Note: Descriptions are shown in the official language in which they were submitted.
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METHOD FOR MANUFACTURING PRINTED CONTAINERS
TECHNICAL FIELD
[0001] The present invention relates to the field of containers. More
specifically, the present invention relates to a method of manufacturing
printed
containers in response to an order.
BACKGROUND
[0002] The manufacturing of printed containers, particularly those with
graphics on them, has two main steps. First, a graphic, logo, trademark, text,
or
other image is printed onto a stock material used to manufacture the
container.
Second, this printed stock material is fed into an automated forming machine,
which cuts, folds, glues, sews, and/or seals the container into its final
form.
[0003] For plastic bags, sacks, pouches, sachets, and other flexible
containers, the stock material is often a thermoplastic film or plastic-based
textile
that is welded together using heating elements to form the bag. For woven and
non-woven fabrics, the stock material may be sewn together to form the bag. In
either case, the bag-forming machine typically folds, cuts, and joins the
printed
stock material according to a pre-set sequence of actions, at a high rate of
speed.
[0004] Bags of this type may be used for a variety of applications,
including
as flexible packaging for other goods, as shopping bags, for waste collection
and
storage, as protective packing materials, or in various other applications
where a
bag may be needed. For example, processed foods, produce, frozen foods, and
bulk products such as coffee or rice may be packaged in plastic or fabric bags
featuring a particular trademark, nutritional information, ingredient lists,
weight,
volume, and/or other labelling requirements. Alternatively, shopping bags of
the
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disposable or reusable type that feature the customer's branding may be
distributed as a promotional item or on a fee-basis.
[0005] For cartons, spiral wound cans, boxes, and other rigid containers
the
stock material is often heavy cardstock, cardboard, heavy gauge paper, or
paperboard that is folded or glued together to form the container. Where
plastic is
used, the stock material is often a semi-rigid plastic capable of being
folded.
Containers of this type are often used as rigid packaging for other goods.
[0006] For purchasers of containers, there is typically two possible
supply
sources. One option is to order the containers from a company close to where
they
are needed, such as in North America or Europe. Another option is to purchase
bags "offshore", in markets with lower production costs such as, Pakistan,
India, or
China.
[0007] Local production typically provides containers that are higher
quality
and more easily changed, but with higher production costs and lower volume
runs.
Containers purchased from local suppliers can be provided to the customer in
as
little as 1-2 weeks after placing the order. Local suppliers also have a
greater
ability to quickly adjust to changes in requirements, such as changes in
volume,
artwork, marketing, and/or the product being packaged (e.g. SKU, ingredients,
labelling, recipes, and new features). Nevertheless, labour costs are often
higher
and local facilities may not be equipped to handle large production runs.
[0008] "Offshore" production typically provides less expensive
containers that
may be of lower quality, but requires longer lead times and is less able to
adapt to
changes in requirements. Offshore suppliers typically require at least 10
weeks
before delivery to the customer, largely due to the added shipping time.
[0009] In particular, containers used as packaging are typically a low
cost
item and so they are often sent using the cheapest (and slowest) shipping
route.
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This increased shipping time often requires additional lead-time to adjust to
any
changes in the customer's requirements. This often leads to excess packaging
being ordered 'just in case', which results in additional expenses for the
customer
with regard to shipping and storing excess inventory.
[0010] This background information is provided for the purpose of making
known information believed by the applicant to be of possible relevance to the
present invention. No admission is necessarily intended, nor should be
construed,
that any of the preceding information constitutes prior art against the
present
invention.
SUMMARY OF THE INVENTION:
[0011] The invention provides a hybrid approach, in which a portion of
the
manufacturing process is carried out locally and a portion is carried out
offshore.
For example, stock may be printed offshore in a first country and shipped to a
local
site in a second country for forming into containers.
[0012] This hybrid approach, in optimum circumstances, may allow for
"local"
lead times and flexibility with "offshore" costs. In some cases, total costs
may be
even lower than a full "offshore" approach, due to decreased shipping costs
and
reductions in inventory oversupply.
[0013] In particular, the authors have found that printing tends to be
the
most labour and capital-intensive step of the bag-making process. This can
result
in bottlenecks during local production. Differential labour costs and/or
economies
of scale may make centralized offshore printing more efficient.
