Bartosz Nowakowski, Poland Country Manager at Eurographic Group, shared valuable insights into the role of digital die-cutting in the production of packaging. Eurographic Group, a leader in advanced digital printing solutions, has significantly expanded its digital capabilities under Nowakowski’s leadership. In 2023, the company invested in a Highcon Beam 2 system and, one year later, became the first beta customer to upgrade to the Highcon Beam 3, the most productive digital die-cutting system on the market.

Here are some key takeaways from the discussion, as led by Szymon Symonowicz from Digiprint:

Why is digital die-cutting so important?

“Digital die-cutting is crucial in planning a job’s execution, from choosing between analogue and digital machines to determining embellishments. It optimizes costs by creating an efficient production path tailored to client specifications. Organizing a digital job queue ensures fast, cost-effective production that aligns with client needs.”

How does digital die-cutting work?

“I adopt a holistic approach, viewing it as part of a larger whole. Digital die-cutting isn’t just a standalone process; it’s part of a larger workflow. Right from the very start, we focus on aggregating order data processed by our systems, ensuring everything is seamlessly in place. Our advanced digital printing capabilities allow us to produce both Pantone and non-Pantone boxes. To optimize costs, we combine jobs, as digital unit costs differ significantly from offset printing. Our digital finishing is equally efficient, with job combinations on a sheet further enhancing cost-effectiveness.

However, this brings us to a less obvious challenge in today’s market: what happens next with the packaging? Cutting it out presents a unique issue. With traditional analog solutions, we would need to order a custom die. If we’ve combined jobs, the die often becomes a one-time-use tool because future orders will likely involve different quantities or configurations. When combining jobs from different clients on a single sheet, the die becomes even less reusable, which is where digital die-cutting proves essential. In my view,  digital die-cutting is actually the starting point for planning. At this stage, we determine whether to use laser cutting, whether we’re combining jobs from multiple clients or working with a single client, or even handling varying package sizes. This integration of data and planning begins right here. With traditional analog methods, it’s nearly impossible to make this process both optimal and cost-effective. For this reason, I consider digital die-cutting one of the most critical components of the entire workflow.

To support this, we’ve invested in a Highcon Beam 3 machine for production. Frankly, I’m not aware of another solution on the market that comes as close to achieving analog-quality results. The product quality is virtually indistinguishable from traditional die-cutting. Today, when we deliver this product, we no longer specify to the client whether it was cut using laser or rotary methods. While industry experts can identify certain differences and understand the limitations of each approach, clients ultimately care about just one thing: the quality of the final product. Whether the packaging is produced digitally, through offset, or another method, the only expectation is that it meets high-quality standards.

Thanks to advancements in digital die-cutting, we now have a solution that meets those expectations for digital packaging production. Creasing and die-cutting have reached a level of precision and quality with this technology that we can confidently use it for mass production. So, to answer the question, “How does it work?”—it works, and it works exceptionally well. All the samples you see here were produced on the Highcon Beam 3. As an industry expert, you might notice subtle differences, but 99% of clients wouldn’t. For them, the product simply meets their standards, regardless of the production method.

Balancing analogue and digital processes

“We use both analogue and digital solutions. The greatest advantage is the flexibility to choose the most  cost-effective path during planning. With a diverse order portfolio, we can optimize for digital production, particularly for short runs, achieving excellent cost efficiency.”

The role of automation in cost optimization

“Automation is key for cost optimization. Using an Esko module, we aggregate orders and automatically combine them without manually pairing jobs with dies. The system optimizes sheet layouts, minimizes waste, and handles the entire process. One person supervises the system rather than manually performing the work, streamlining operations significantly.”

Nowakowski added, “With Highcon’s laser cutting, we can achieve intricate designs, like cutting detailed text in packaging, which would be extremely time-consuming and costly with analogue methods. The Highcon automates these processes, delivering precision and eliminating tedious manual clean-up.” This allows for creating designs that would otherwise be unattainable or prohibitively expensive using traditional methods.

