DIGITAL PRE-PRINT PAPER, SHEET, AND BOX MANUFACTURING SYSTEMS

• US 20190018629A1
• Filed: 07/12/2018
• Published: 01/17/2019
• Est. Priority Date: 07/14/2017
• Status: Active Grant

• Current Assignee: Georgia Pacific Corrugated LLC (KOCH Industries Incorporated)
• Original Assignee: Georgia Pacific Corrugated LLC (KOCH Industries Incorporated)
• Inventors: Seay, Robert Dennis
• Granted Patent: US 11,449,290 B2
• Time in Patent Office: Days
• CPC Class Codes: B26D 7/27 Means for performing other operations combined with cutting B26D9/00 takes precedence
• CPC Class Codes: B31B 50/006 Controlling; Regulating; Measuring; Improving safety
• CPC Class Codes: B31B 50/16 Cutting webs
• CPC Class Codes: B31B 50/88 Printing; Embossing
• CPC Class Codes: B31F 1/28 combined with uniting the corrugated webs to flat webs ; Making double-faced corrugated cardboard
• CPC Class Codes: B31F 1/2822 involving additional operations
• CPC Class Codes: B31F 1/2831 Control
• CPC Class Codes: B65H 2301/4148 slitting
• CPC Class Codes: B65H 35/0086 using movable cutting elements
• CPC Class Codes: B65H 35/02 from or with longitudinal slitters or perforators
• CPC Class Codes: G06F 3/1204 resulting in reduced user or operator actions, e.g. presetting, automatic actions, using hardware token storing data
• CPC Class Codes: G06F 3/1205 resulting in increased flexibility in print job configuration, e.g. job settings, print requirements, job tickets
• CPC Class Codes: G06F 3/1215 achieving increased printing speed, i.e. reducing the time between printing start and printing end
• CPC Class Codes: G06F 3/1243 Variable data printing, e.g. document forms, templates, labels, coupons, advertisements, logos, watermarks, transactional printing, fixed content versioning
• CPC Class Codes: G06F 3/1251 for continuous media, e.g. web media, rolls
• CPC Class Codes: G06F 3/126 Job scheduling, e.g. queuing, determine appropriate device
• CPC Class Codes: G06F 3/1282 High volume printer device
• CPC Class Codes: G06Q 10/043 Optimisation of two dimensional placement, e.g. cutting of clothes or wood
• CPC Class Codes: G06Q 10/0631 Resource planning, allocation, distributing or scheduling for enterprises or organisations

Abstract

Systems for providing efficient manufacturing of paper, sheet, and/or box products of varying size and structure, often with pre-applied print (“pre-print”), are provided herein. One or more controllers can be used to aggregate orders and information to prepare one or more control plans (e.g., reel maps, reel plans, etc.) for processing a roll of web product through the manufacturing process. The control plan may include a set of instructions for operating one or more systems within the manufacturing process to form the desired finished paper-based product. In such a regard, efficient manufacturing of various paper-based products, including corrugated boxes, folded carton, labels, flexible paper, industrial bags, plates, cups, décor, and many others, can be achieved. Further, efficient customer ordering/tracking, job aggregation, print imposition, corrugator planning, and tracking and adjustments throughout the manufacturing process are contemplated.

Claims

1. A system for controlling manufacturing of one or more paper-based products, the system comprising:

at least one printer configured to print on a roll of web product to form a roll of printed web product;

at least one sheet formation/processing system that includes at least one cutting arrangement that is configured to cut a portion of the roll of printed web product;

at least one controller configured to;

generate a control plan associated with the roll of web product for at least one order from among a plurality of orders for the one or more paper-based products, wherein each order of the plurality of orders comprises at least one design for at least one paper-based product, wherein the at least one design includes one or more printed images, wherein the control plan includes at least a set of first order instructions for forming one or more first paper-based products from the roll of web product for fulfilling a first order, wherein the set of first order instructions comprises first plan instructions for forming one or more first sheet or box structure areas on the roll of web product, wherein each of the first sheet or box structure areas include a first printed image and are used to form the one or more first paper-based products;

provide the control plan to the printer for controlling operation of the printer, wherein the control plan includes printing instructions to control operation of the printer to cause the first printed image to print at a desired position within each of the first sheet or box structure areas on the roll of web product to form the roll of printed web product; and

provide the control plan to the sheet formation/processing system for controlling operation of the sheet formation/processing system, wherein the control plan includes cutting instructions to control operation of the cutting arrangement to cause one or more first sheet or box structures with the first printed image therein to be cut from the roll of printed web product, wherein the one or more first sheet or box structures with the first printed image therein are used to form the one or more first paper-based products for fulfilling the first order.

2. The system of claim 1, wherein the at least one sheet formation/processing system further includes a web formation device that is configured to use the roll of printed web product to form an updated web that includes at least one additional layer of material, wherein the updated web is used to form the one or more first paper-based products.

3. The system of claim 1 further comprising at least one finishing system for performing finishing operations on the one or more paper-based products, wherein the at least one controller is configured to provide the control plan to the finishing system for controlling operation of the finishing system, wherein the control plan includes finishing instructions to control operation of the finishing system to cause the one or more first paper-based products to be formed using the one or more first sheet or box structures.

