWI Global installations in 2014 include:1. Rock Tenn (USA) Completion of 60 ESP

installations in one ESP dataset;2. Tailim Ansam (South Korea) They run

approximately 1,000 orders per day;3. Duropack (Bulgaria) First customer to be

running Cyrillic;4. Rengo (Hawaii) Start-up of a greenfield site;

(see related article here)5. Oji (India) Significant start-up in a growing

market;6. BioPappel (Mexico) The start of a large roll out

in Central America;7. Allpak (USA) An extremely complex sheet

plant project;8. Rigid Charta (UK) Manufacturer of special

corrugated fitments, edge protection and single face rolls.

Packaging companies Rock-Tenn Co (RKT.N) and MeadWestvaco Corp (MWV.N) agreed to

form a combined $16 billion company to take on market leader International Paper Co (IP.N) in the United States and abroad. Shares of MeadWestvaco and Rock-Tenn rose to record highs.

Demand for the corrugated boxes made by both

companies has risen sharply as internet shopping has taken off. Worldwide e-commerce sales are expected to have risen 20 percent to $1.5 trillion last year, according to industry data firm eMarketer.

The merger, announced by both companies on Monday, will create the second-largest U.S. packaging company behind International Paper, which has a market capitalization of nearly $23 billion. "There's significant opportunity around the world for us to grow as we see more activity in emerging markets," MeadWestvaco Chief Executive John Luke said on a call with analysts, citing India, Brazil and China as growth regions. MeadWestvaco shares were up 14 percent to $51.33 in afternoon trading. Rock-Tenn's stock was up 6 percent at $66.78.

Rock-Tenn, MeadWestvaco Create Packaging Giant

FIRST CUT merupakan produk diecut dan berbagai tooling untuk produksi corrugated (flatbed die cuter), folding carton, flexible circuit ataupun greeting card. Tim kami telah berpengalaman untuk memproduksi diecut dari berbagai macam folding boxes dan corrugated boxes. Pengalaman dari tim kami akan memastikan pembuatan produk yang berkualitas, biaya yang ekonomis dan efisien.

Setiap proyek akan diteliti oleh tim berpengalaman kami dengan memperhatikan secara detail apa saja yang dibutuhkan agar produksi Anda menjadi lebih produktif dan lancar. Kami bersedia memberikan saran ataupun internal training di perusahaan anda jika dibutuhkan. Pengalaman dan skill tim

Die Maker EquipmentsDie Board CuttingStripping ToolsSample Making

kami dilengkapi dengan teknologi terbaru dilengkapi dengan peralatan yang memadai:• Software khusus untuk kemasan• Laser cutting machines• Automated rule processing cutting• Automated bending machines• Sample PlotterKami memiliki data base yang lengkap untuk memenuhi kebutuhan customer kami, baik corrugated (FEFCO) maupun folding carton/ECMA dan display boxes, Software khusus kami untuk kemasan dapat mempersiapkan gambar detail yang tepat dan efisiensi untuk memenuhi kebutuhan customer kami (sesuai dengan permintaan dari Brand Owner).

Kami dapat membuat layout dengan otomatis baik untuk single atau multiple nesting yang memastikan efisiensi pada produksi dengan minimum waste. Software kami akan mengikuti kriteria dari material yang digunakan arah dari flute atau grain dari kertas dengan

secara otomatis memilih arah yang dibutuhkan untuk produksi. Membuat design male, female, dan front edge strippers dengan tingkat keakuratan yang tepat. Stripping sistem yang didesain dengan menggunakan dynamic stripping system.Kami juga menyediakan jasa pembuatan Sample atau contoh untuk :

CartonsC o r r u g a t e d boxesDisplay boxesLabelsBagsFlow wraps

Peralatan Penunjang :

CAD system for cutting out

cartonsDie cutting and creasing

www.firstpackagingasia.com

23

Rengo acquires a 90 percent share in PT Indoris PrintingdoRengo announces that Thai Containers Group Co., Ltd. (TCG), a joint venture between Rengo and SCG Paper Public Company Limited (a subsidiary of The Siam Cement Public Company Ltd.), has completed the acquisition of a 90% stake in PT Indoris Printingdo, a manufacturer of corrugated packaging and folding cartons which operates outside of downtown Jakarta.