[0014] The cost of shipping rolls of printed stock is also considerably
less
than finished containers, which take up more room, require packing prior to
shipment, and are generally more difficult and costly to handle. In addition,
the
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cost of handling excess inventory may be reduced when handled as bulk rolls of
printed stock, since the cost of forming the stock and storing finished
containers
may be avoided for such excess inventory.
[0015] The present invention may also improve lead times over
traditional
"offshore" approaches. For example, parallel facilities, one local and one
offshore,
may be utilized in tandem to provide portions of the same order. The portion
produced locally may benefit from reduced lead times and increased
responsiveness, whereas the portion produced offshore may benefit from reduced
costs. In particular, the local portion of the order may be delivered to the
client
while the offshore portion is in transit, thereby reducing lead times. This
may
provide greater flexibility when launching new SKUs or changing existing
packaging.
[0016] Alternatively, or in addition, the local portion may be used to
address
those aspects of the order that are more variable (e.g. variable demand,
promotional runs, rush orders, top-up orders, etcetera), whereas the offshore
portion may be used to address more stable portions of the order (e.g.
standardized packaging, standardized containers, and other predictable
quantities).
[0017] The present invention may also improve the security of supply for
the
customer, since containers may be formed and shipped locally from stock
printed
offshore. This reduces the likelihood of a customer running out of containers
during a key part of its production cycle, such as packaging the final product
of an
assembly line. Moreover, the present invention may facilitate 'just in time'
delivery
schedules, without the corresponding cost increase associated with a fully
localized
production process.
[0018] In one broad aspect, the invention provides a method of
manufacturing a container including the steps of: printing an image or text on
an
elongate sheet of flexible stock material in a first country; transporting the
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elongate sheet stock material to a second country; and forming the elongate
sheet
stock material into one or more bags containers in the second country.
[0019] In another broad aspect, the invention provides a method of
manufacturing containers to fulfill an order from a customer, including the
steps of:
separating the order into a first portion and a second portion; for the first
portion
of the order: printing an image or text on a first elongate sheet of flexible
stock
material in a first country, transporting the first elongate sheet stock
material to a
second country, forming the first elongate sheet stock material into a first
lot of
bags containers in the second country; and for the second portion of the
order:
printing the image or text on a second elongate sheet of flexible stock
material in
the second country, and forming the second elongate sheet stock material into
a
second lot of bags containers in the second country.
[0020] In yet another broad aspect, the invention provides a method of
manufacturing containers to fulfill an order by a customer, including the
steps of:
separating the order into a first portion and a second portion; for the first
portion
of the order: printing an image or text on a first stock material in a first
country,
forming the first stock material into a first lot of containers in the first
country, and
transporting the first lot of containers to a second country; for the second
portion
of the order: printing the image or text on a second stock material in the
second
country, and forming the second stock material into a second lot of containers
in
the second country.
[0021] In preferred embodiments, the customer is located in the second
country, the second country has a higher cost of labour than the first
country,
and/or the containers are for use in the second country. In some embodiments,
the first stock material is an elongate sheet and is transported to the second
country in bulk rolls. In such embodiments, the bulk rolls may be stored in
the
second country, prior to forming.
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[0022] The first and second stock material may be a thermoplastic film
or
textile, cardstock, paperboard, heavy gauge paper, semi-rigid plastic, or the
like.
The container may be of various types, including bags, pouches, rollstock,
cans,
bottles, cartons, boxes, sacks, flasks, sachets, envelopes, tins, jars, and
the like.
The forming step may include cutting, folding, welding, sewing, or gluing. In
some
embodiments, the forming step includes cutting the stock material
longitudinally
into two or more sections for use in forming two or more containers.
[0023] The order may be split into portions based on the relative
production
costs, transit times, and inventory carrying costs of the first and second
country.
In an embodiment, the first portion of the order is approximately 80% of the
order
and the second portion is approximately 20% of the order.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG 1 is a schematic drawing of an embodiment of the present
invention, showing the transport of rolls of printed stock from a first
country for
forming into containers at a second country.
