{"id":97801,"date":"2026-07-28T11:00:48","date_gmt":"2026-07-28T09:00:48","guid":{"rendered":"https:\/\/www.converter.it\/?p=97801"},"modified":"2026-07-14T14:29:22","modified_gmt":"2026-07-14T12:29:22","slug":"unleashing-the-full-capacity-of-folder-gluers","status":"publish","type":"post","link":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/","title":{"rendered":"Unleashing the full capacity of folder-gluers"},"content":{"rendered":"

Investing in a high-speed folder-gluer is often seen as the fastest route to increase production capacity.<\/strong> Yet even the most advanced machine cannot deliver its full potential if the rest of the finishing line cannot keep pace. For many folding carton manufacturers, the real bottleneck lies at the end of the line with manual packing: Impack technology is the solution<\/strong><\/em><\/p>\n

\"Impack\"<\/p>\n

Installing a new folder-gluer and immediately operate it at its intended production speed it\u2019s possible. That was the challenge facing Qualvis, based in Uk and specialized in producing folding cartons for the food and cosmetics industries.<\/strong> As customer demand continued to grow, the company’s finishing department reached its capacity limits. Rather than simply investing in a faster folder-gluer, Qualvis took a broader approach, pairing its new high-speed gluing line with an end-of-line packing solution designed to match its performance from day one: Ergosa by Impack<\/strong>, allowing the company to unlock the full capability of its new finishing line while improving ergonomics for its operators and creating a scalable platform for future automation.<\/p>\n

Investments to answer customer needs<\/strong><\/p>\n

\"\"<\/p>\n

Many Qualvis customers\u00a0 experienced significant organic growth over the years. As their businesses expanded, their demand shifted toward high-volume straight-line carton production and the company had to invest because capacity had simply reached its limit and Qualvis ultimately became the first company in the world to install the new straight-line-only Koenig & Bauer folder-gluer.<\/strong> However, purchasing a machine capable of running at dramatically higher speeds immediately exposed another challenge: manual packing that \u00a0limited throughput. At the speeds of the new folder-gluer, it simply would not have been sustainable. To match this speed Qualvis decided to install Ergosa, the semi-automated packer by Impack.<\/p>\n

\"\"<\/strong><\/p>\n

It was important to choose the right level of automation:<\/strong> although fully automatic packing systems were considered, Qualvis decided that making the leap directly from manual packing to full automation would be too much complex. Ergosa provides instead a practical balance between performance, flexibility, and operator familiarity. “We were close to choosing fully automatic packing. But it’s quite a big leap from hand packing to going right into fully automatic. Ergosa provides a very good middle ground while still giving us the option to run at very high speeds\u201d<\/em>, says Jordan Pugh, Head of Operations & Supply Chain at Qualvis.<\/strong><\/p>\n

Flexibility without compromise<\/strong><\/p>\n

Production at Qualvis varies considerably.<\/strong> Some carton designs run continuously for several days, while others require multiple changeovers within a single shift. Ergosa’s fast setup times and configurable packing patterns allow the company to efficiently handle both scenarios. Although approximately 95% of production on the new line will involve standard single-row, single-layer packing, the ability to accommodate more complex case configurations was considered an important long-term advantage.<\/p>\n

\"\"<\/p>\n

For a food packaging manufacturer like Qualvis, maintaining accurate carton counts without marking individual cartons is essential. The integrated INH box-turner solves the problem, while maintaining precise batch counts throughout production. Essentially, the INH module maintains the correct sequence and batch count even when individual cartons are rejected, without the need to mark each carton or interrupt production.<\/p>\n

Before installation, Qualvis established an internal target of 60,000 cartons per hour across its principal production lines. The new folder-gluer and Ergosa combination has already exceeded those expectations. With production already surpassing 75,000 cartons per hour, the company believes additional performance gains remain possible as operators gain experience.<\/strong><\/p>\n

Better ergonomics for long-term employees and fast operator adoption<\/strong><\/p>\n

