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Description
Right Pack Ltd. has recognized a growing demand for eco-cardboard substitutes for plastic items. Their existing equipment cannot produce eco-cardboard packaging effectively due to the material''s sensitivity to humidity and temperature, which affects size and prevents post-production refinement processes.
The project''s main objective is to enhance Right Pack Ltd.''s capacity for eco-cardboard packaging production by introducing an automatic varnish and hot foil registration machine. This innovative machine leverages Artificial Intelligence to achieve automatic registration for inkjet heads over pre-printed sheets, significantly improving efficiency and productivity.
This project responds to the European Union''s Plastic Strategy, which seeks to revolutionize the design, production, usage, and recycling of plastic products. Specifically, it aligns with the goal of making all plastic packaging reusable or recyclable in a cost-effective manner by 2030, as well as addressing environmental impacts of single-use plastics.
The environmental benefits of this technology are noteworthy, including enhanced UV protection with lower energy consumption, improved resource efficiency by eliminating the need for plates, screens, dies, and varnish, reduced waste generation, and the use of recycled paper.
The project is expected to lead to a 30% reduction in generated waste, saving approximately 42MWh of energy annually, and promoting better utilization of raw materials. This green initiative is poised to reduce CO2 emissions by approximately 30 tons per year, contributing to a more sustainable and environmentally responsible production process.
Summary of project results
The project aimed to address several critical issues and challenges related to the adoption of sustainable packaging solutions, particularly in response to the EU’s Plastics Strategy and related initiatives. These challenges included:
Transition to Recyclable and Reusable Packaging: The EU’s Plastics Strategy set ambitious goals for all plastic packaging to be reusable or recyclable in a cost-effective manner by 2030, which was later expanded to include all packaging materials under the European Green Deal and Circular Economy Action Plan. Right Pack Ltd. needed to align with these regulatory requirements and the growing market demand for eco-friendly alternatives to traditional plastic packaging.
Addressing Market Trends and Opportunities: The adoption of measures such as the Single-Use Plastics Directive introduced strict regulations on single-use plastic products, including packaging, creating an increased demand for sustainable alternatives like eco-cardboard. The project aimed to position Right Pack Ltd. to take advantage of this growing market opportunity and increase its share in the eco-packaging sector.
Technical Limitations of Current Equipment: Right Pack Ltd.’s existing equipment was unsuitable for producing eco-cardboard packaging. Eco cardboard, being highly sensitive to humidity and temperature, experienced significant size alterations (up to 5%) upon contact with water or alcohol during the current printing processes. This made it impossible to apply essential refinements such as hot stamping, partial varnishing, and embossed varnishing, which were critical for high-quality packaging.
Improving Production Capabilities: The project focused on overcoming the limitations of current processes by introducing an automatic varnish and hot foil registration machine. This upgrade was necessary to enhance the company’s ability to produce eco cardboard packaging efficiently while maintaining quality standards, thus enabling it to meet regulatory requirements and market demands.
By addressing these challenges, the project sought to enable Right Pack Ltd. to contribute to the broader goals of sustainability, comply with EU directives, and capitalize on the expanding eco-packaging market.
The project enabled Right Pack Ltd. to significantly enhance its capacity for cardboard printing by acquiring and implementing an advanced automatic varnish and hot foil registration machine. This cutting-edge machine relied on Artificial Intelligence to perform varnish and hot foil registration for inkjet heads over preprinted sheets.
Key actions taken under the project included:
Integration of Advanced Technology: The new machine utilized print image and inkjet synchronization algorithms alongside a patented Automatic Identification System (AIS) capable of performing over 5,000 billion operations per second. This represented a major technological advancement in the printing and finishing industry.
Improved Operational Efficiency: By incorporating the new system, the project Eliminated more than 80% of the operator setup time required for registration processes.
Streamlined Workflow Integration: The machine’s innovative “scan and register” setup process allowed for quick and seamless integration into existing job workflows, simplifying operations and reducing the complexity of job preparation.
Enhanced Productivity and Cost-Effectiveness: The project boosted throughput and job completion speed, enabling greater overall productivity. Additionally, it helped the company minimize operator wage costs and paper waste associated with traditional analog setup processes, leading to rapid equipment amortization and cost savings.
Through these actions, the project not only modernized Right Pack Ltd.’s production capabilities but also positioned the company as a competitive player in the eco-packaging market, aligning with sustainability goals and meeting growing industry demands.
The project achieved significant environmental, operational, and market-oriented outcomes, benefiting Right Pack Ltd., its clients, and the broader community.
Environmental Benefits:
- Energy Efficiency: The equipment reduced energy consumption by 42 MWh annually, contributing to lower operational costs and reduced environmental impact.
- Resource Efficiency: The advanced system eliminated the need for consumables such as offset plates, silkscreen screens, dies for hot foiling, and varnish. This reduced reliance on petroleum-based materials and other resources.
- Waste Reduction: The project decreased waste generation by 30% annually, lowering waste from 585 tonnes in 2019 to an expected 410 tonnes in 2024. This waste reduction also translated into a reduction of 30 tonnes of CO₂ emissions each year.
- Improved Raw Material Utilization: By switching to recycled paper for eco-cardboard production, the company achieved better resource utilization. Every tonne of recycled paper replaced approximately 3.5 m² of wood, aligning with sustainable forestry practices.
- Elimination of Cleaning Waste: The automatic inkjet head cleaning system negated the need for manual cleaning between processes, further minimizing waste.
Operational Advancements:
- Enhanced UV protection with lower energy requirements provided more efficient and cost-effective production processes.
- The elimination of traditional setup consumables and processes resulted in reduced downtime and faster job turnover, improving productivity.
Beneficiaries:
- Right Pack Ltd.: The company gained a competitive edge in the eco-packaging market by reducing production costs, increasing efficiency, and adopting more sustainable practices. These improvements positioned it as a leader in environmentally friendly packaging solutions.
- Clients: Customers benefited from access to high-quality, eco-friendly packaging that aligned with their own sustainability goals.
- The Environment: The reduction in energy use, waste generation, CO₂ emissions, and reliance on non-recycled materials contributed to broader environmental sustainability.
- The Community: By supporting sustainable practices, the project generated positive social and environmental impacts, aligning with global climate action goals.
Overall, the project created a win-win scenario by combining economic growth for Right Pack Ltd. with environmental benefits for society.