When Germany-based corrugated packaging specialist Carl Eichhorn identified that waste issues were impacting its success, the company naturally turned to SUN Automation Group®, a recognised leader in the global corrugated sector, to help.

Already a happy customer of SUN Automation, it was the quality of SUN’s products specified in its other installations that encouraged Carl Eichhorn to seek a new solution from SUN – in the form of the innovative MicroGrind® die cut accuracy system. MicroGrind provides a big advantage for box plants that need accurate and consistent crease, score, and perforation in order to facilitate fault free auto-fill and shelf presentation in corrugated packaging.

Established 160 years ago in 1855, Carl Eichhorn is even today owner-managed by a fifth generation of family members. Technical Manager at Carl Eichhorn, Martin Keirath, explained: “We are more than just service providers and focus on forming lasting partnerships with our customers. Every customer has different requirements, so we individually tailor products to their needs.”

The company identified that the die cutting system installed on its Gopfert 16/28 Evolution from 2001 was producing an unacceptable level of waste and sometimes jamming up, resulting in customer complaints and costly downtime. By installing the MicroGrind die cut accuracy system, Carl Eichhorn was not only able to reduce its waste but also produce much better quality boxes for its customers. Additionally, the requirement to rotate anvil covers weekly was completely removed, increasing production time still further.

Martin Keirath added: “Since we installed SUN Automation’s MicroGrind on our rotary die cutter our waste issues have been almost eliminated – something that is very important to us as we are committed to maximising our environmental credentials. Customer satisfaction is of paramount importance and this has greatly improved with the better quality of cut and very accurate scoring facilitated by the new MicroGrind. We are very pleased with the results and I would not hesitate to recommend SUN Automation and its machinery to other converters”.

Rob Dal Lago, SUN Automation’s General Manager EMEA, added: “We have a long-standing relationship with Carl Eichhorn and, as with all our customers, constantly endeavor to provide the best machinery solutions to resolve any issues that are hindering productivity and profitability. MicroGrind is a unique proprietary innovation and is quickly becoming the preferred system for converters worldwide with over 600 units installed to date. We’re delighted to see another happy customer reaping the benefits.” 

MicroGrind is available as an upgrade for existing machines, as well as for almost all new machine models in the market including top anvil machines. It uses a tungsten carbide roll to grind the anvil flat and true, allowing the surface to be treated in micro amounts automatically with precision, without operator intervention. By utilising a full-width grinding roll engaged systematically against the entire anvil surface, and then adjusting the anvil speed, box makers can significantly advance the quality and productivity of their rotary die cutting machines.

Consistently smooth anvil covers which perform ‘as new’ during their entire life assure clean cuts and perforations, thus appreciably easing scrap issues. Rejections and returned boxes are significantly reduced as breaker and packing machines are able to run smoother at higher speeds with minimal jams.

More brands than ever are turning to retail ready packaging. This is placing pressure on box plants to transition to high-output rotary die cutters that increase production and ensure maximum quality. MicroGrind assists with this transition and facilitates the step-up in quality required to meet this high demand of retail ready packaging.