by Melissa Donovan
One of digital’s biggest strengths is cost-effective short runs and personalized packaging, especially in the corrugated space. Versioning, quick response (QR) codes, serialization, and regional graphics—the amount of data any of these campaigns include must be organized correctly. Software solutions are designed just for this, making unique packaging possible without slowing down production.
Above: With over 70 configurable modules HiFlow tailors its software to fit each packaging business.
Mariusz Sosnowski, CEO, HiFlow Solutions, believes that personalization, versioning, and short-run production has transformed software from a production support tool into a critical operational platform.
“Traditionally, corrugated MIS software focused on estimating, scheduling, inventory management, and production tracking. Today, digital corrugated workflows must manage thousands of product variations, artwork versions, customer-specific graphics, QR codes, and market-specific packaging requirements. As a result, workflow software has become the central system connecting sales, estimating, prepress, production, logistics, and quality control,” continues Sosnowski.
Modern workflow software automates variable data and much more before a job even reaches the printer.
Software makes it possible to print thousands of unique packages without even slowing production.
“Instead of manually creating and managing individual jobs, software allows for linking product specifications, approval status, and production parameters under one job number. Variable data records, serial numbers, QR codes, and regional content can be merged automatically into print-ready files and delivered directly to the digital front end,” shares Sosnowksi.
Today’s solutions are tasked with monitoring all of this data, which Sosnowki admits is probably the biggest challenge. Manufacturers have to ensure the correct artwork is linked to the correct SKU, all QR codes and serialized data are unique and compliant, regulatory information matches the target market, regional languages and graphics are correct, customer approvals are current, and production operators always receive the latest approved version.
“Without workflow automation, these tasks become highly error prone. A single outdated artwork file or incorrect version can result in costly reprints, wasted material, recalls, or compliance issues. The challenge grows exponentially as the number of SKUs increases, making automated version control, approval management, and traceability essential,” says Sosnowksi.
To minimize errors such as these from occurring, workflow systems offer a controlled and trackable process from order entry to production. Solutions include automated workflow validation, barcode and QR code tracking, version control, production scheduling rules, MES data collection, and real-time production feedback.
With these tools in place, Sosnowksi believes that there is a “significantly lower risk of printing the wrong SKU, wrong language version, or outdated artwork.”
Artificial intelligence (AI) is another tool that modern workflow solutions rely on to reduce errors. Its role in corrugated package production printing is increasing, especially as personalized, customized output is preferred.
“Within digital corrugated production specifically, AI is increasingly used for automated file preparation, quality inspection using computer vision, adaptive color management, predictive maintenance of digital printheads, detection of workflow bottlenecks, and automated data extraction from purchase orders and customer documents,” lists Sosnowksi.
In the future AI will be used in different ways, according to Sosnowksi. “It will move from providing recommendations toward semi-autonomous and eventually fully autonomous workflow decisions, further reducing manual intervention while increasing production efficiency.”
Modern Solutions
Advantive’s Advantzware is a mid-market ERP software for packaging manufacturers that need to automate estimating, scheduling, inventory, and order-to-cash across corrugated, folding carton, point of purchase, paperboard, and foam fabrication operations. The solution offers a centralized database and integration to optional modules like ecommerce, CRM, and scheduling.
Amtech Software connects quoting, scheduling, and the plant floor in one solution. EnCore ERP is the main system, built specifically as an ERP for corrugated sheet plants and integrated manufacturers. EnCore supports high-volume, high-complexity production environments with full operational visibility. Advanced Planning Board is AI-assisted scheduling that helps build better machine lineups with less manual effort.
ScoreKeeper offers real-time machine monitoring to improve performance and reduce downtime on any machine—even older ones. Automated Performance Costing helps understand job profitability using cost models that match how a plant really runs.
Fiery, LLC offers technologies with variable data printing capabilities that easily fit into any workflow. Fiery FreeForm Create is a free, standalone application that makes it easy to add personalization to any print job. Add variable text, images, QR codes, and barcodes to files in minutes to create impactful, customized pieces that connect with customers. Seamlessly integrated with Fiery servers, it’s the fast, free way to add value to every print. It offers data preflight as well as smart barcode detection.
From the onboarding of a job through final invoicing and shipping, HiFlow MIS/MES is the umbrella that covers an entire business and production ecosystem. With over 70 configurable modules HiFlow tailors its software to fit each unique packaging business. HiFlow integrates product management, job management, artwork status, production planning, MES functionality, and data collection into a single environment. The goal is to ensure that every department works from the same approved information while maintaining full visibility and traceability throughout production.
Recently, HiFlow introduced an AI-powered invoice processing module. It helps reduce manual invoice entry by capturing data from PDF invoices received via email and populating key invoice fields within the HiFlow ERP system, including line items, quantities, amounts, purchase order numbers, and vendor information. Prepared invoice data then moves into HiFlow’s standard Accounts Payable workflow for matching, approval routing, and posting.
Supporting Print
Brands demand more personalized packaging, which influences software’s role in digital corrugated production. Today’s workflow solutions are tasked with managing data through the entire process, from prepress to final print and beyond.
Oct2026, Industrial Print Magazine
