With PackEx Portal for folding box production

Worms, April 2019 - Agile, fast, flexible: PackEx works fully digitised in the production and procurement of standard folding boxes in small series. For this purpose, we have automated and digitised all five production steps from order acceptance to goods dispatch. Highlights are the specially developed PackEx Portal, which enables smart procurement around the clock, and the innovative laser process, which produces cost-effectively and without lead times.

Every single step of production is digital. PackEx has thus revolutionised the production of standard folding boxes in small batches. We are moving order management to the web, which significantly streamlines the procurement process. In addition, the printing, die-cutting and gluing process is highly automated. Smart shipping ensures fewer emissions and faster delivery times. The decisive factor for the digital business model is the change in consumer behaviour. The market demands demand-driven procurement of packaging materials. Fast, simple and inexpensive. We meet this demand with our business concept.

On new paths to the web-to-pack

PackEx is thus moving away from conventional manufacturing towards web-to-pack. This solution is changing the industry significantly. Instead of expensive and complex one-off productions, individual mass productions become possible through standardisation and automation. Individualisation, flexibility and a shorter time to market are thus guaranteed.

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Step 1: Ordering with the PackEx portal

PackEx has fully digitalised the ordering process and developed the intuitive PackEx Portal for this purpose. This is a professional web-based software solution. Unlike a conventional online shop, it offers more innovations. Customers can design, configure and view folding boxes individually. But the portal offers even more: previous orders can be easily and conveniently adjusted as needed and reordered at any time. Physical storage areas are thus a thing of the past. The PackEx portal is also a virtual warehouse. When design changes occur, our customers no longer have to destroy boxes that have already been produced and stored. Instead, they order on-demand, reconfigure in case of a change and thus save considerable costs. The cost-effectiveness and flexibility of the portal are also reflected in the fact that not only the final order but also reference samples can be ordered cost-effectively at any time and from any location. In this way, our customers benefit from a particularly fast time to market.

Step 2: The intelligent cloud workflow 

The intelligent PackEx cloud workflow also reduces costs and time in the second production step. It controls offset or digital printing in a job-specific and fully automated manner. The print data is broken down into production-ready data and combined in a meaningful way. The process allows these to be placed on the printed sheets in a resource-saving manner. These can then be made available to the respective batch production stage, i.e. offset or digital printing, and production starts. And what's more: both printing techniques are coupled with the 7-colour printing system. Unlike CMYK printing, almost all special colours can be reproduced cost-effectively according to Pantone 7 Plus Series.

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Step 3: Neither lead times nor set-up costs thanks to high-power laser 

A core innovation of PackEx is the high-power laser. This is used as the third production stage. Whereas conventional punching tools first have to be ordered, manufactured and delivered, laser technology makes it possible to completely digitalise the punching process. The result: neither lead times nor tooling or set-up costs are incurred. In addition, we are guided by the "good creasability" measuring method. This not only guarantees that the restoring forces are adhered to in concrete terms, but also ensures 100% machine runnability. This means that nothing stands in the way of simple further processing on the customer's side.

Step 4: At the splice line, Video Quality Assurance ensures optimum quality

PackEx also relies on automation for quality assurance, the fourth step of production. Since manual inspections often take more time and have an increased error rate, we use Video Quality Assurance. High-speed cameras scan all packages for defects. This ensures 100% quality assurance.

Step 5: Smart parcel shipping

The last stage of the innovative PackEx production process is smart parcel shipping. For this, we produce customised outer boxes. Instead of the usual truck deliveries on Euro pallets, we work together with parcel service providers. The result is speed, lower transport costs and reduced CO₂emissions.
We have successfully implemented the transfer to e-commerce. Future-oriented manufacturing makes digitalisation possible: agile, flexible and close to the needs of our customers.