5 ways to boost efficiency throughout the folding carton converting workflow

Mex, Switzerland, 13 November 2025

The folding carton sector is undergoing a transformation driven by fast-evolving consumer preferences, market trends, and technological advancements. Speed-to-market and shelf appeal vs competitors are critical factors for the success of many brands, driving the need for smaller batches, shorter runs and faster turnaround times. Converters are being asked to deliver more sophisticated folding carton packages that stand out on the shelves and engage with consumers in new ways. At the same time, sustainability considerations are changing market dynamics, for example with reusable and recyclable folding carton packaging replacing plastic packaging for single-use purposes.

In this context, converters need greater efficiency throughout their workflows to meet the needs of their customers. Digitalization is bringing significant benefits here in terms of workflow optimization, digital printing, digital cutting and digital embellishment. Automation is helping to improve efficiency further and reduce costs, while also helping converters to manage the ongoing issue of skilled labor shortages in the packaging industry.

At BOBST, we have been focusing on our industry vision to shape the future of the packaging world through the four key pillars of automation, digitalization, connectivity and sustainability for several years. This focus has enabled us to create efficiencies throughout the entire converting workflow for folding carton, from the planning stage through the whole production process.

Here we outline five ways that converters can boost efficiencies throughout their folding carton workflows. ​

1. Optimize preparation with BOBST Connect

They say preparation is the key to success. With BOBST Connect, the all-in-one digital platform that enhances and improves packaging productivity, converters can prepare their jobs to enable significant efficiencies.

For example, users can create and manage job recipes in advance of production and send them to the machine where they are downloaded by the operator to set up the machine. This Job and Recipe Management Workflow streamlines the setup, improves precision, and ensures consistency across shifts and operators. By preparing job recipes in the back office, operators can focus on production rather than setup, leading to faster and more efficient operations. Any changes made during production are then transferred back to the platform. This ensures data is updated to guarantee production continuity.

We know how important it is for converters to be able to create innovative and eye-catching packaging solutions, including embellishment. On hot stamping transfer machines, OACS (Optimal Advance Computing System) Connect can be used to calculate the best film advance options ahead of production in back office and – just as the job recipes – sent the machine. This allows to plan film supply, reduce changeover times and contributes to optimize foil use.

Data transfer also happens between tools and machines. With TooLink, a microchip connects the cutting die to the die-cutter’s HMI, which enables instant retrieval of job data for machine setup. The chip saves any data changes for the next run. Through BOBST Connect, this data is available for production overview and management.

BOBST Connect not only allows converters to prepare and follow-up jobs. With Equipment Monitoring and Performance Management as part of the platform’s features, users can gain invaluable insights on equipment, shift and job performance and energy consumption, optimizing sustainability and cost.

2. Automate and optimize setup

Automation is enhancing packaging manufacturing at every step. For example, the EXPERTFOLD 50/80/110 is now available with a Matic setup of the main machine elements. Combined with the Job and Recipe Management, this allows to save 10 minutes during every changeover.

With ACCUPRESS, an additional 5 minutes can be saved when setting up the EXPERTFOLD. The system enables the different pressure zones in the delivery to be recalled through the HMI SPHERE and set up automatically. Changing from manual to digital setup ensures regular and precise settings and guarantees ideal glue adherence.

The setup times for the folding carton die-cutter range can be reduced with SPEED CHANGE, a range of features which increase setup connectivity, automation and machine ergonomics. And with ACCUPLATEN, patching time on BOBST die-cutters can be cut by up to 80%, simply by compensating platen pressure irregularities to minimize deformation.

By utilizing automation and time-saving machine features, we can make many incremental gains which add up to significant efficiency advantages for converters.

3. Support efficient and flexible production processes

When it comes to the production process, BOBST boosts efficiency and productivity through process optimization and flexibility, with solutions that can be adapted to different needs.

For greater hot stamping transfer versatility, the NOVAFOIL 106 can be equipped with a cross-foil module to increase film application performance on added-value boxes. However, the machine is also available with up to 10 dedicated hologram modules, which can be set up and mounted individually according to specific production needs. This NOVAFOIL 106 Hologram version is ideal for flexible and highly efficient hologram applications.

