Mondi Develops Zero-Defect Corrugated Packaging System
Mondi, in collaboration with Procter & Gamble (P&G), has developed a new system designed to achieve zero-defect production in corrugated packaging. The solution is aimed particularly at customers in the food and beverage and personal care sectors, where consistent packaging quality is critical.
Mondi began its Zero Defect project in 2009 with the goal of achieving 100% defect-free production on inline machines while improving customer satisfaction. As part of the initiative, the company conducted an in-depth analysis of customer complaints, production issues and associated costs to identify opportunities for improving quality control.
The resulting Mondi Pro Excellence System enables continuous monitoring throughout the corrugated packaging production process. Special sensors inspect every box, while the system continuously compares actual production values with predefined target and tolerance values. This allows potential defects to be identified during production rather than after the packaging has been completed.
The system is designed to prevent boxes with incorrect adhesive bonding from being classified as approved. Faulty boxes are automatically identified, clearly marked and removed from the production process. An automated reporting system provides real-time monitoring information and generates a quality assurance certificate confirming that the packaging meets the required zero-defect standard.
The technology also helps address adhesive bonding issues, reducing production stoppages caused by gluing problems. Predefined tolerance values can be configured to optimise adhesive application and maintain consistent bonding quality.
Mondi plans to install the Pro Excellence System across its corrugated packaging plants in the near future, supporting more reliable production, improved quality assurance and greater consistency for customers.
