Mono Cartons Optimization


Specifications Optimization 


Key Strategies

  • -Standardized size of cartons for multiple SKU’s to increase Convertors volumes & Reduce cost of tooling

  • Reverse print on film Vs Surface print on Board Materials used in Premium Cartons

  • For Volumes in Excess of 1 M, evaluated in line web production Vs Traditional Sheet Fed Multi Step Processes


  • -For a few mm size of  Cartons , the tooling were non standard impacting costs. Design Optimization led to major savings

  • Printing on films improved Aesthics and reduces Ink consumption by more than 25%

  • Large Volumes moved to in line producers of cartons wherein Labour, wastage were much lower



Material Reengineering

  • New BOPP Lamination films recommended

  • Using Semi-Chemical fluting adhesives instead of standard water based for increased resistance to water and lower Paper GSM for Corrugation

  • Introduced low migration ,higher mileage  inks

  • Evaluated and tested Lower Micron Bopp films offering similar or better tensile & printable properties

  • Located vendors offering automatic Semi Chemical fluting for corrugation –tested and organized regulatory approvals for using these inks for Pharma/Food proceeses.


Intelligent Costing / Should Cost Model

  • Should cost calculator linked to input material index including Paper board /Kraft etc

  • Monthly review of  costing


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