The main challenge: transforming outdated systems into a high-efficiency production line

A client in the former Soviet Union specializing in liquid packaging and folding cartons faced a significant challenge: their existing production processes were outdated and unable to meet the high production volumes required. With old equipment and an inefficient production process, they struggled to meet demand, which slowed production and increased costs. The client needed a solution that would triple their production capacity and improve the quality of their packaging while keeping costs manageable.

This led them to approach Madern with a clear question: How can we boost our capacity, reduce operational costs, and improve product quality to future sustainable standards?

 

A fully integrated RDC-system from Madern

Madern provided the client with a complete solution: a fully integrated Rotary Die Cutter (RDC) system and spreader-stacker system. This system offered the unique advantage of purchasing all the necessary equipment from a single supplier. This ‘one-stop-shop’ approach was crucial for the client, allowing them to reduce the complexity of working with multiple suppliers and ensure seamless integration of their systems.

Previously, the client worked with separate suppliers for the Rotary Die Cutter, stacker, and spreader. Now, Madern offers an all-in-one system in a turn-key project delivery which significantly improves efficiency and consistency. The system was customized to fit the client’s budget while meeting all production requirements.

Results: increased capacity and reduced waste

Thanks to Madern’s solution, the client now operates with an optimized production process and significantly higher output. Their production capacity has tripled, leading to a substantial reduction in waste. The high-quality Rotary Die Cutter, equipped with advanced tooling, ensures more consistent product quality. Every step of the packaging process is precisely aligned, resulting in a uniform, high-quality product.

Additionally, the new system is more sustainable and reliable, increasing the overall equipment efficiency (OEE) and contributing to a more hygienic production process.

 

A customer-focused approach with attention to detail

Our collaboration with the client began six years ago and has since grown into a successful partnership. What makes this project unique is the location and the dynamic between the various parties involved. Thanks to our expertise, track record, and previous successful implementations in the region, Madern was able to provide a solution tailored to the client’s specific needs, even in a more remote location like Kazakhstan.

The client expressed confidence in our approach and was particularly pleased with the solution Madern provided. They appreciated the simplicity of working with a single supplier and the seamless integration of the various systems. This trust has led to a position wherein we continue to play a crucial role in their expanding ambitions.

 

A sustainable solution for the packaging industry

This specific case highlights how Madern offers innovative post-press, customer-centric solutions that meet technical requirements and fit within the client’s budget and business goals. With our in-depth market knowledge and ability to integrate complex systems, we continue to be a reliable partner for companies worldwide within the Packaging Industry.