Looking beyond die-cutting, Nowakowski said automation extends to folding, glueing, and other finishing stages: “We use fully automated solutions compatible with the entire digital process, with setup times in minutes rather than hours.”

“Digital production must be approached holistically. Printing alone isn’t enough if the rest of the process isn’t optimized. Rapid execution and seamless integration allow us to handle orders ranging from one to 100,000 packages within 24 hours. While producing small batches is straightforward, managing hundreds of small orders efficiently is a greater challenge — one that automation helps solve.”

Final Thoughts
We thank Nowakowski for his detailed insights into the transformative role of digital die cutting. Check out the full panel discussion here.

Contact us today to learn how we can help you overcome challenges, drive growth and meet the evolving demands of your customers.

• Get more information about Highcon’s solutions
• Reach out directly for an in-depth discussion on how Highcon can transform your business

The post From Concept to Box: Digital for Packaging Production first appeared on Highcon.

In the fast-evolving packaging industry, staying ahead demands packaging innovation, efficiency and sustainability. Schumacher Packaging, a family-owned leader specializing in customized corrugated packaging and solid board, embodies this approach. With over 29 sites across Europe, Schumacher  Packaging has consistently invested in advanced technologies to meet the shifting demands of the market.

A pivotal step in this strategy was the installation of the Highcon Beam 2C digital die cutting system at Schumacher Packaging & Display in Breda,  The Netherlands, in August 2022. This decision has transformed their production capabilities and opened up new avenues for business growth. The integration of the Highcon Beam 2C is part of Schumacher Packaging’s broader strategy to maintain its leadership in the European packaging market, positioning the company for continued growth and innovation.

Enhancing Production Capabilities

Schumacher Packaging’s commitment to innovation is driven by CEO Björn Schumacher’s vision of digital technology revolutionizing the packaging industry. Recognizing the need for shorter runs, faster cycle times, and quicker turnarounds, the company has heavily invested in digital production to stay ahead of market trends. The Highcon Beam 2C plays a crucial role in this strategy, enabling the company to handle complex projects with efficiency and precision.

On their website, Schumacher describes the benefits of digital die cutting technology: “No tools are required for the subsequent die cutting with the laser. Neither wood, metal nor rubber are used, which are required for the production of a conventional cutting die. And there is also no need for transport and storage. This saves material, costs, and time.” This reduction in setup time and material usage not only improves production efficiency but also aligns with the company’s broader sustainability goals.”

Unlocking New Business Opportunities

The Highcon Beam 2C has been transformative for Schumacher Packaging, especially in projects requiring quick turnarounds. Its fully digital workflow, including patented DART (Digital Adhesive Rule Technology) and contactless laser die-cutting, allows for the efficient production of customized packaging that were previously impossible with traditional methods. This has been particularly advantageous in the fast-moving consumer goods (FMCG) sector, where agility is essential.

“The Beam 2C closes the gap between design creativity and production capability and takes digital punching and creasing to a new dimension of added value – both for us and for our customers,” states the company. This digital workflow enables Schumacher to run more jobs per shift, offering shorter run lengths with no minimum order quantities (MOQs), providing brands with the flexibility needed to remain competitive.

A standout example is the creation of an award-winning, candy-shaped packaging featuring a detailed winter landscape. This intricate design, which earned Schumacher Packaging a gold award at the Display Superstar Award 2023, was made possible by the precision and flexibility of the Beam 2C laser die-cutter. “Their production was only possible digitally using the Beam 2C laser die-cutter,” notes Schumacher, highlighting the unique possibilities enabled by digital die cutting and creasing.

Commitment to Sustainability

Sustainability is at the heart of Schumacher Packaging’s operations. The company has made significant investments in renewable energy and resource-efficient technologies across its European sites. The Highcon Beam 2C supports these initiatives by enabling the use of lighter-weight boards, reducing material consumption, and minimizing the carbon footprint of their products. By eliminating the need for traditional cutting dies, the Beam 2C also contributes to waste reduction and enhances the environmental responsibility of Schumacher Packaging’s processes.

