Colorman Ireland installs Bobst’s fully automated folding carton production line

Colorman Ireland has become the first company in Europe to adopt the fully automated ExpertFold 80 line configuration for carton folding by Bobst. The Dublin-based printed packaging and carton manufacturing company says the installation is “a significant step forward in automation.”

The ExpertFold 80 line is equipped with Bobst’s EasyFeeder, designed to handle sheet feeding with “minimal” involvement by an operator, and an AccuCheck that monitors quality throughout the run. 

The line also features an AccuJet that can automatically remove non-conforming cartons, and a CartonPack 4 that automates counting and stacking at the end of the line to lower manual handling for a more consistent and reliable output at pace, Colorman Ireland outlines. 

John Keating, operations director at Colorman Ireland, states: “We wouldn’t consider Bobst a supplier, but rather a key strategic partner. We made the choice to partner with them in kitting out our folding carton division, which is an integral part of the Colorman Ireland business.”

Enhanced quality assurance

Colorman Ireland’s adoption of the ExpertFold 80 line follows its use of Bobst’s earlier ExpertFold 110 folder-fluer. 

Liam Myers, carton manager at Colorman Ireland, comments: “When we bought the ExpertFold 110, we knew we had a good machine, and we wanted to continue the success we’d had with it. Having AccuCheck has made all the difference.”

“We can produce reports, and our customers feel more reassured knowing everything is monitored and recorded. AccuCheck has enhanced our whole quality assurance on the machine. With it, we’re striving for zero-fault packaging,” he continues. 

AccuCheck can further control print, registration, blank integrity, and finishes, such as foil, embossing, and varnish, while detecting minor imperfections, Colorman Ireland highlights. 

Colorman Ireland says that utilizing the hot stamping transfer press has improved production through increased speeds, greater quality, and through Bobst’s AccuRegister system.

Digital Inspection Table

Bobst’s Digital Inspection Table (DIT) operates with the ExpertFold 80 within the same factory ecosystem. Colorman Ireland says it now uses DIT across printing, die-cutting, hot foil stamping, and Braille embossing. 

The company indicates that DIT functions as a validation layer between production stages to make sure every job is checked before it moves forward. 

Myers describes DIT as a “validation piece” that ensures every printed and manufactured job by the company is double-checked before it goes through the next process. 

“For die-cutting, operators use it to confirm correct registration before a job runs. For foiling, it checks that the correct dies are being used and that positioning is right. The operators enjoy using it, and it enhances their overall quality assurance across everything they do,” he explains.

Stuart Alvey-Taylor, sales manager at Bobst, adds: “Colorman Ireland is the kind of partner that brings out the best in what we do. Over nine years, their team has pushed us with sharp feedback on Bobst Connect, with demanding applications for the DIT and with a production environment where zero-fault isn’t a marketing phrase but a daily expectation.”

“Seeing how they’ve built their folding carton divisionwith each investment reinforcing the last, is a source of pride for us. This is what a long-term technology partnership should look like, and we’re committed to being part of whatever comes next for Colorman Ireland.” 

Last month, Bobst updated its Masterfold 170, 230, and 300 folder-gluers for corrugated board converting to improve their safety, connectivity, and production efficiency.

In a recent conversation with Packaging Insights, Bobst told us that digital printing is moving into wider packaging formats such as flexible packaging, folding carton, corrugated board, and shrink sleeves.