Lasers Support Digital Manufacturing In Carton Production
The traditional methods of manufacturing folding cartons can often be complex and time consuming . Each stage in the process , from artwork approval by the brand owner , through printing , die cutting , finishing , and shipping tends to be performed in isolation . This can often lead to large quantities of work in progress and multiple set-ups to change from one product to another .
However , the flexibility and power of lasers makes it possible to streamline these processes and operations into a single digital production line , which delivers the highest levels of productivity , and even allows the production of different product variants , on the fly .
CartonsInMinutes ® is an automated process for laser cutting and scoring folding carton materials into stacks of cartons ready for folding and gluing . The ability to link the individual manufacturing process digitally within LasX ’ s CartonsInMinutes ® digital manufacturing process , makes it possible to produce only what is needed , when it is needed . Eliminating unnecessary work in progress , set up times and product handling reduces both manufacturing timescales and costs .
From a product designer ’ s perspective , removing the constraints imposed by the mechanical die-sets traditionally used in carton production offers greater degrees of freedom . In addition to the product artwork , each item is located with fiducials and identified by a bar code - originating from a layered PDF file - containing the cut and scoring information required by the laser . Complex , variable , and nested shapes can all be created whilst matching digital printing speeds .
48 FDPP - www . fdpp . co . uk
The CartonsInMinutes ® process is capable of producing intricate shapes on demand
Several different sized and shaped folding cartons can be produced on a single sheet , optimising material usage . Furthermore , lasers offer the ability to combine multiple processes in a single run , which means cutting , scoring , perforating , and etching can all be done using the same system in one step as opposed to many . These factors all lead to reduce lead times , setup , and tooling
costs .
The CartonsInMinutes ® process is a specific configuration for LasX ’ s digital finishing equipment solutions designed to meet the needs of the folding carton market . LasX ’ s LaserSharp ® equipment uses patented laser control software and advanced vision technology to assure precise , repeatable cut-to-print registration . Instant job change at production speed is accomplished either through programming or by reading the printed bar codes . These digital manufacturing systems , which are capable of using either sheet fed or roll fed material , are scalable to meet the needs of any production environment . Systems can be configured with up to two 1000W lasers to perform mixed converting operations while achieving throughput speeds as high as 15,000 cartons per hour , still with instant order / product changeover capabilities in continuous production runs .
Using LasX ’ s CartonsInMinutes ® process , finished cartons can be available for shipping within minutes of final customer design and artwork approval
Following printing and laser processing , automation also aids in the digital manufacturing workflow . Pick-andplace robots , positioned after the laser-processing module , identify each piece and stack , sort , rotate and / or shingle them as required . By organising the finished parts using
automation , significant time-savings can be realised . The laser-processed pieces can then be directly sent to additional finishing processes such as folder-gluers and then packaged . Multiple conveyor belts can be used at the end of a laser-processing module to send different products to various stations .
LasX ’ s CartonsInMinutes ® process and technology described in this article are available from Bromsgrove based TLM Laser , who are the UK and Ireland distributors for LasX Industries , a technology and industry leader in high performance production class laser converting systems and services . TLM Laser also offers a comprehensive range of Laser processing systems for cutting , welding , marking , engraving , cleaning , 3D additive layer manufacturing , plus laser safety equipment .
www . tlm-laser . com