Custom Packaging Box Manufacturing via Digital Printing

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Solution Overview

Problem

E-commerce companies face logistical challenges such as inefficient packaging, high storage costs for various box sizes, and issues with mislabeled or damaged packages, which hinder cost-effectiveness and customer experience.

Innovation Solution

A method of manufacturing customized packaging boxes by digitally printing on packaging material before cutting, allowing for minimal stockholding and optimized box dimensions based on merchandise articles, while incorporating machine-readable codes for improved labeling accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If packaging boxes of different predetermined sizes are stocked in large quantities, then various merchandise dimensions can be accommodated, but storage costs and logistic problems increase

Engineering Contradiction:

Improveaccommodation of various merchandise dimensionsVSAvoidstock of packaging boxes

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The patent applies parameter changes by transitioning from discrete, predetermined box sizes to continuous, customizable dimensions. The packaging machine adjusts box parameters (length, width, height) dynamically based on merchandise dimensions, eliminating the need to stock multiple fixed-size boxes while maintaining versatility for all product sizes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system implements dynamics by making packaging box dimensions adjustable and adaptable in real-time. Instead of static, pre-manufactured boxes, the system continuously modifies box parameters according to the specific merchandise being packaged, enabling a single machine to replace multiple fixed-size box inventories.

Inventive Principle:

Principle #15Dynamics

2Reliability

If free space in packaging boxes is filled with filler material, then merchandise is protected, but shipping efficiency decreases due to fewer boxes per delivery vehicle

Engineering Contradiction:

Improvemerchandise protectionVSAvoidshipping efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system changes the dimensional parameters of packaging boxes to minimize free space. By precisely matching box dimensions to merchandise size, the patent eliminates the need for filler material while maintaining protection, and increases the number of boxes that can be loaded per delivery vehicle.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If labels are applied separately to packaging boxes, then labeling can be done, but mislabeled or damaged labels occur

Engineering Contradiction:

Improvelabeling processVSAvoidlabeling accuracy

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges the labeling function with the packaging box manufacturing process. Labels are printed and applied directly onto the box during production, eliminating separate labeling operations. This integration ensures labels are correctly positioned, properly attached, and cannot be misplaced or damaged during subsequent handling.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system performs labeling as a preliminary action during box manufacturing, before the boxes are filled with merchandise and shipped. By printing and applying labels in advance during production, the system prevents labeling errors that would occur later during packing or shipping operations.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If multiple packaging box sizes are manufactured and stocked, then customization is possible, but manufacturing complexity and costs increase

Engineering Contradiction:

Improvecustomized packaging dimensionsVSAvoidpackaging system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs dynamics by implementing a programmable packaging machine that can dynamically adjust to different box dimensions through software control. This replaces the need for multiple dedicated manufacturing lines with a single versatile machine that reconfigures parameters digitally, reducing overall system complexity.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12325546B2Manufacturing of packaging

Publication Date: 2025.06.10 AGFA NV

AI summary

Method of manufacturing a packaging box (8) including the steps of: a) determining minimal packaging box dimensions based on outer dimensions of one or more merchandise articles (19) to be packaged into the packaging box; b) digitally printing an image according to the minimal packaging box dimensions on packaging material (1), such as corrugated card board; and c) cutting and creasing the packaging box from the packaging material according to the minimal packaging box dimensions. A manufacturing line for packaging boxes of different dimensions is also disclosed.