Trimbox

TrimBox

TrimBox is a software suite designed for corrugated-packaging and carton plants. Aimed mainly at medium- and large-scale companies with a high degree of automation, it is also suitable for smaller businesses:

companies with double- and triple-knife corrugators
companies with single-knife corrugators
medium- and large-size carton plants

TrimBox can be deployed immediately, even in a simpler configuration, and then evolve gradually toward more sophisticated levels of automation and process detail.

Price Quotation

You can quote a new product or one that has already been produced. For a new product, you create a preliminary data sheet containing the relevant information to price formation. For an existing product, historical data on setup times, productivity, and waste are used.

Margin simulations can be run in terms of profit, price per kg, and price per m². Raw-material price variations can also be simulated. TrimBox generates the quotation document to be sent to the customer and an internal cost-breakdown sheet for production.

TrimBox generates the quotation document to be sent to the customer and an internal cost-breakdown sheet for production.

Machine Capacity Evaluation

The machine-load module allows an assessment of corrugator and converting-machine capacity.

It also lets you evaluate production balance among the various machine types (flexo, die-cutter, etc.) and define precise delivery dates for orders.

When setting an order's delivery date, TrimBox calculates the earliest date on which machine time is available, considering that existing later-dated orders could be scheduled afterward without risk of delay.

Paper Reel Control

TrimBox tracks every paper reel individually: receipt, weight, quality tests, corrugator consumption, and return of leftovers to stock. Upon receipt it prints an ID label with a barcode.

TrimBox also forecasts paper consumption and compares it with stock levels, assisting the purchasing process.

Double- or Triple-Knife Corrugator Optimization

This is the most complex TrimBox module, continuously improved over many years. Internally, the optimizer builds a system of equations and solves it in seconds.

Because every possible cut combination is analyzed, the optimal solution is always found. No other system—or even an expert planner—will achieve better results.

The optimizer minimizes combination waste, grade-upgrade costs, starch usage, paper availability, corrugator cost (wider widths are more productive), optional orders, and more.

Upgrading the grade of an order to combine it in a slightly higher composition is handled by comparing the added cost with the waste reduction.

Production Scheduling

TrimBox sequences corrugator production by grouping flute combinations, widths, compositions, and minimizing open orders.

Where electronic interfaces are available, TrimBox sends the combinations directly to the corrugator, eliminating manual entry. It receives real-time production data, downtime, and machine status, storing the information for all users.

Conversion-machine scheduling is also done in TrimBox. For printers, ink colors are displayed clearly to minimize setups.

Production Reporting

Automatic production reporting for conversion uses an electronic device with sensors on the printers. Setup times, production counts, and downtimes are captured automatically.

With automatic reporting, operators can focus on production rather than data logging. After the machine is running, operators record only the causes of downtime, whose duration is captured automatically. Accurate data have delivered productivity gains of 20-30%, exceeding the most optimistic expectations.

Finished Goods & Shipping

TrimBox tracks each finished-goods pallet individually. When accessories such as lids are needed, it identifies them to ensure correct loading.

It handles Kanban items—products kept in stock for immediate delivery and automatically replenished when the reorder point is reached.

If loading leftovers occur, TrimBox alerts the production planner so the surplus can be used on the next order.

Shipping (load list) is performed by scanning pallet barcodes, guaranteeing correct quantities.

WMS - Warehouse Management System

The finished-goods area is divided into numbered “boxes” where pallets are stored. Forklifts are equipped with data collectors connected to the network via radio frequency.

When a new pallet is ready, the TrimBox WMS suggests the box where it should be stored.

Shipments are pre-planned, taking into account produced pallets and scheduled (yet-to-be-produced) pallets. During truck loading, the WMS shows each pallet and its location, guiding and validating collection.

Quality Control

TrimBox stores all quantitative and visual tests on paper, board, and boxes, and issues technical reports.

Tests can be queried by machine, composition, sampling date, or production order. Results are shown graphically with Gaussian curves, averages, standard deviations, and confidence intervals.

Paper-reel quality control lets you compare supplier tests with in-house QC results. Data can be exported to Excel or other statistical software.

Tooling Control

TrimBox provides detailed control of printing plates and cutting dies, recording every purchase, refurbishment, and production run.

Tool usage is captured automatically from production-order reporting.

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