Ensuring quality, consistency and productivity in RSC box converting with BOBST NOVAFFG

The packaging market is witnessing a considerable shift from plastic solutions to more sustainable fiber-based alternatives – a direct result of consumers’ concern for the environment and increasingly stricter regulations around waste, recycling and reuse.

In addition, the proliferation of online shopping, where goods are shipped directly to the consumer’s home or workplace, has elevated the importance of corrugated packaging. No longer simply used to transport and protect the goods, in today’s e-commerce world, the humble brown box has become a direct extension of the brand’s image.

Both trends put strong demands on the producers of secondary and tertiary packaging, requiring them to deliver repeatable, high quality boxes produced in the most sustainable way possible.

Excellent price-performance ratio
Millions of high-quality RSC (Regular Slotted Container) boxes roll off BOBST equipment production lines across the globe each day to meet the demands of this rapidly evolving market. Through a series of intricate processes, BOBST FFG (flexo-folder-gluer) machines effortlessly transforms corrugated sheets into finished boxes with great precision at high speed.  

The most recent addition to BOBST’s FFG portfolio is the NOVAFFG, which builds on the company’s deep expertise in this sector. Specifically developed to streamline the production of standard, medium- to large-size RSC boxes, the NOVAFFG offers high productivity with accurate and consistent output quality. Its user-friendly interface results in faster setups and changeovers with less staff required to operate the machine, while optimized energy consumption further saves on costs and adds to the sustainability of the process. This is all presented in a lean footprint and layout devised to take up less valuable space on the factory floor.

“BOBST has built decades of knowhow into the new NOVAFFG to offer an excellent price-performance ratio in a sector where margins are small and competition is high,” explained David Arnaud, Product Marketing Director FFG DRO from BOBST. “Standard RSC boxes are the bread and butter of the corrugated industry, but quality outcomes can vary greatly, and excessive waste is often generated in the process. The high-productivity NOVAFFG is designed to remove these barriers to success by lifting quality, ensuring consistency and improving sustainability, without costing the earth.”    

RSC logistics box

Accurate and consistent output
Delivering up to 18,000 boxes per hour, the NOVAFFG converts single and double-walled board from 1.4mm to 10mm thick. It is a cost-effective solution that will appeal to box makers in the RSC space due to its high reliability and efficiency. In market where brand owners require consistent quality delivered at speed, this production line greatly improves capabilities while also reducing waste across every stage of box production.

“The competitive price point of the NOVAFFG allows us to expand our installation base by reaching new customers looking to produce quality RSC boxes that meet and even exceed current market standards,” said David Arnaud. “It incorporates numerous well-proven printing, cutting and handling features that elevate the production process and guarantee accurate, consistent output not just over a single run, but also when the job is repeated tomorrow, next week, or even next year.” 

From smooth feeding to final bundle, the NOVAFFG will produce sellable boxes right from the first sheet. The servo-driven folder and top counter-ejector sections ensure clean, square folds with minimal fishtailing and perfectly maintained gaps, crucial for producing high-quality RSC boxes.

Upstream, the mechanically driven sections feed smoothly into a powerful slotter unit, which incorporates four pairs of shafts, three pre-creasers, and an independent glue-lap cutting shaft for flawless trimming and efficient waste removal. In addition, the NOVAFFG includes a practical bottom die-cutter suited for simpler tasks such as creating flap cuts, hand holes, and vent holes.  

Making production easier and faster
A real highlight of the NOVAFFG is its user-friendly design which allows quick job setups to be performed by a single operator . Its HMI (Human Machine Interface) is straightforward to operate with intuitive color touchscreens giving a clear overview and control of production parameters settings. There is easy access to the die-cutting section ensuring fast and efficient tool change in a matter of minutes, with those opting for a top die-cutter able to utilize BOBST’s Posilock® quick positioning and locking system. The automated slotter unit needs no operator intervention during setting and print registration is managed by motion controllers requiring very little in terms of calibration.

“The NOVAFFG has been designed with efficiency in mind for converters wanting to increase automation in their production of RSC boxes without compromising on quality. This not only ensures high productivity with quick turnaround of jobs but also minimizes the number of people needed to run the machine. By not relying heavily on the skills of the individual operator, the NOVAFFG will help future-proof businesses as it becomes increasingly difficult to find well-trained staff,” concludes David.
 

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