Aiming for zero-defect production is crucial for the success of any printing and packaging company. With the advancement of technology, automation has emerged as a key enabler in ensuring high-quality output while minimising defects. Implementing automation in the printing and packaging process can enhance efficiency and significantly reduce the margin of error.

The term "zero-defect" originated in the early 1960s in the context of the US Army Perishing Missile System. It has since become a standard practice in manufacturing aimed at minimising defects and errors in processes and striving for accuracy. The primary objective is to eliminate the number of defective products.

In the packaging arena, the zero-defect concept can be applied across packaging production environments to bolster quality and reduce expenses. However, the successful implementation of zero defects hinges on the presence of optimal conditions. Striving for zero-defect quality products and processes is driven by safety imperatives and the need to meet customer expectations. To achieve this, it is imperative to possess practical tools for its execution.

To push the concept in India, Bobst hosted an open house at its plant in Pirangut. Close to 110 delegates from the Indian packaging industry from across India got a glimpse into the company's packaging converting machines and its manufacturing prowess. The Bobst team — Cyril Ruiz-Moise, Venugopal Menon, Sameer Joshi, Allegra Allesi, and Sachin Patil shared insights on the Bobst technology and demonstrated how the packagers can navigate in the evolving packaging landscape, integrate automation and move forward in their pursuit of zero-defect production that will be crucial in driving profitability and sustainability.

Venugopal Menon, the zone business director of the printing converting unit for the Indian Subcontinent at Bobst India, emphasises how Bobst's industry vision is aimed at shaping the future of the packaging world based on its four pillars — connectivity, digitalisation, automation, and sustainability. "Bobst aims to transition from solely providing machinery and services to offering solutions and data, with stakeholders and customers connected through a digitised and automated workflow. This will allow access to cloud-based platforms anytime, anywhere, creating a flexible and collaborative platform," he says.

On the sidelines were Bobst partners, showcasing monitoring and optimisation tools.

Intelligent automation
One of the key innovations, Menon says, is BobstConnect, a technology that enables seamless data integration and cloud connectivity. "By connecting machines to the cloud, Bobst Connect allows for real-time data collection, performance management, remote monitoring, and assistance, empowering packaging service providers to optimise their operations."

According to Allegra Allesi, product manager for IoT at Bobst, the platform gathers real-time data from Bobst's machines every 10 seconds and feeds it into a cloud-based Microsoft Azure platform. "Some key benefits of BobstConnect include remote problem resolution, automated data tracking, and optimised machine performance. Additionally, the platform features the TooLink management system, which uses RFID chips to track detailed usage data of dies and cutting tools, allowing customers to proactively order replacements and minimise downtime."

To highlight the important role of advanced technology in driving the success of packaging production, Menon draws attention to the Accuregister feature on the Novacut 106E die-cutting machine. "Packagers face a significant challenge in managing the wide range of products they produce. A die-cutting machine, in particular, requires flexibility," explains Menon. "Irrespective of the material being processed by the machine, the quality must consistently remain top-notch. The precision of the register and the flatness must stand out in the market."

According to Menon, the Bobst Novacut 106 ER is the world's first flat-bed die-cutter equipped with the new Accuregister "contactless" sheet-register system. This new sheet-register system is based on the renowned optical power register, introduced by Bobst in 2000 and remains unique to this day. Bobst has tailored the Accuregister by incorporating the best features of the Power Register specifically for the Novacut line. "Consequently, the new sheet-register system enables quick set-up times in the die-cutting process and minimises feeder-related stoppages. This reduces waste during set-up and production, leading to a more sustainable production process and products," says Menon.

The high-performance camera fitted into the system reads both printed images and marks. And if that is not possible, the cameras simply read the sheet edges. "When the sheets are fed into the machine, the system calculates within milliseconds the corrections required and automatically remedies them as the sheets accelerate; over a wide correcting range, up to ±6mm in forward direction and ±13mm in lateral direction - even with transparent material," explains Menon.

Yet another automation tool in the Bobst portfolio is the Toolink, which Menon says revolutionises how packaging converters manage their tooling. Menon said TooLink solutions for die-cutting tools and Accubraille tools, including the Speedpatch and Accuplaten technologies, addressed the issue of reducing makeready time. The Speedpatch, Menon explains, can reduce patching on die-cutters by up to 50%. "This solution works by optimising the patching requirement, a critical component in makeready time on die-cutters and thus shortening the change over time, while the Accuplaten, which would be a totally new redesigned platen on Expertcut 106 PER would revolutionise the patch-up time required by almost 80% and thus moving towards zero-patching."

Employee training and collaboration
While automation plays a significant role in minimising defects, it is essential to provide comprehensive training to employees to effectively operate and maintain automated systems. Collaboration between human workers and automated technologies is critical in achieving zero-defect production, as human expertise combined with automation can lead to superior quality output.

Ashok Narayanan of Pidilite says his company's approach to zero-defect packaging extends beyond just product quality. The company has recognised the critical role that education and collaboration play in achieving this goal. "Pidilite plans to establish a technical or experience centre where converters can receive hands-on training and gain a deeper understanding of adhesive technology, testing methods, and best practices. "We believe that education is key," Narayanan explains. "We'll have users coming to this centre, and we'll impart the best practices, the adhesive technology behind it, and the testing methods. This will help our customers better understand how to use our products effectively and achieve zero-defect packaging."

