Software upgrade project at DS Smith Launceston sees improved corrugator performance

DS Smith needs little introduction. As one of the largest vertically integrated paper and corrugated packaging producers in the world, the company has grown significantly over many decades through acquisition as well as building state-of-the-art greenfield plants. With a geographic spread that encompasses Europe and North America, the company prides itself on producing a fully sustainable and recyclable packaging product, in the form of corrugated board packaging.

Award winners

Located in Cornwall in the south-west of England, DS Smith runs an award-winning corrugated board plant in the small town of Launceston. It is well known in the industry for designing and manufacturing high end and niche packaging solutions for a wide range of industries, but is particularly noted for producing insulated and water-resistant trays for the shipping of fresh and chilled fish. The facility is a typical “legacy” plant, which has had to be adapted over the last few decades to allow it to accommodate faster and wider equipment.

Invariably, with equipment that has been running for some time, issues start to arise. On the combination MedesaFosber corrugator, the company was looking to increase the overall speed of the line, while keep an eye on reducing waste. “ We were starting to see warp and delamination figures rising as we started to increase operating speeds, ” explains Shane Hooper, corrugator - waste coordinator, DS Smith Launceston.

“We needed to get these two processes under control, a major part of which was through temperature setting and more importantly our knowledge and understanding around the hotplate shoe control settings. We identified that there was a knowledge gap and with team planning, our discussions focused on where we could improve and upgrade our system if this was deemed necessary for improvements.” So began detailed discussions with eProductivity Software Escada, allowing Shane Hooper and his team the time and level of detail needed to assess the various options and solutions. “We arranged a full site audit, which resulted in a report from the team at eProductivity Software Escada on what options were available to us,” continues Hooper.

A full site and comprehensive system audit is a specific service offered by eProductivity Software Escada that is tailor-made to help customers identify key areas of improvement around the corrugator and processes. So began detailed discussions with eProductivity software Escada, allowing Shane Hooper and his team the time and level of detail needed to assess the various options and solutions. “We arranged a full site audit, which resulted in a report from the team at eProductivity software Escada on what options were available to us,” continues Hooper.

This service leverages all of the eProductivity Software team’s collective experience with optimising corrugator productivity, to help identify improved working practices and deliver a comprehensive list of actions customers can make to improve their machine performance and productivity. “With this detailed document, we fully understood what we needed to do,” says Hooper. “Once we started the ball rolling on planning and project implementation, it really did not take that long for eProductivity Software Escada to deliver and install.”

The project was broken down into several key areas, including training, equipment upgrades, process control enhancements– all centred around eProductivity Software Escada Syncro 7, a single point corrugator control system that can cover everything from roll stands through to take-off conveyors. Syncro 7 ensures harmonious operation through flexible interfaces to any mixture of machines, delivering maximum performance every time. 

The shoe control mechanism was also improved, giving the corrugator team at DS Smith Launceston more control in the hot plate section. It did not take long for eProductivity Software Escada to install everything, once the project plan was agreed.

“Essentially, it took a weekend to install the software and complete the measurement review,” explains Hooper. “eProductivity Software Escada were then on site for three days after this to adjust settings and watch the running process to see the shape of the board.

We then had a gap of around six weeks where eProductivity Software Escada let us watch our own system and report back any issues we had before coming back to site to go over the training and tweak the system further. These final adjustments took an additional three days or so.”