[0025] FIG 2 is a schematic drawing of another embodiment of the present
invention wherein an order is divided into first and second portions, in which
the
first portion is printed in the first country and formed in the second country
and the
second portion is printed in the second country and formed in the second
country.
[0026] FIG 3 is a schematic drawing of yet another embodiment of the
present invention wherein the order is divided into a first portion and a
second
portion, in which the first portion is printed and formed in the first country
and the
second portion is printed and formed in the second country.
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DETAILED DESCRIPTION
[0027] To gain a better understanding of the invention described herein,
the
following illustrative embodiments are set forth. It will be understood that
these
embodiments are intended to describe examples of the invention and are not
intended to limit the scope of the invention in any way.
[0028] FIG 1 provides an overview of an embodiment of the present
invention, in which the containers are plastic bags or pouches. Although the
invention is described below with reference to bags or pouches, the invention
may
also be applied to other types of printed containers, including rollstock,
cans,
bottles, cartons, spiral wound cans, boxes, sacks, flasks, sachets, envelopes,
tins,
jars and the like, which may be made of paper, plastic, metal, fabric, or
other
suitable materials, as appropriate for the application.
[0029] In the embodiment shown in FIG 1, the printing step of the
manufacturing process is carried out in a first country 100, in this case
Pakistan.
An image is printed onto an elongate sheet of plastic, fabric, textile, or
other stock
material. The image may be of various types, including graphics for product
packaging, such as bagged foods. The printing process produces a printed stock
material, which in this embodiment is wound on to large rolls 110.
[0030] The printed rolls 110 are then transported (e.g. by boat, train,
or
other low cost means) to a second country 200, in this case the United States.
In
the second country 200, the printed rolls 110 are fed into automated forming
machines of the conventional type, which produce a run of containers 220 (in
this
case, bags) by cutting, folding, and joining the stock material.
[0031] The printing step involves a significant amount of time and
effort, as
well as a specialized skill set. Images must be prepared with separate colour
channels, cylinders or plates need to be manufactured to specific tolerances,
and
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suitable inks need to be chosen for the application. Once properly tooled, the
press must also be regularly cleaned and maintained during print runs to
ensure
consistent and high-quality printing. Misalignments between colour layers can
be
problematic, and dirty presses can result in smearing or spattering if not
closely
monitored. In particular, the process of retooling the press to print
different rolls
110 of stock for different containers 220 can take a considerable amount of
labour.
[0032] In contrast, the assembly process may be substantially identical
for
different containers 220 of the same design, regardless of the images printed
on
the roll 110. This may allow for an entire product line to be assembled using
the
same machine configuration. The container forming machine may also be less
prone to errors and deviations than the printing press, if properly
maintained.
[0033] Localizing the assembly process may also increase the security of
supply for the customer. For example, in Figure 1 the bags 120, 220 may be
formed on demand for the customer in the second country 200, boxed into
cartons,
and shipped locally to the client for use in the second country 200. This
eliminates
logistical delays that would otherwise arise when shipping finished bags from
the
first country 100 to the second country 200.
[0034] In a preferred embodiment, the first country 100 has a low cost
of
labour and/or a centralized location with easy transportation access.
Similarly, it
may be preferable for the second country 200 to be located at or near where
the
containers 120, 220 are needed by the customer (e.g. where the customer is
located or where the bags will be used for packaging or other purposes).
[0035] By manufacturing the containers 120, 220 in this manner, the more
labour and capital intensive portion of the manufacturing process (i.e. the
printing
step) is centralized in the first country 100.
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[0036] At the same time, transportation costs are minimized by shipping
bulk
rolls 110 of stock to the second country 200 rather than finished containers
220.
This avoids the need to package the finished bags 220 for shipment and may
reduce overall handling costs as compared to shipping printed rolls 110.
[0037] Excess stock may also be held in inventory at the second country
200
as bulk rolls 110, rather than boxes of finished containers 220. Thus, the
cost of
forming and packing the unneeded containers 220 can be avoided and the rolls
110
may be stored more easily for future use.
