Case study · Packaging
Flexo Press Ink Wash-Up & Tooling Changeover Sequencing
A flexible packaging converter operating 8 wide-web flexographic printing presses producing high-barrier food packaging pouches.
Engagement record
- Client
- Flexible packaging converter
- Industry
- Packaging
- System
- Flexo Press Changeover Matrix Optimization
- Timeline
- 5 Weeks
About this write-up
This case study describes the engagement as recorded. The client is not named; figures and outcomes are as reported by the client and have not been independently audited.
The challenge
The converter's press room lost 24 hours per press weekly in setup downtime from uncoordinated Pantone spot color transitions, cylinder repeat changes, and extensive solvent wash-ups. Schedulers queued jobs chronologically by order receipt date rather than color compatibility, generating massive solvent waste.
Objectives
- Connect press room MES cycle logs, ink dispensing databases, and ERP orders.
- Sequence printing jobs in light-to-dark Pantone compatibility order to minimize wash cycles.
- Alert ink kitchen technicians to pre-stage mixed inks and plates prior to job completion.
Discovery
Changeover time-study demonstrated that 48% of setup idle hours were spent performing full color washes between dark and light ink transitions that could have been avoided by optimized sequence grouping.
What was built
- Flexo Press MES & Ink Kitchen Data Bridges. Ingests active job progress, ink formulation records, and cylinder tooling inventory.
- Pantone Transition & Anilox Matrix Solver. Multi-variable algorithm calculating lowest-cost job sequences factoring in color compatibility and cylinder repeats.
- Interactive Press Room Schedule Board. Real-time Gantt console providing press leads with live job sequence recommendations.
- Solvent Wash-Up Reduction & VOC Monitoring Engine. Tracks wash solvent consumption and hazardous waste minimization metrics.
Outcomes as reported
Reported summary: -36% Setup Downtime & $390K Annual Value.
| Figure | What it refers to |
|---|---|
| 36% Less Setup Time | Press wash-up and changeover downtime reduced across all 8 flexo lines |
| +19h Line Capacity | Weekly productive printing press uptime recovered per machine |
| 98.1% OTIF Delivery | On-time pouch converting delivery to food packaging brand clients |
| -41% Solvent Waste | Hazardous ink wash solvent consumption eliminated from the press room |
Figures as reported in the engagement record; not independently audited.
Lessons
- Sequencing spot colors from light yellow/transparent to dark blue/black eliminates 3 full-press deck washes per shift.
- Direct integration with the ink kitchen ensures pre-mixed Pantone formulas are staged line-side before the previous job ends.
Next steps
Connecting solvent distillation and ink reclamation tank telemetry into the master scheduler.
Implementation questions
Schedulers can insert rush orders with one click, and the algorithm re-calculates the optimal sequence in 15 seconds.
We support W&H, Bobst, Comexi, Uteco, Mark Andy, Heidelberg, and Komori presses.
Fewer full-press color washes directly cut solvent wash usage by 35–45%, supporting corporate ESG emission targets.