“On our way to climate neutrality, we want to further advance the digitalization of our production processes. For this reason, we have installed the first Highcon Beam 2C laser die cutter for corrugated packaging at our display plant in Breda,” Schumacher Packaging states. “This commitment to digitalization not only supports sustainability but also positions Schumacher Packaging as a leader in the transition to more environmentally friendly production methods.”

The installation of the Highcon Beam 2C laser die cutter at Schumacher Packaging’s Breda facility has proven to be a transformative move, enhancing production efficiency, unlocking new business opportunities, and reinforcing the company’s commitment to sustainability. As Schumacher Packaging continues to grow and innovate, the partnership with Highcon will undoubtedly play a crucial role in driving the company’s future success.

Let us help you stay ahead of the curve. Explore our cutting-edge digital die cutting solutions and see how Highcon can contribute to your success.

• Get more information about Highcon’s solutions
• Reach out directly for an in-depth discussion on how Highcon can transform your business

The post Transforming Packaging with Highcon: A Schumacher Packaging Success Story first appeared on Highcon.

THIMM, a leader in innovative packaging solutions, recently secured impressive wins at the OBAL ROKU 2024 National Competition for Packaging Innovations and Design. The jury, comprised of experts, evaluated entries based on innovation, functionality, technical processing, design, and sustainability. Among THIMM’s triumphs were two standout packaging solutions—G(o)rila Box for Orkla Foods Czech Republic and Slovkia and PSINA for SpokojenyPes.cz—both created using Highcon’s cutting-edge digital die-cutting system.

As one of Highcon’s early adopters of the Highcon Beam 2C in Všetaty, Czech Republic, THIMM has utilized digital cutting and creasing to transform corrugated packaging. Their success at OBAL ROKU demonstrates how Highcon’s innovative technology powers creative, functional, and sustainable packaging.

Premium Presentation Package for Orkla Foods

For Orkla Foods, THIMM designed a premium presentation package that  impresses with aesthetic appeal, provides a high level of content protection and reinforces brand identity. The combination of digital printing and laser cutting resulted in a detailed design that creates an exceptional marketing tool that promotes the company’s image and helps to increase sales.

“The dominant element of the package is the logo and slogan “Let’s Gorilla!, laser cut into the corrugated cardboard, ensuring precise lines and a unique texture. Underneath the die-cut logo is a layer of colour that highlights these elements and adds a dynamic look,” according to the THIMM team. “The package includes corrugated cardboard fixings for stability and product safety during transport. All materials used are fully recyclable.”

Durable, Functional and Visually Appealing PSINA Board Game Packaging

The PSINA board game packaging brought a playful, fresh approach to the world of board games. Its attention-grabbing design makes a statement from the first glance, with moveable eyelets on the lid that immediately draw attention. The game components, shaped like paws, add a unique character that complements the fun and interactive nature of the product. Beyond its visual appeal, the packaging provides full protection for the game pieces while displaying the contents in an eye-catching manner. It’s environmentally friendly and an excellent platform for conveying brand messaging.

“The fixation of the elements has a dog paw design, which emphasizes the game’s theme and ensures that the elements are safely stored during transport,” says the THIMM team. “For a perfect impression, a print was created using the digital printing method, which fits perfectly with the game concept. To further increase the appeal and 3D effect, dog paws and tongue were added to the lid of the packaging. And as a unique feature, moving eyes were also added to give the game owner a surprise and add a dynamic dimension to the cover.”

THIMM’s award-winning designs showcase the potential of creative, sustainable packaging, all made possible by Highcon’s digital die-cutting technology. Their ability to merge functionality with eye-catching design has set a new standard for what’s possible in packaging innovation.

Interested in transforming your packaging with innovative digital die-cutting solutions? Reach out to learn how Highcon’s solutions can help you deliver creative, sustainable, and efficient packaging solutions for your brand. Discover the future of packaging today!

Connect with us

• Get more information about Highcon’s solutions for corrugated
• Reach out directly for an in-depth discussion on how Highcon can transform your business

The post THIMM’s Award-Winning Packaging Solutions with Highcon Technology first appeared on Highcon.