[0038] Alternatively, or in addition, a single bulk roll 110 may also be
printed
as a master roll intended for multiple containers 220. In this embodiment, the
master roll 110 is shipped to the second country 200 and then cut
longitudinally at
the second country 200 into multiple strips, one for each container 220 that
is to
be formed. This may be particularly advantageous for small containers 220,
such
as small plastic bags. The master roll 110 may have the same or different
images
printed on each section thereof. Strips cut from the master roll 110 may be
processed immediately into containers 120 or wound onto sub-rolls for future
use.
FIG 2 provides a schematic outline of another embodiment of the present
invention, using bags or pouches as an example container 120, 220. In this
embodiment, an order 10 is received from a customer. The order 10 is divided
into
a first portion 12 and a second portion 14. The first portion 12 of the order
10 is
printed in a first country 100 and the second portion 14 of the order 10 is
printed
in a second country 200.
[0039] In the first country 100, the stock material (not shown) is sent
for
printing 101, which generates a printed stock 110 that may be spooled onto
bulk
rolls 110, for easier transport. These rolls 110 are then transported to the
second
country 200 (e.g. by boat, train, or other low-cost means) and used in a
forming
step 202 to produce a first lot of finished containers 120 (in this example,
bags or
pouches).
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[0040] In the second country 200, the stock material (not shown) is sent
for
printing 201 and forming 202 steps, which generates a second lot of finished
containers 220 (in this example, bags or pouches). In some embodiments, the
printing 201 and forming 202 are done immediately after one another. In other
embodiments, there may be an additional storage step in which the printed
stock
(not shown) may be held in inventory before forming 202.
[0041] The need to transport the printed stock 110 from the first
country 100
to the second country 200 typically means that the first and second lots 120,
220
will be produced at different times. In preferred embodiments, the second lot
220
will be available for delivery to the customer before the first lot 120. An
example
production schedule is provided below.
Table 1: Example Production Schedule
Week First Country Second Country
(Offshore Facility) (Local Facility)
0 = Receive purchase order
= Pre-production = Pre-production
2 = Printing = Printing
4 = Ship printed stock = Form containers
from local
stock
6 = First delivery to customer
8 = Form containers from
offshore stock
= Pre-production = Second delivery to customer
12 = Printing = (Printing, if required)
14 = Ship printed stock = (Form containers from local
stock, if required)
16 = (Further delivery to
customer, if required)
18 = Form containers from
offshore stock
20-52 (Repeat above) (Repeat above)
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[0042] As can be seen in Table 1, this allows for the short-term
fulfilment of
the customer's order using the second lot 220, followed by long-term order
fulfillment using one or more first lots 120. In some embodiments, this may
allow
the manufacturer to take advantage of a fast turn around time using local
facilities
in the second country 200, while also minimizing long-term costs by using
offshore
facilities in the first country 100.
[0043] Alternative schedules are also possible, in which the gaps
between
printing steps 101 in the first country 100 are timed to permit that facility
to send
different sets of printed stock 110 to multiple facilities in one or more
second
countries 200. In such embodiments, this may allow for economies of scale by
centralizing print operations for several countries at a single offshore
facility in the
first country 100.
[0044] As indicated in Table 1 above, the second country 200 can also
engage in additional rounds of printing 201 and forming 202 as required to
supplement the printed stock 110 received from the first country 100. This
provides additional flexibility for responding to customer requirements, such
as
promotional runs, unexpected increases in volume, top-up orders, rush orders,
new
SKUs, or the like.
[0045] The proportions of the first portion 12 and the second portion 14
in
the order 10 can vary, depending on the application. In a preferred
embodiment,
the first portion 12 is approximately 80% of the order 10 and the second
portion
14 is approximately 20% of the order 10.
[0046] Other proportions may also be used, depending on the application.
For example, it may be preferable to increase the first portion 12 beyond 80%
where the per-unit production costs in the first country 100 are significantly
lower
than those in the second country 200. Likewise, it may be preferable to
increase
the second portion 14 above 20% if the transit time between the first country
100
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and second country 200 is particularly long. Relative inventory carrying costs
in
the first country 100 versus the second country 200 may also favour one
location
over the other, and hence production of an increased proportion of the order
10 in
the less costly country 100, 200. Additional factors may also play into the
determination of the first 12 and second 14 portions.