By eliminating repetitive twisting, lifting, and reaching motions, Ergosa has significantly reduced the physical demands placed on finishing operators. It allows people to be a lot more comfortable. \u00a0Introducing automation after years of manual packing might have been expected to require a lengthy transition. Instead, operator acceptance proved remarkably quick: most operators became comfortable with the system within only a few days, supported by an efficient training.<\/p>\n

\"\"<\/p>\n

Building for the future<\/strong><\/p>\n

For Qualvis, this investment represents the beginning, not the end, of its automation journey.<\/strong> The modular design of Ergosa provides a platform that can evolve alongside production requirements, allowing additional automation to be incorporated as volumes continue to grow. The project demonstrates an increasingly important lesson for folding carton manufacturers: maximizing the performance of today’s high-speed folder-gluers is no longer simply a question of machine speed. By addressing the bottleneck at the end of the line, Qualvis has transformed a high-speed folder-gluer \u00a0into a production line capable of delivering its full potential every day.<\/p>\n","protected":false},"excerpt":{"rendered":"

Investing in a high-speed folder-gluer is often seen as the fastest route to increase production capacity. Yet even the most advanced machine cannot deliver its full potential if the rest of the finishing line cannot keep pace. For many folding carton manufacturers, the real bottleneck lies at the end of the line with manual packing: […]<\/p>\n","protected":false},"author":2,"featured_media":97791,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[456,550,476],"tags":[],"class_list":["post-97801","post","type-post","status-publish","format-standard","has-post-thumbnail","category-converter-cartotecnica","category-converting-technologies-en","category-industry-news-converter-cartotecnica"],"acf":[],"yoast_head":"\nUnleashing the full capacity of folder-gluers - Converter<\/title>\n<meta name=\"description\" content=\"Investing in a high-speed folder-gluer is often seen as the fastest route to increase production capacity.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Unleashing the full capacity of folder-gluers - Converter\" \/>\n<meta property=\"og:description\" content=\"Investing in a high-speed folder-gluer is often seen as the fastest route to increase production capacity.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/\" \/>\n<meta property=\"og:site_name\" content=\"Converter\" \/>\n<meta property=\"article:published_time\" content=\"2026-07-28T09:00:48+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/07\/IMPACK-Qualvis-ergosa-horizontal-pink-straight-line-08.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"1440\" \/>\n\t<meta property=\"og:image:height\" content=\"810\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"author\" content=\"Converter\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Converter\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"6 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/#article\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/\"},\"author\":{\"name\":\"Converter\",\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/#\\\/schema\\\/person\\\/b2e394dc5b62985280853bee849121fd\"},\"headline\":\"Unleashing the full capacity of folder-gluers\",\"datePublished\":\"2026-07-28T09:00:48+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/\"},\"wordCount\":737,\"image\":{\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/www.converter.it\\\/wp-content\\\/uploads\\\/2026\\\/07\\\/IMPACK-Qualvis-ergosa-horizontal-pink-straight-line-08.jpg\",\"articleSection\":[\"Converter & Cartotecnica\",\"Converting Technologies\",\"Industry - News\"],\"inLanguage\":\"en-US\"},{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/\",\"url\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/\",\"name\":\"Unleashing the full capacity of folder-gluers - Converter\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/#primaryimage\"},\"image\":{\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/www.converter.it\\\/wp-content\\\/uploads\\\/2026\\\/07\\\/IMPACK-Qualvis-ergosa-horizontal-pink-straight-line-08.jpg\",\"datePublished\":\"2026-07-28T09:00:48+00:00\",\"author\":{\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/#\\\/schema\\\/person\\\/b2e394dc5b62985280853bee849121fd\"},\"description\":\"Investing in a high-speed folder-gluer is often seen as the fastest route to increase production capacity.