On the MASTERCUT 165 PER, the Dual Stream delivery option allows to either deliver blanks in counted batches, or in piles on a pallet. Depending on downstream processing requirements, the machine can be adapted with the turn of a switch. Downstream processing has also been a major consideration for creating an inline banding solution for folder-gluer lines equipped with CARTONPACK 4 packer. Instead of automatically packing the boxes loosely in containers, the banding of counted batches allows operators at packaging machines to transfer the boxes efficiently into the machines, without deteriorating packaging quality.

With ACCUBRAILLE, ACCUCHECK and GYROBOX, BOBST folder-gluers also enable converters to adapt their machine to their production needs and integrate important production steps directly into the folding-gluing process, to simplify and accelerate the production workflow.

For short-to-midsize runs, there is now the option to utilize an all-in-one digital printing and converting platform with the DIGITAL MASTER 55, a new platform tailored for the folding carton industry, which drastically increases opportunities with short lead times and high product quality. Combining printing, embellishment, quality control, and die-cutting inline at 100 mpm, the DIGITAL MASTER 55 ensures the shortest time to market (even offering same-day delivery) and the best Total Cost of Ownership (TCO) among printing and converting solutions.

There really is an option for every need and requirement – and all of them greatly increase converter efficiency. ​

4. Boost non-stop production

Once production is up and running, converters need to maximize uptime and throughput.

Introduced recently on the NOVACUT 106 and VISIONCUT 106, the ACCUREGISTER – a “non-edge-contact” registration system - is designed to enhance die-cutting accuracy in packaging production. High-performance cameras align sheets precisely, either by the edge or a print mark. This guarantees optimal sheet alignment and die-cutting quality, while minimizing feed-related stops.

When it comes to facilitating die-cutting logistics, the BOBST Automatic Pile Transfer (APT) system optimizes the material flow by continuously supplying full pallets to the feeder, while pallets are transported to the machine’s delivery to be loaded with blanks.

Meanwhile, peripherals for the folder-gluer range ensure continuous material flow which optimize the production capabilities of the machines. With the EASYFEEDER 4 pre-feeder and the BATCH INVERTER 4, blank feeding on folder-gluers is continuous, without constant operator presence, and ensures the highest productivity at any given speed.

5. Save resources with sustainable solutions

With sustainability and cost-efficiency major focuses for all converters, BOBST is continually rolling out new initiatives aimed at reducing environmental impact and production cost.

The POWER REGISTER’s register recognition capacities have been adapted to include very small square reference marks at the side of each sheet. This POWER REGISTER Plus saves up to 4mm of carton for the front register marks, reducing carton cost by up to 0.5%, which can save up to 1 ton of carton for 1 million sheets. ​

Meanwhile, the Energy Efficiency Pack is a set of features including energy-efficient air pumps and an Energy Recovery System, which transforms kinetic machine braking energy into electricity. These and other measures in the pack can reduce energy consumption by up to 20% on die-cutters and hot stamping transfer machines.

The new independent motorized glue unit on the EXPERTFOLD folder-gluer helps converters to save energy, glue and maintenance time. The independent motor enables the station to run, even if the rest of the machine is on standby – the glue wheel continues to move, ensuring that the glue does not dry and that the following boxes can be produced without any impact on the gluing quality.

Sustainability and cost-efficiency often go hand in hand – improve the first and you almost guarantee improving the latter.

Conclusion

There are significant opportunities throughout the folding carton converting workflow to boost efficiency and productivity. BOBST is the go-to supplier to provide end-to-end solutions – including service and long-term production change requirements. The solutions developed by BOBST throughout the folding carton converting process can provide a significant competitive advantage and enable converters to keep up with the pace of change in the years to come.

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About BOBST
​We are one of the world’s leading suppliers of substrate processing, printing and converting equipment and services for the label, flexible packaging, folding carton and corrugated industries. Our vision is to shape the future of the packaging world based on four pillars: connectivity, digitalization, automation and sustainability.
​Founded in 1890 by Joseph Bobst in Lausanne, Switzerland, BOBST has a presence in more than 50 countries, runs 21 production facilities in 12 countries and employs more than 6 400 people around the world. The firm recorded a consolidated turnover of CHF 1.891 billion for the year ended December 31, 2024.

Press contact:
​Gudrun Alex
​BOBST PR Representative
​Tel.: +49 211 58 58 66 66 ​
​Mobile: +49 160 48 41 439
​Email: gudrun.alex@bobst.com

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