[0047] Finally, master rolls 110 designed for use with more than one
container 120 may also be employed in this embodiment, as described above,
where appropriate.
[0048] FIG 3 provides a schematic overview of a further embodiment of
the
invention, using bags or pouches as an example container 120, 220. In this
embodiment, an order 10 is received from a customer. The order 10 is divided
into
a first portion 12 and a second portion 14. The first portion 12 of the order
10 is
printed 101 and formed 102 in a first country 100 and the second portion 14 of
the
order 10 is printed 201 and formed 202 in a second country 200. Finished
containers 120 are then transported from the first country 100 to the second
country 200.
[0049] Other than the foregoing, the basic principles are similar to
those
described above for FIG 2. Unlike the embodiment shown in FIG 2, however, the
embodiment shown in FIG 3 may not provide the additional cost benefits of bulk
storage of printed rolls 110 or the avoidance of overproduction of finished
bags
120, 220.
[0050] Nevertheless, the order 10 may be divided as between the first
country 100 and the second country 200 in the same manner described above.
This permits the manufacturer to rely on a more responsive and higher cost
production facility in the second country 200 to fulfill immediate and short-
term
orders using the second lot of bags 220 while the first lot of bags 120 is in
transit
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from the first country. Likewise, promotional runs and unexpected demands can
be met using bags 220 printed 201 and formed 202 in the second country 200.
[0051] This particular embodiment may be preferred in circumstances
where
the bag-forming facilities in the second country 200 are lacking in capacity
and/or
where the facility in the second country 200 is also expected to manufacture a
variety of bags 220 for other purposes. Similarly, this embodiment may be
useful
in applications where the demand for containers 120, 220 is relatively stable.
[0052] Finally, like the other embodiments, master rolls 110 designed
for use
with more than one container 120 may also be employed in this embodiment, as
described above, where appropriate. The embodiments described above may be
used in association with the manufacture of containers 120, 220 of various
types.
[0053] For example, where the containers 120, 220 are plastic bags, the
stock material may be a thermoplastic film or textile and the bag-making
machine
may cut, fold, and weld the thermoplastic to form the bags 120, 220. Where the
containers 120, 220 are fabric bags, the stock material may be an elongate
sheet
of fabric and the bag-making machine may cut, fold, and sew the fabric to form
the
bags 120, 220.
[0054] Where the containers 120, 220 are folding cartons, the stock
material
may be cardstock, which may or may not be cut into a blank before being folded
and glued into the finished container 120, 220. Where the containers 120, 220
are
spiral wound cans, the stock material may be paperboard, which may be wound
into tubes, cut to length, and joined with metal caps. Alternatively, or in
addition,
the stock material may be a paper or plastic film that is applied to the
exterior of a
can, carton, or other container during the forming process, using heat-
shrinking,
glue, or the like.
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[0055] A variety of printing and forming machines are also contemplated
in
association with the present invention. For example, the printing step may be
carried out using a flexography, offset, and/or a rotogravure printing
process.
Suitable machines can be obtained from various suppliers, including J.M.
Heaford
Solutions, Cheshire, England or Windmoller & Holscher of Lengerich, Germany.
The forming process may also be carried out using automated machines of the
conventional type. For bags, suitable machines can be obtained from various
suppliers, including Fen-Tech Industries Corp. of Burlington, Ontario, Canada.
Other suppliers are readily available for cartons, spiral wound cans, and the
like.
[0056] The embodiments of the present disclosure are intended to be
examples only. Those of skill in the art may effect alterations, modifications
and
variations to the particular embodiments without departing from the intended
scope of the present application.
[0057] In particular, features from one or more of the above-described
embodiments may be selected to create alternate embodiments comprised of a
subcombination of features that may not be explicitly described above. In
addition, features from one or more of the above-described embodiments may be
selected and combined to create alternate embodiments comprised of a
combination of features that may not be explicitly described above. Features
suitable for such combinations and subcombinations would be readily apparent
to
persons skilled in the art upon review of the present application as a whole.
The
subject matter described herein and in the recited claims intends to cover and
embrace all suitable changes in technology.
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