\",\"breadcrumb\":{\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/#breadcrumb\"},\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"ReadAction\",\"target\":[\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/\"]}]},{\"@type\":\"ImageObject\",\"inLanguage\":\"en-US\",\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/#primaryimage\",\"url\":\"https:\\\/\\\/www.converter.it\\\/wp-content\\\/uploads\\\/2026\\\/07\\\/IMPACK-Qualvis-ergosa-horizontal-pink-straight-line-08.jpg\",\"contentUrl\":\"https:\\\/\\\/www.converter.it\\\/wp-content\\\/uploads\\\/2026\\\/07\\\/IMPACK-Qualvis-ergosa-horizontal-pink-straight-line-08.jpg\",\"width\":1440,\"height\":810,\"caption\":\"Impack\"},{\"@type\":\"BreadcrumbList\",\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/unleashing-the-full-capacity-of-folder-gluers\\\/#breadcrumb\",\"itemListElement\":[{\"@type\":\"ListItem\",\"position\":1,\"name\":\"Home\",\"item\":\"https:\\\/\\\/www.converter.it\\\/en\\\/\"},{\"@type\":\"ListItem\",\"position\":2,\"name\":\"Unleashing the full capacity of folder-gluers\"}]},{\"@type\":\"WebSite\",\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/#website\",\"url\":\"https:\\\/\\\/www.converter.it\\\/en\\\/\",\"name\":\"Converter\",\"description\":\"Riviste tecniche di Stampa e Imballaggi\",\"potentialAction\":[{\"@type\":\"SearchAction\",\"target\":{\"@type\":\"EntryPoint\",\"urlTemplate\":\"https:\\\/\\\/www.converter.it\\\/en\\\/?s={search_term_string}\"},\"query-input\":{\"@type\":\"PropertyValueSpecification\",\"valueRequired\":true,\"valueName\":\"search_term_string\"}}],\"inLanguage\":\"en-US\"},{\"@type\":\"Person\",\"@id\":\"https:\\\/\\\/www.converter.it\\\/en\\\/#\\\/schema\\\/person\\\/b2e394dc5b62985280853bee849121fd\",\"name\":\"Converter\",\"image\":{\"@type\":\"ImageObject\",\"inLanguage\":\"en-US\",\"@id\":\"https:\\\/\\\/secure.gravatar.com\\\/avatar\\\/0abc22c129dc4223656982c585b9e72905780b6e1c6e6154605144d08de252e3?s=96&d=mm&r=g\",\"url\":\"https:\\\/\\\/secure.gravatar.com\\\/avatar\\\/0abc22c129dc4223656982c585b9e72905780b6e1c6e6154605144d08de252e3?s=96&d=mm&r=g\",\"contentUrl\":\"https:\\\/\\\/secure.gravatar.com\\\/avatar\\\/0abc22c129dc4223656982c585b9e72905780b6e1c6e6154605144d08de252e3?s=96&d=mm&r=g\",\"caption\":\"Converter\"},\"url\":\"https:\\\/\\\/www.converter.it\\\/en\\\/author\\\/editor\\\/\"}]}<\/script>\n<!-- \/ Yoast SEO plugin. -->","yoast_head_json":{"title":"Unleashing the full capacity of folder-gluers - Converter","description":"Investing in a high-speed folder-gluer is often seen as the fastest route to increase production capacity.","robots":{"index":"index","follow":"follow","max-snippet":"max-snippet:-1","max-image-preview":"max-image-preview:large","max-video-preview":"max-video-preview:-1"},"canonical":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/","og_locale":"en_US","og_type":"article","og_title":"Unleashing the full capacity of folder-gluers - Converter","og_description":"Investing in a high-speed folder-gluer is often seen as the fastest route to increase production capacity.","og_url":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/","og_site_name":"Converter","article_published_time":"2026-07-28T09:00:48+00:00","og_image":[{"width":1440,"height":810,"url":"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/07\/IMPACK-Qualvis-ergosa-horizontal-pink-straight-line-08.jpg","type":"image\/jpeg"}],"author":"Converter","twitter_card":"summary_large_image","twitter_misc":{"Written by":"Converter","Est. reading time":"6 minutes"},"schema":{"@context":"https:\/\/schema.org","@graph":[{"@type":"Article","@id":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/#article","isPartOf":{"@id":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/"},"author":{"name":"Converter","@id":"https:\/\/www.converter.it\/en\/#\/schema\/person\/b2e394dc5b62985280853bee849121fd"},"headline":"Unleashing