Extensive laboratory tests were carried out on new products from a carton board manufacturing group to determine the optimal creasing parameters for the entire range of grammages. The results were presented at a workshop, and staff from all departments were trained in the processes involved in folding carton production and in the key quality requirements of carton board.

(Troubleshooting, Packaging optimization)

An increasing problem, ranging from tears of a few millimeters to complete rupture, was observed with print-mark-controlled aluminum foils for tablet blister packs on several different, but structurally identical packaging machines. The machines and the aluminum foils had been used unchanged over a period of many years without any problems. The possible cause of the tearing was eventually found after extensive and complex troubleshooting involving microscopic tests undertaken at Munich University of Applied Sciences. As a result, the client was able to prepare a facts-based complaint and solve the quality problem.

Support for the FFI association in various projects:

• Leading a project group tasked with revising the DIN 55 437 series of standards (assessment of the creasability of carton board)
• Technical training in the processes of carton board and folding carton production for employees from member companies
• Conducting a project on the runnability of folding cartons in packaging machines
• Data collection and evaluation for the implementation of a carton board database
• Technical advice to member companies in cases of complaints

(Process design and simulation, Packaging optimization, Material selection, Sustainability)

On behalf of an internationally active pharmaceutical company, a new, fully automated secondary packaging system (platform system) was developed which would consider the foreseeable expansion of the portfolio. The cost of implementing the new system was coordinated with various packaging material manufacturers (folding cartons, package leaflets, adhesive labels). A number of different packaging machine manufacturers were asked to put forward their designs for machines. In collaboration with the client a rating matrix was generated for the packaging system and the proposed packaging machines. This enabled us to identify a future-proof and cost-effective packaging material/machine combination.