by Melissa Donovan
End-of-line automation eliminates the extra person manually cutting or moving material at the conclusion of a print job. Corrugated board is prime for automation. Its unwieldy, unpredictable construction leaves room for error. End-of-line automation eliminates material challenges and allows for complex jobs being handled with ease.
Above: Advanced feeding/stacking with the Zünd BHS180 Board Handling System.
Useful Options
Automation frees up press operators for other tasks. In a corrugated printing environment, end-of-line automation options include mechanisms like material feeders and stackers, robotic arms, conveyors, and intuitive software.
“Feeders and stackers reduce labor dependency, enhance workplace safety, and eliminate inconsistencies caused by fatigue, human error, or skill differences,” explains Steven Lueders, co-owner, Infinite Motion Control (IMC).
Using automation, stronger return on investment is achieved through higher output and reduced waste, states Lueders. Take for example IMC’s Vector Feeder. Adding it to a digital printing line increases production throughput up to 60 percent while maximizing equipment uptime, according to the company.
“Pre-feeders, stackers, conveyors, bundle forming, palletizing, and inline inspection keep production continuous, efficient, and consistent,” lists Rob Casella, technical director, SUN Automation Group.
Cutter extensions as well as robotic picking and sorting devices can keep material consistently moving and free up operators from repetitive handling tasks, shares Martin Thornton, packaging business development manager, Zund America, Inc. “This lets teams redeploy labor to areas where operators add the most value, while also improving process reliability, throughput, and overall equipment efficiency.”
Collaborative robot (co-bot) solutions designed for Zünd by Robotfactory include the Robot PortaTable 130, which automates the removal of cut materials. This co-bot works side by side with the operator and takes on loading/unloading tasks—including picking and sorting—as needed. The Robot PortaTable 130 is extremely flexible. Thanks to its mobility, it can quickly and easily be repositioned around the machine or moved from one Zünd cutter to another.
According to Nimil David, product manager, robotics and automation, Kongsberg Precision Cutting Systems (PCS), automation is closing the gap when it comes to lost revenue. “True productivity is defined by how continuously the knife or blade of the digital cutting table is in the material. In other words, how long production is actually ‘live.’ If the machine sits idle while an operator loads or unloads a sheet, that’s lost revenue.”
Automation tools eliminate human error and ensure precision with every cut, explains David. Kongsberg PCS offers end-of-line automation for cutting tables with its Feeder & Stacker and Robotic Material Handler. Also helpful, a vision system with top and under side cameras that simplifies operations for print side down applications and scans registration marks or barcodes to automatically pull up correct digital files.
Specialty Media
For corrugated board in particular, end-of-line automation is important. It keeps production moving and avoids errors that can occur when manually handling the material.
Since the material “is large, unwieldy, and often processed in higher volumes” it makes “manual handling inefficient, inconsistent, and physically demanding,” notes Thornton.
“Automation reduces the risk of damage that often occurs during manual handling, while also ensuring a consistent throughput. By automating the end of the line, shops remove the physical strain on their workers while ensuring every crease and fold is perfectly aligned,” explains David.
Automation plays a crucial role in the corrugated industry, says Lueders. It does so “by converting production from a fluctuating, operator-dependent process into a predictable and repeatable process from job to job and shift to shift. This creates more reliable delivery schedules and boosts confidence in meeting deadlines, ultimately improving overall operational consistency and performance.”
“Corrugated production is high volume, heavy, and fast paced. Automation keeps lines moving smoothly, prevents bottlenecks, ensures consistent stacking, and reduces intensity,” adds Casella.
Solution Sets
Corrugated board benefits directly from automated solutions like feeders, conveyor belts, and cameras found on finishing hardware.
A feeder is vital, insists Lueders. “It reliably de-stacks warped sheets from distorted pallets and presents them flat to printers or cutters by holding the front edge until the machine takes control. This is especially important because almost all types of corrugated cardboard—single wall, double wall, or recycled—are affected by temperature and humidity, which can cause warping. Even corrugated plastic can weaken in moist conditions.”
