The Zone of Disruption

So that speed now comes in at least two forms, medium-speed sheet-fed systems that print directly onto sheets of corrugated board, and high-speed machines that print a top sheet that is later glued to flutes in a corrugating machine. Both fit the corrugated carton market in different ways and target different printers’ needs.

The sheet-fed system consists of the CorrStream 20, 40 and 66 models from SUN Automation, which has recently installed a press in the southeastern United States at an undisclosed location. Because the machines print directly on corrugated sheets, no additional work is needed beyond trimming and scoring. “The CorrStream reduces box maker cost while offering margin-adding opportunity for multiple SKUs, shippers and displays,” says Moloney. “The question comes down to the costs on conventional presses for setup and plate costs versus the cost of heads and inks with digital, then factoring in the value of shorter runs with less waste and no obsolescence.”

Extending the approach of HP’s continuous feed inkjet presses being used for publishing and direct mail applications, HP’s T400 Simplex Color Inkjet Web press prints 40˝ wide topsheet liners at 600 feet per minute. The topsheet still needs to be run through a corrugator, trimmed and scored, but can be a fit for some operations, such as Obaly Morava in the Czech Republic (see sidebar).

Where does digital fit?

“Corrugated industry box makers appreciate its value,” says Moloney. “It’s clear that commercial printers, signage and POP shop and brand owners are also engaged as they begin to see opportunity offered by inkjet technology.”

Digital preprint is ideal for many shorter- to mid-run length jobs, in which inventory, frequent changes, make-ready, and time-to-market are putting stress on the converter.

“At first, brand owners didn’t even think of digital preprint on corrugated boxes because they didn’t think it was possible,” relates Murphy. “It’s similar to how they thought of digital for commercial applications before Indigo introduced its first digital press. Then they started to take notice and ask, ‘What if?’ Over time, as they became educated about what is possible, they started to design differently and build campaigns around digital.”

“For corrugated packaging, we are still in the early days of market education, but based on early orders and growing inquiries, we know demand will grow steadily over time.”