the full capacity of folder-gluers","datePublished":"2026-07-28T09:00:48+00:00","mainEntityOfPage":{"@id":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/"},"wordCount":737,"image":{"@id":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/#primaryimage"},"thumbnailUrl":"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/07\/IMPACK-Qualvis-ergosa-horizontal-pink-straight-line-08.jpg","articleSection":["Converter & Cartotecnica","Converting Technologies","Industry - News"],"inLanguage":"en-US"},{"@type":"WebPage","@id":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/","url":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/","name":"Unleashing the full capacity of folder-gluers - Converter","isPartOf":{"@id":"https:\/\/www.converter.it\/en\/#website"},"primaryImageOfPage":{"@id":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/#primaryimage"},"image":{"@id":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/#primaryimage"},"thumbnailUrl":"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/07\/IMPACK-Qualvis-ergosa-horizontal-pink-straight-line-08.jpg","datePublished":"2026-07-28T09:00:48+00:00","author":{"@id":"https:\/\/www.converter.it\/en\/#\/schema\/person\/b2e394dc5b62985280853bee849121fd"},"description":"Investing in a high-speed folder-gluer is often seen as the fastest route to increase production capacity.","breadcrumb":{"@id":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/#breadcrumb"},"inLanguage":"en-US","potentialAction":[{"@type":"ReadAction","target":["https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/"]}]},{"@type":"ImageObject","inLanguage":"en-US","@id":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/#primaryimage","url":"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/07\/IMPACK-Qualvis-ergosa-horizontal-pink-straight-line-08.jpg","contentUrl":"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/07\/IMPACK-Qualvis-ergosa-horizontal-pink-straight-line-08.jpg","width":1440,"height":810,"caption":"Impack"},{"@type":"BreadcrumbList","@id":"https:\/\/www.converter.it\/en\/unleashing-the-full-capacity-of-folder-gluers\/#breadcrumb","itemListElement":[{"@type":"ListItem","position":1,"name":"Home","item":"https:\/\/www.converter.it\/en\/"},{"@type":"ListItem","position":2,"name":"Unleashing the full capacity of folder-gluers"}]},{"@type":"WebSite","@id":"https:\/\/www.converter.it\/en\/#website","url":"https:\/\/www.converter.it\/en\/","name":"Converter","description":"Riviste tecniche di Stampa e Imballaggi","potentialAction":[{"@type":"SearchAction","target":{"@type":"EntryPoint","urlTemplate":"https:\/\/www.converter.it\/en\/?s={search_term_string}"},"query-input":{"@type":"PropertyValueSpecification","valueRequired":true,"valueName":"search_term_string"}}],"inLanguage":"en-US"},{"@type":"Person","@id":"https:\/\/www.converter.it\/en\/#\/schema\/person\/b2e394dc5b62985280853bee849121fd","name":"Converter","image":{"@type":"ImageObject","inLanguage":"en-US","@id":"https:\/\/secure.gravatar.com\/avatar\/0abc22c129dc4223656982c585b9e72905780b6e1c6e6154605144d08de252e3?s=96&d=mm&r=g","url":"https:\/\/secure.gravatar.com\/avatar\/0abc22c129dc4223656982c585b9e72905780b6e1c6e6154605144d08de252e3?s=96&d=mm&r=g","contentUrl":"https:\/\/secure.gravatar.com\/avatar\/0abc22c129dc4223656982c585b9e72905780b6e1c6e6154605144d08de252e3?s=96&d=mm&r=g","caption":"Converter"},"url":"https:\/\/www.converter.it\/en\/author\/editor\/"}]}},"_links":{"self":[{"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/posts\/97801","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/comments?post=97801"}],"version-history":[{"count":2,"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/posts\/97801\/revisions"}],"predecessor-version":[{"id":97803,"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/posts\/97801\/revisions\/97803"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/media\/97791"}],"wp:attachment":[{"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/media?parent=97801"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/categories?post=97801"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.converter.it\/en\/wp-json\/wp\/v2\/tags?post=97801"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}