For many folding carton manufacturers, the gluing department sits at the heart of production — and of its pressures. Multiple make-readies, short runs, demanding substrates, and relentless throughput targets make it one of the most challenging areas to optimise. When Midland Regional Printers Ltd reached the point where their existing equipment was holding them back, Stephen Bates, Managing Director, set out to find something fundamentally better. What he found was the DGM TechnoFold 1200 — and a partnership with Ipack Solutions that gave the business the confidence to commit.
Carton gluing had long been a bottleneck at Midland Regional Printers. With constant make-readies and short runs throughout each shift, the operation needed to become noticeably more efficient. The existing equipment was struggling — not just with throughput, but with versatility. The company glues across a wide range of substrates, from folding boxboard to E-flute, and produces formats including side seam, crash lock, and 4- and 6-corner cartons.
“Carton gluing has always been a busy process and one of the production processes that is constantly operating under pressure. In an environment that has multiple make-readies and short runs in a shift, we needed to somehow make the whole operation slicker,” said Bates. “Multiple make-readies and production of different formats in a shift is normal practice for our business. Extended make-readies are costly both in time and money, so reducing them and increasing output results in happier customers.”
He continued, “During our investigations, it became quite apparent that servo-driven equipment was an absolute must, especially with a lot of our work being repeat sizes, so recalling jobs from memory and having the machine automatically assist in the make-ready process was a game-changer. The solution presented by DGM in comparison to other options we considered was quite impressive. There was a lot of machine on offer, with a variety of options if required, and this flexibility allowed us to create our perfect solution.”
A visit to DGM’s Barcelona facility provided a further opportunity to put the TechnoFold 1200 and the team to the test. Bates came away impressed on both counts. “We were impressed with the demonstration and the facilities in Barcelona,” he recalls. “The showroom had a variety of equipment within it, all of which we were shown. We were also given a couple of additional demonstrations on what appeared to be some very advanced technology.”
Running alongside the entire process was the involvement of John Hall at Ipack Solutions. “We have had dealings with John Hall over a number of years, but it was John’s extensive knowledge and advice before, during and after the order was placed that assured us we were in good hands,” added Bates.
The TechnoFold is currently being prepared for shipment and is due to arrive at the beginning of June — a moment the team has been working towards throughout the entire evaluation and procurement process.
