How can we reduce scrap rates and improve efficiency in express box production through process improvements?
Release Time : 2025-12-31
In the production of express boxes, reducing the scrap rate through process improvement is a core aspect of enhancing enterprise efficiency. Fluctuations in the scrap rate not only directly relate to explicit costs such as raw material loss and energy consumption, but also imply implicit losses such as reduced equipment efficiency and increased labor costs. Therefore, a systematic improvement plan needs to be constructed from seven dimensions: raw material processing, molding process optimization, application of intelligent equipment, standardization of production processes, improvement of quality inspection systems, employee skills training, and innovation in recycling models.
Raw material processing is the first hurdle in express box production. In traditional processes, recycled waste cardboard boxes require multiple processes such as crushing, deinking, and bleaching before repulping. However, residual impurities such as tape and ink can easily lead to a decrease in pulp fiber strength. By introducing fiber separation technology, long and short fibers can be precisely classified during the pulping stage, strengthening the interweaving force between fibers and improving the bursting strength of recycled cardboard. Simultaneously, customized mixing equipment is used to adjust the fiber ratio according to the intended use of the cardboard box, meeting both lightweight requirements and ensuring load-bearing performance, thus reducing waste caused by insufficient material performance at the source.
Optimizing the forming process requires focusing on the production stages of corrugated cardboard. Traditional corrugated roll designs often result in uneven corrugation height, affecting the cardboard's compressive strength. By adjusting the tooth profile parameters of the corrugated rolls, precise control of the corrugation height can be achieved, allowing the cardboard to maintain compressive strength while reducing thickness. Furthermore, improvements to the lamination process are equally crucial. Using hot melt adhesive instead of traditional starch adhesive, coupled with an automated gluing system, ensures uniform adhesive layer coverage and precise application, preventing cardboard delamination due to weak adhesion. In the die-cutting stage, introducing high-speed automated die-cutting machines and using laser positioning technology achieves precise cutting, reducing waste caused by dimensional deviations.
The widespread adoption of intelligent equipment is a vital support for reducing scrap rates. Automated production lines integrate sensors, machine vision, and AI algorithms to monitor key parameters such as cardboard thickness and moisture content in real time, and dynamically adjust production parameters to ensure product consistency. For example, in the printing stage, intelligent printing machines can automatically identify pattern positions, avoiding waste caused by printing misalignment; in the gluing stage, robotic arms working with high-precision servo motors can achieve precise control of adhesive application and gluing position, reducing quality problems caused by operational errors. Standardization of the production process is fundamental to reducing human error. By developing detailed work instructions that clearly define the operational procedures and quality standards for each process, waste caused by arbitrary operations can be reduced. For example, in the cardboard stacking process, specifying the stacking height and spacing of each layer prevents deformation caused by compression from affecting subsequent processing. In the finished product inspection process, establishing graded inspection standards allows for the rework and repair of products with minor defects, rather than direct scrapping, thus improving resource utilization.
A robust quality inspection system must be implemented throughout the entire production process. Introducing online testing equipment, such as thickness gauges and burst strength testers, provides real-time feedback on product quality data, offering a basis for process adjustments. Simultaneously, establishing a quality traceability system, using QR codes or RFID tags to record the production batch, raw material source, and test results for each batch of products, allows for rapid identification of the cause in case of problems, preventing batch-wide waste.
Employee skills training is a crucial guarantee for the implementation of process improvements. Regularly organizing training for operators on equipment maintenance, quality standards, and emergency handling enhances their understanding and execution capabilities regarding process parameters. For example, simulating fault scenarios trains employees to quickly troubleshoot problems, reducing production interruptions and increased waste caused by equipment downtime.
Innovative recycling models can further reduce waste rates. Establishing a waste sorting and recycling mechanism allows minor, repairable defects to be reprocessed into lining materials or cushioning pads, maximizing resource utilization. Simultaneously, collaborating with downstream customers to promote reusable parcel boxes reduces waste per packaging use through multiple applications, lowering production costs while complying with environmental policies.