Customer Voice | Changeover 50% Faster, Efficiency +20%! ESTUN Drives a "Flexible Revolution" in High-End Gift Box Manufacturing

A gift box may seem simple, and many people think "box making" is just "folding and pasting." But the answer may be different from what you expect.

In this edition of Customer Voice, we visit a benchmark packaging machinery enterprise located in the Yangtze River Delta. As a national high-tech enterprise, this company focuses on the R&D and manufacturing of high-end gift box intelligent box-making equipment. It has been deeply engaged in the customized field of 3C mobile phones, high-end jewelry, premium liquor, and tobacco and liquor gift boxes for more than 20 years, with business covering domestic and overseas markets and a broad customer base in the global premium packaging equipment market. The industry has extremely strict requirements for forming precision, surface texture, and corner neatness, allowing no defects. With numerous product categories and frequent specification changes, higher demands are also placed on production management.

In its early years, the customer's production line relied entirely on manual work. In recent years, problems have become increasingly prominent: unstable capacity, with output directly affected by worker proficiency; difficult-to-control manual errors, with positioning offset, uneven glue application, and skewed corner pasting leading to high rework rates and losses. High-end brand orders have strict quality requirements, and minor defects may lead to rejection. Traditional automated equipment, however, adapts to a single box type and has cumbersome changeover debugging, resulting in low efficiency when facing small-batch, multi-style orders. The dual pressure of delivery and capacity has caused development bottlenecks in capacity expansion and quality control.

To break through these difficulties, the customer joined hands with ESTUN to introduce a fully automatic high-speed box-making and corner-pasting integrated solution. With the trinity of self-developed control system, high-precision servos, and flexible recipe management, it provides a one-stop solution to the full-process challenges of premium packaging box making, helping this benchmark enterprise in the packaging industry move toward a new stage of fewer-person and unmanned intelligent production lines, and making China's intelligent manufacturing visible on the global packaging stage.

01

Self-Developed Control System, High-Speed, High-Precision, and Stable Operation

Premium gift boxes have extremely high requirements for forming precision, surface texture, and corner neatness. Positioning offset, uneven glue application, and skewed corner pasting may cause scrapping. ESTUN's fully automatic high-speed box-making and corner-pasting integrated solution specifically meets precision box-making needs:

Self-developed controller and servo system: It adopts the ESTUN Nano controller with customizable cam curves and smooth motion; paired with DX3 series servo high-precision motors, positioning accuracy reaches ±0.2 mm, eliminating skewed corner pasting and uneven bonding, with uniform finished product quality and a high qualification rate.

Full-process automation: The equipment is divided into three parts: gluing and positioning, corner pasting, and forming. It is further subdivided into face paper feeding, automatic gluing, positioning and bonding, edge folding and forming, and pressing and corner pasting. The full process runs automatically without manual intervention.

Touch screen intelligent control: Faults are directly displayed on the touch screen, and single-step debugging is supported. New product trial production, process fine-tuning, and troubleshooting are efficient and convenient, greatly reducing downtime.

02

Flexible Recipe Management, Solving High-Frequency Changeover Challenges

The premium packaging industry has numerous product categories and frequent specification changes. Traditional equipment adapts to a single box type and has cumbersome changeover debugging. ESTUN's solution precisely solves this bottleneck with flexible manufacturing capabilities:

Multi-recipe storage: The equipment can store more than 100 sets of recipes, supports six to seven box-making modes and multiple corner-pasting modes, and can produce boxes with heights from 30 mm to 110 mm.

Multi-material compatibility: Coated paper, specialty paper, and corrugated paper—changing materials does not require changing equipment. One machine covers the process needs of multiple face paper types.

Flexible operation modes: The dual-head forming machine can run at 55-60 pcs/min for box heights below 50 mm. The A and B sides can work independently, and the corner-pasting machine and box-making machine can be linked or operated separately, so neither large nor small orders are delayed.

03

User-Friendly Design, Greatly Lowering Operation and Maintenance Threshold

Traditional equipment has cumbersome changeover debugging, long new product trial production cycles, and troubleshooting that relies on professionals, making production line downtime difficult to control. Starting from the operating experience, ESTUN greatly lowers the equipment usage threshold:

Intuitive fault display: The touch screen directly displays fault information, eliminating the need for professionals to troubleshoot item by item and greatly shortening fault location time.

Single-step debugging support: New product trial production and process fine-tuning can both be completed through single-step debugging without repeatedly starting and stopping the entire line, significantly improving debugging efficiency.

Rapid changeover: The comprehensive improvement of flexible production capability shortens changeover time by at least 50%, perfectly adapting to multi-category and customized orders.

The person in charge of the enterprise said: "The equipment has been running for more than a year, operating continuously 24 hours a day. Capacity has been greatly improved, and the mass production efficiency of small boxes has increased by 20%. Multi-material and multi-specification products are produced stably, the yield rate has increased by 5%, and material loss and rework rates have dropped significantly. Most importantly, the comprehensive improvement of flexible production capability has shortened our changeover time by at least 50%, perfectly adapting to multi-category and customized orders."

From a manual production line to a fully automatic high-speed box-making and corner-pasting integrated solution, from relying on manual labor to flexible intelligent production—the three major industry challenges of "precision, flexibility, and usability" are being solved one by one by ESTUN. In the future, ESTUN will continue to empower the packaging industry with full-chain independent technology, driving China's intelligent manufacturing to grow to greater heights and be seen by more people on the global stage.