4. A system for controlling manufacturing of one or more paper-based products, the system comprising:

at least one controller configured to;

generate a control plan associated with a roll of web product for at least one order from among a plurality of orders for the one or more paper-based products, wherein each order of the plurality of orders comprises at least one design for at least one paper-based product, wherein the at least one design includes one or more printed images, wherein the control plan includes at least a set of first order instructions for forming one or more first paper-based products from the roll of web product for fulfilling a first order, wherein the set of first order instructions comprises first plan instructions for forming one or more first sheet or box structure areas on the roll of web product, wherein each of the first sheet or box structure areas include a first printed image and are used to form the one or more first paper-based products;

provide the control plan to at least one printer for controlling operation of the printer, wherein the control plan includes printing instructions to control operation of the printer to cause the first printed image to print at a desired position within each of the first sheet or box structure areas on the roll of web product to form a roll of printed web product; and

provide the control plan to at least one sheet formation/processing system for controlling operation of the sheet formation/processing system, wherein the at least one sheet formation/processing system includes at least one cutting arrangement that is configured to cut a portion of the roll of printed web product, wherein the control plan includes cutting instructions to control operation of the cutting arrangement to cause one or more first sheet or box structures with the first printed image therein to be cut from the roll of printed web product, wherein the one or more first sheet or box structures with the first printed image therein are used to form the one or more first paper-based products for fulfilling the first order.

5. The system of claim 4, wherein the at least one sheet formation/processing system further includes a web formation device that is configured to use the roll of printed web product to form an updated web that includes at least one additional layer of material, wherein the updated web is used to form the one or more first paper-based products.

6. The system of claim 4, wherein the at least one sheet formation/processing system comprises a corrugator that is configured to form corrugated board web using the roll of printed web product, wherein the first paper-based product is a corrugated box with the first printed image.

7. The system of claim 4, wherein the at least one controller is configured to provide the control plan to at least one finishing system for controlling operation of the finishing system, wherein the control plan includes finishing instructions to control operation of the finishing system to cause the one or more first paper-based products to be formed using the one or more first sheet or box structures.

8. The system of claim 7, wherein the at least one controller is configured to determine if the one or more first paper-based products formed by the finishing system satisfies the first order.

9. The system of claim 7, wherein the finishing system comprises a folding device that is configured to fold and glue the one or more first sheet or box structures for use in formation of the one or more first paper-based products, wherein the one or more first paper-based products are one or more folded cartons that each include at least the first printed image.

10. The system of claim 7, wherein the finishing system comprises:

a tubing device that is configured to form the one or more first sheet or box structures into a tube; and

a bottoming device that is configured to form a bottom of the tube for use in formation of the one or more first paper-based products,

wherein the one or more first paper-based products are one or more industrial bags that each include at least the first printed image.

11. The system of claim 7, wherein the finishing system comprises a cup forming device that is configured to form the one or more first sheet or box structures into one or more cups, wherein the one or more first paper-based products are one or more cups that each include the first printed image.

12. The system of claim 7, wherein the finishing system comprises a plate forming device that is configured to form the one or more first sheet or box structures into one or more plates, wherein the one or more first paper-based products are one or more plates that each include the first printed image.

13. The system of claim 4, wherein the at least one controller is configured to provide the control plan to at least one reel editor for controlling operation of the reel editor, wherein the control plan includes editing instructions to control operation of the reel editor to cause one or more portions of the roll of printed web product to be removed.

14. The system of claim 13, wherein the at least one controller is configured to update the control plan based on the one or more portions of the roll of printed web product that were removed.

15. The system of claim 4, wherein the at least one controller is configured to receive one or more of the plurality of orders for the one or more paper-based products.

16. The system of claim 4, wherein the at least one controller is configured to track the one or more first sheet or box structures after formation.

17. The system of claim 4, wherein the at least one controller is configured to determine if the one or more first sheet or box structures formed by the sheet formation processing system satisfies the first order.

18. The system of claim 4, wherein the control plan for the roll of web product includes at least a set of second order instructions for forming one or more second paper-based products from the roll of web product for fulfilling a second order, wherein the set of second order instructions comprises second plan instructions for forming one or more second sheet or box structure areas on the roll of web product, wherein each of the second sheet or box structure areas include a second printed image and are used to form the one or more second paper-based products.

19. The system of claim 18, wherein the first plan instructions and the second plan instructions are configured to cause the one or more first sheet or box structure areas and the one or more second sheet or box structure areas to be formed adjacent to each other in a width direction on the roll of web product.

20. A method for controlling manufacturing of one or more paper-based products, the method comprising:

generating a control plan associated with a roll of web product for at least one order from among a plurality of orders for the one or more paper-based products, wherein each order of the plurality of orders comprises at least one design for at least one paper-based product, wherein the at least one design includes one or more printed images, wherein the control plan includes at least a set of first order instructions for forming one or more first paper-based products from the roll of web product for fulfilling a first order, wherein the set of first order instructions comprises first plan instructions for forming one or more first sheet or box structure areas on the roll of web product, wherein each of the first sheet or box structure areas include a first printed image and are used to form the one or more first paper-based products;

controlling, using the control plan, at least one printer, wherein the control plan includes printing instructions to control operation of the printer to cause the first printed image to print at a desired position within each of the first sheet or box structure areas on the roll of web product to form a roll of printed web product; and

controlling, using the control plan, at least one sheet formation/processing system, wherein the at least one sheet formation/processing system includes at least one cutting arrangement that is configured to cut a portion of the roll of printed web product, wherein the control plan includes cutting instructions to control operation of the cutting arrangement to cause one or more first sheet or box structures with the first printed image therein to be cut from the roll of printed web product, wherein the one or more first sheet or box structures with the first printed image therein are used to form the one or more first paper-based products for fulfilling the first order.