Pre-feeders, stackers, conveyors, strapping, inspection, and palletizing are all key automated solutions for corrugated, lists Casella. “Together, they enable continuous flow, consistent output, and reduced labor, improving efficiency and reliability.”
“Automated feeding and stacking are essential because they remove the biggest bottlenecks—loading large, unwieldy sheets and efficiently managing finished stacks. These solutions ensure consistent, uninterrupted production and allow operators to focus on quality and process management rather than material handling,” says Thornton.
Things to look for in a solution designed for corrugated board, suggests David, are features that reduce damage while handling the sheets, are able to deal with warps, and support preventing any interruptions in the operation.
According to David, in a corrugated workflow, the goal is to treat the cutting table like a high-speed production factory. “By combining sheet feeders and cameras, you remove the biggest obstacles brought by manual operations—physical exhaustion, alignment errors, and set up delays, which in turn ensures consistent productivity.”
Easy Peasy
Not all solutions are created equal. It’s important to work with reputable vendors when considering implementing an automation solution. The majority of the time these vendors have the staff, training, and tools available to minimize any downtime during installation as well eliminate most of the learning curve.
“The ease of implementing end-of-line automation depends on the equipment being automated, the automation options available for that equipment, and which part of the production workflow the customer wants to streamline,” suggests Thornton.
David suggests businesses considering an investment in finishing automation “ensure their tables integrate with current systems and printer speeds to cause the least disruption to operations.”
For example, Kongsberg PCS automation solutions are modular, which allows for ease in adding a loading or loading/unloading solution to an existing Kongsberg PCS cutting table. Installation and training is completed in a few days because the products are intuitive in nature.
Due to the modularity of Zünd systems, workflow automation—both in terms of software and hardware—can be added after the fact, even years after the initial installation. “This allows for gradual scaling without having to purchase more than immediate needs dictate, which helps reduce the initial investment in finishing equipment,” adds Thornton.
“Most automation is modular and easy to integrate, with operators typically up to speed in days. Brief downtime may occur during installation, but long-term uptime improves thanks to fewer jams and automated handling,” admits Casella.
IMC’s automation offers a scalable foundation for modular growth, allowing for gradual expansion, one device at a time if desired. The printer or cutter can be upgraded with initial feeding, followed by a stacker, and a flipper for two-sided printing or print-side-down cutting.
An Ally in Business
When we think of automation, minds go to concerns about machines taking over. However, it’s best to think of automation as an ally.
“Automation should not be considered a threat but rather an ally that takes away manual, repetitive tasks so you can focus on more productive and skillful work. For instance, instead of being the worker who simply moves material, you become the person who manages the process and maximizes the potential of the equipment. This allows you to be more creative and engaged. Ultimately, automation helps you work smarter, not harder,” suggests David.
Thornton agrees. “Zünd automation is designed to support operators, not replace them. It tends to make their job easier and takes over the most repetitive, physically demanding material handling tasks so they can focus on quality control, fine tuning operations, and other higher value responsibilities. In most shops, this ultimately makes the operator’s role safer, less strenuous, and becomes essential in maintaining a smooth, consistent production workflow.”
“Automation enhances operators’ roles, replacing repetitive tasks with higher value work in setup, quality control, and optimization. Production becomes safer, less physical, and more technical,” attests Casella.
The possibility for workplace accidents is reduced, as is the risk of injury, when automated feeding and stacking is integrated. Tasks like manual lifting of heavy or oddly shaped, oversized boards is likely eliminated, adds Lueders.
Natural Next Step
No longer a luxury, automating components of the corrugated production process is becoming a necessity. This includes feeders, stackers, robotic arms, and much more that push through the clutter and maximize productivity on the back end.
Jun2026, Industrial Print Magazine
