Digitalization in the Packaging Industry: Reduced Downtime, Continuous Improvement

78% First-Print Success Rate Achieved – Significantly Fewer Downtimes Thanks to Automated Data Capture in Production

In the world of flexible packaging, every second—and every color—counts. For production managers in the printing industry, this is a daily challenge: costly test prints, time-consuming setup processes, and the constant question of how to simultaneously improve quality and efficiency.

Here, a leading manufacturer with more than a dozen locations across Europe shares how leveraging smart machine data not only increased the number of successful first prints but also strengthened a culture of responsibility and agility on the production floor. This example shows how production data platforms can simplify daily operations and deliver tangible results.

Initial Situation: Test Prints as a Cost Factor

In the printing process, the test print is critical. It verifies print quality before full production begins. Ideally, one test print confirms all settings. However, when multiple test prints are required for a job, the following increase:

• Material consumption,

• Setup times, and

• Costs—especially due to expensive inks and specialty coatings.

The goal is clear: achieve “first-time-right” prints as quickly and frequently as possible to avoid unnecessary costs and waste.

Process Before ENLYZE: Good Approach but Time-Consuming

Even before ENLYZE, the team worked on process improvements. The rate of perfect first prints increased from 60% (2017) to 70% (2023) through continuous improvement—an impressive achievement in the printing industry.

However, the analysis required for continuous improvement was manual and slow:

• Test prints were painstakingly documented and analyzed only in monthly meetings

• Causes for additional test prints were identified with delay

• Process improvements could not be implemented flexibly or in a timely manner

More Perfect First Prints Through Transparency and Real-Time Analysis

The print shop manager set ambitious targets:

• 75% of jobs to be successfully completed with the first test print

• Faster detection of problems and root causes through real-time process monitoring

• Immediate implementation of targeted adjustments

Digitalized Printing Process – Less Downtime, Higher Quality

With the ENLYZE Manufacturing Data Platform, the printing process was fully digitalized. Process data from the gravure printing machine is extracted from machine controls, processed, and made accessible via the ENLYZE app.

The captured data and continuous process monitoring help improve print quality and increase the effectiveness and efficiency of the entire production process.

A highlight: automatic downtime detection. The platform automatically recognizes stoppages. Operators can quickly add comments and then focus on solutions. At the same time, ENLYZE provides digital test print data summaries that can be reviewed and discussed by the team the same day.

The Result: 78% First-Print Success, Faster Process Optimization

With ENLYZE, the team exceeded the 75% target, achieving 78%. This impressive improvement was driven by faster feedback loops and increased employee awareness. The digital preparation and comment function for downtime capture enabled more efficient analysis of challenging jobs, allowing quicker implementation of adjustments.

Jobs that previously required multiple test prints are now usually optimized on the same day. This positive change in workflows resulted in:

• Higher efficiency through faster analyses and direct team meetings

• Increased employee accountability

• More targeted process adjustments

Next Steps: 80% First-Print Success and Stable Processes

The team aims to raise the first-print rate further to 80% through sustainable standardization of all processes with ENLYZE.

“With ENLYZE, we found a solution that not only saves us time and costs but also provides continuous support for our team in daily operations. Having a digital companion in manufacturing is now indispensable.” — Head of Print Shop & Color Warehouse

Insights and Keys to Success for Digitalization in Manufacturing

• Automated Data Capture: Switching to digital machine data acquisition saves time, frees shift teams from manual documentation, and provides precise real-time data.

• Elevated Culture of Continuous Improvement: Immediate data availability increases accountability and motivates employees.

• Faster Process Adjustments: Continuous data access enables immediate implementation of improvements and measurement of their effectiveness—no more waiting for monthly meetings.

• Sustainable Process Optimization: ENLYZE helps identify root causes easily and eliminate them permanently through targeted actions.

Save Time and Costs with a Culture of Continuous Improvement

What benefits could your production gain if you truly use machine data—instead of just collecting it?