The packaging industry's changing landscape further underscores the importance of this initiative. Narayanan cited the Nestle Maggi incident: "It has significantly increased customer compliance requirements, with even smaller and mid-range converters becoming more aware of the need for stringent quality control."

Narayanan acknowledges the potential of technological innovations in machines but also highlights the inherent challenges in the adhesives industry. "The adhesive universe is very wide," he explained, "and it's difficult for someone to understand everything. That's why we believe in a collaborative approach, where we work closely with our customers, machine manufacturers, and other stakeholders to address quality issues."

Markus Baldauf of Cito and Arun Gandhi of CGSASP agree that achieving zero-defect packaging requires a collaborative effort.

"Zero defect packaging means that each box that is going to reach the end consumer is fulfilling the properties that our end users and the customers are waiting for," explains Baldauf. "This is what we need to make sure on all over the runs that the box makers are producing."

Baldauf shares a successful example where the team focused on optimising the makeready process by balancing the die before starting the patching. This small but impactful step significantly reduced makeready time over the long term. "If you start with the right balancing, coming from the machine with good machinery, then you can optimise the whole makeready, and from a long-term perspective, you will downsize the makeready time a lot," Baldauf explains.

Quality control systems
Implementing automated quality control systems such as vision inspection systems can significantly reduce the chances of defects in printing and packaging. These systems utilise advanced cameras and software to detect imperfections in real-time, ensuring that only products meeting the defined quality standards proceed further in the production process.

Valco Melton is a manufacturer of adhesive application equipment, and its new inspection systems system, developed by the ClearVision brand, is particularly tailored for the corrugated industry. N Ravi Kiran, director for Valco Melton India, UAE, Malaysia, Indonesia and Singapore, says, "The PrintCheck system utilises high-resolution cameras to capture real-time images of the boxes, which are then compared to a master reference. Any discrepancies or errors are immediately identified, and the system can automatically eject the affected boxes from the production line."

At the Bobst open house, Valco Melton's Neel Mehta shares information about the company's comprehensive approach to quality control, citing a case study of Valco Melton's successful implementation of its inspection system at Sri Lakshmi Container. "By replacing the previous folder-based approach with Valco Melton's blinks-based inspection and standard machines, Sri Lakshmi Container has achieved a new level of quality and compliance in its packaging operations," explains Mehta.

Baumer HHS specialises in adhesive application and quality control. Marcell van Meegen of Baumer HHS explains that "zero packaging" is a fundamental goal for the printing industry and the entire packaging sector. "Everybody today is talking about sustainability, being more sustainable, and what supports that best is to have less waste," he says.

A key driver behind this push for zero-defect packaging is the need to minimise waste throughout the production process. "Most of the waste we are having in the packaging industry is due to the fact that we are not detecting our production," Meegen notes. "By investing in advanced verification and detection technologies, manufacturers can significantly reduce waste and improve profitability."

This trend is particularly evident in the Indian market, where Meegen notes a growing demand for verification and detection technologies. "They understand that as long as they can achieve a good product and be sure that everything is in the right position, they reduce their waste dramatically," he says.

As an ink company, Seigwerk's focus is not on defining packaging itself but developing specialised ink solutions tailored to the unique needs of different packaging types. "We treat that packaging as nutrition, pharma, and hygiene, and then we derive or develop our solutions in line with that," he explained.

According to Vivek Budhwar of Siegwerk, standardisation is the key to achieving zero-defect packaging. "Implementing automated workflow systems can help standardise processes and reduce the likelihood of errors. Standardise your press, standardise your ink kitchen. That's the first step to proceed," he advises.

Die-cutting and zero-defect packaging
Brajesh Naykpura, director at Son N Naykpura, says the link between die-cutting and zero-defect packaging is undeniable. "When a converter has a perfect die, it will get zero-defect packaging."

This understanding has driven Son N Naykpura to continuously invest in new technologies and innovations to ensure their tooling solutions are optimised for the latest packaging requirements.

One such innovation is the integration of RFID chips into their die-boards. "By providing a pre-drilled provision for these chips, we streamline the set-up process for converters, allowing them to simply affix the chip and be ready to run their machines. This level of compatibility and foresight is crucial in an industry where time is of the essence, and any downtime can significantly impact productivity," says Naykpura.

Naykpura shares how using the best dies can improve productivity and drive efficiencies such as zero-effect production. "A packaging converter customer had been running its machines at a relatively slow speed of 4,400 sheets per hour due to the limitations of the existing tooling they were using from another supplier. However, after consulting with us, the converter was able to unlock the full potential of their machines by implementing SonNaykpura's advanced tooling."

Naykpura explains, "By simply paying a 10-15% premium for Son N Naykpura's tooling, the customer was able to increase their machine speed from 4,400 sheets per hour to a remarkable 8,000 sheets per hour. This productivity doubling was achieved without additional capital investment in new machines or infrastructure."

Conclusion
The integration of advanced technology, automation, and innovative solutions in the packaging industry is essential for achieving zero-defect production. The commitment to quality, efficiency, and sustainability demonstrated by companies like Bobst and partners at the open house, sets a promising path for the future of packaging production. “By embracing these advancements, packaging companies can enhance their operations, minimise defects, and drive profitability while meeting the evolving demands of the market,” concludes Menon.