HP and KBA collaborate to develop digital inkjet solutions for corrugated packagingHewlett-Packard (HP) and Koenig & Bauer AG (KBA) are collaborating to develop new roll-to-roll inkjet solutions for the high-volume corrugated packaging market. KBA will be bringing its experience in paper handling, manufacturing scale and wide knowledge of the packaging market to the joint initiative, while HP will contribute its inkjet and IT technology as well as digital press go-to-market capabilities. The US$2.5 billion corrugated package printing market has been pushing the industry’s growth worldwide due to brand globalization, population growth and a resurging economy. In parallel, trends such

News...!

as stock keeping unit (SKU) proliferation, micro-segmentation and shorter product lifecycles are driving demand for the shorter run lengths enabled by digital print.

KIWI Global installations in 2014 include:1. Rock Tenn (USA) Completion of 60 ESP

installations in one ESP dataset;2. Tailim Ansam (South Korea) They run

approximately 1,000 orders per day;3. Duropack (Bulgaria) First customer to be

running Cyrillic;4. Rengo (Hawaii) Start-up of a greenfield site;

(see related article here)5. Oji (India) Significant start-up in a growing

market;6. BioPappel (Mexico) The start of a large roll out

in Central America;7. Allpak (USA) An extremely complex sheet

plant project;8. Rigid Charta (UK) Manufacturer of special

corrugated fitments, edge protection and single face rolls.

Packaging companies Rock-Tenn Co (RKT.N) and MeadWestvaco Corp (MWV.N) agreed to

form a combined $16 billion company to take on market leader International Paper Co (IP.N) in the United States and abroad. Shares of MeadWestvaco and Rock-Tenn rose to record highs.

Demand for the corrugated boxes made by both

companies has risen sharply as internet shopping has taken off. Worldwide e-commerce sales are expected to have risen 20 percent to $1.5 trillion last year, according to industry data firm eMarketer.

The merger, announced by both companies on Monday, will create the second-largest U.S. packaging company behind International Paper, which has a market capitalization of nearly $23 billion. "There's significant opportunity around the world for us to grow as we see more activity in emerging markets," MeadWestvaco Chief Executive John Luke said on a call with analysts, citing India, Brazil and China as growth regions. MeadWestvaco shares were up 14 percent to $51.33 in afternoon trading. Rock-Tenn's stock was up 6 percent at $66.78.

Rock-Tenn, MeadWestvaco Create Packaging Giant

FIRST CUT merupakan produk diecut dan berbagai tooling untuk produksi corrugated (flatbed die cuter), folding carton, flexible circuit ataupun greeting card. Tim kami telah berpengalaman untuk memproduksi diecut dari berbagai macam folding boxes dan corrugated boxes. Pengalaman dari tim kami akan memastikan pembuatan produk yang berkualitas, biaya yang ekonomis dan efisien.

Setiap proyek akan diteliti oleh tim berpengalaman kami dengan memperhatikan secara detail apa saja yang dibutuhkan agar produksi Anda menjadi lebih produktif dan lancar. Kami bersedia memberikan saran ataupun internal training di perusahaan anda jika dibutuhkan. Pengalaman dan skill tim

Die Maker EquipmentsDie Board CuttingStripping ToolsSample Making

kami dilengkapi dengan teknologi terbaru dilengkapi dengan peralatan yang memadai:• Software khusus untuk kemasan• Laser cutting machines• Automated rule processing cutting• Automated bending machines• Sample PlotterKami memiliki data base yang lengkap untuk memenuhi kebutuhan customer kami, baik corrugated (FEFCO) maupun folding carton/ECMA dan display boxes, Software khusus kami untuk kemasan dapat mempersiapkan gambar detail yang tepat dan efisiensi untuk memenuhi kebutuhan customer kami (sesuai dengan permintaan dari Brand Owner).

Kami dapat membuat layout dengan otomatis baik untuk single atau multiple nesting yang memastikan efisiensi pada produksi dengan minimum waste. Software kami akan mengikuti kriteria dari material yang digunakan arah dari flute atau grain dari kertas dengan

secara otomatis memilih arah yang dibutuhkan untuk produksi. Membuat design male, female, dan front edge strippers dengan tingkat keakuratan yang tepat. Stripping sistem yang didesain dengan menggunakan dynamic stripping system.Kami juga menyediakan jasa pembuatan Sample atau contoh untuk :

CartonsC o r r u g a t e d boxesDisplay boxesLabelsBagsFlow wraps

Peralatan Penunjang :

CAD system for cutting out

cartonsDie cutting and creasing


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