by Industrial Print Magazine Staff
From order management to production planning and inventory control to quality assurance, the latest corrugated software can improve efficiency and productivity, enhance customer experience, and eliminate redundancy.
Above: Ablebox enhanced its operational capabilities and sustainability by partnering with ePS Packaging.
With three manufacturing facilities across the South of the U.K., Ablebox is a leading innovator in the U.K. corrugated packaging industry. The company has significantly enhanced its operational capabilities and sustainability through a strategic partnership with ePS Packaging, specifically by utilizing the Escada system. This collaboration has transformed the company’s production metrics, achieving efficiency gains, waste reduction, and improved product quality.
Ablebox serves a range of industries including food and beverage, pharmaceuticals, and fast-moving consumer goods. The company is committed to pioneering sustainable and superior quality packaging solutions.
Solving Challenges
Ablebox’s partnership with ePS Escada corrugated technology drives innovation in corrugated packaging manufacturing, as it continues its journey of technological transformation and utilizes artificial intelligence (AI) to enhance the corrugated board and box making process.
Prior to the integration of Escada, Ablebox faced challenges with optimizing its J.S. India Machine JET 300 double wall corrugator, which was commissioned in late 2020.
The company was looking to enhance high-volume output, ensure consistent product quality, reduce production waste, and decrease operator dependency to streamline operations in a highly competitive market.
The solution was to implement Escada’s corrugator quality and process control system. The decision was influenced by ePS’ proactive support and collaborative approach in tailoring solutions to meet the packaging provider’s specific needs.
“Escada’s technology is a game changer, introducing advanced automation capabilities that refine production processes and dramatically improve operational efficiency,” states Jack Lloyd, managing director, Ablebox.
The specific technologies implemented at Ablebox include Escada Profile, which is a closed-loop process control system with laser bar, and Escada Synchro 7, a single-point corrugated control system.
Escada Profile redefines corrugator performance by delivering improved repeatability and consistency in reducing variation in the production process. The system decreases warp and delamination issues and ensures waste reduction of typically 0.5 percent, resulting in substantial cost savings and a more sustainable approach to production. Additionally, Profile optimizes starch consumption, leading to starch reductions of up to 25 percent.
Escada Syncro maximizes efficiency and productivity by integrating corrugator dry and wet end operations. It covers every phase of corrugator application, from the roll stands through to the take-off conveyors. Syncro Dry End Control connects your production planning system with your dry end machinery, automatically aligning orders and performing efficient automatic order changes at maximum speeds. Syncro Wet End Control provides a complete range of functions, some of the integrated modules include butt roll calculation and display, end-of-roll splicing, splice removal, automatic bridge contents control, bridge contents validation, and synchronized splicing.
Synergy at Work
Implementing Escada technology at Ablebox resulted in impressive results that were proven within a matter of months of installation.
The company saw a 30 percent increase in output, optimizing production flow; a 30 precent reduction in production waste, bolstering environmental sustainability; and a 15 percent increase in conversion efficiencies and throughput thanks to the consistent production of flat, high-quality board.
“These enhancements not only streamlined operational workflows but also significantly alleviated the physical and mental load on facility operators, creating a more productive and supportive work environment,” adds Lloyd.
Ablebox views ePS Escada as an integral partner for ongoing technological advancements. The focus is on further automating and refining processes and using AI as a way to maintain leadership in the corrugated packaging sector. Continuous improvements are aimed at scalability and sustainability.
“The synergy between Ablebox and ePS Escada sets a high standard in the industry, showcasing the transformative potential of integrated technology in manufacturing. The successful deployment of Escada systems within our operations exemplifies industry-leading innovation in process optimization and environmental responsibility,” adds Lloyd.
Transforming Operations
Ablebox’s implementation of ePS Escada was pivotal to the transformation of its operational dynamics. The Escada system helps enhance its production capabilities and advance its environmental and sustainability goals.
“This partnership equipped us to better meet customer demands and tackle industry challenges head on. We eagerly anticipate continued collaboration with the Escada team as we explore further technological enhancements in corrugated packaging,” concludes Lloyd.
Apr2026, Industrial Print Magazine
