PH Flexible Packaging Ltd, a leading UK-based manufacturer and supplier of innovative packaging solutions, has carved a niche in delivering high-quality custom box production for industries ranging from e-commerce to automotive. Based in Swadlincote, the company specializes in converting materials like bubble wrap, foam, and corrugated cardboard into tailored packaging formats, including protective bags, sheets, and bespoke corrugated boxes. Their commitment to sustainability, rapid turnaround times, and a “customer-first” approach—values that align with their recent investment in Aopack’s BM3000-HD Heavy-Duty Corrugated Box Maker.
The Challenge: Meeting Demand for Short-Run, Heavy-Duty Custom Box Production
As demand surged for specialized packaging across industries like e-commerce, automotive, and industrial goods, PH Flexible Packaging faced two critical challenges:
- Cost and Time Constraints with Traditional Machinery: Conventional box-making machines relied on physical molds to cut complex shapes, increasing upfront costs and lead times for custom orders.
- Limitations in Handling Heavy-Duty Materials: Clients increasingly requested boxes made from AAA flute and multi-ply corrugated cardboard (up to 7 layers) for heavy-load applications, but existing equipment struggled with thicker, denser materials.
To maintain competitiveness, the company needed a solution that combined versatility, speed, and the ability to process robust materials without sacrificing customization capabilities.
The Solution: Aopack BM3000-HD – A Game-Changer for Custom Box Production
In April 2025, PH Flexible Packaging partnered with GTS Europe Ltd, Aopack’s UK agent, to install the BM3000-HD Heavy-Duty Corrugated Box Maker. This machine addresses their challenges through cutting-edge features:
Vibrating Knife Precision Cutting
Unlike traditional die-cut systems, the BM3000-HD’s vibrating knife effortlessly creates intricate shapes—circles, arcs, slanted lines, and irregular geometries—without requiring physical molds. This eliminates mold costs and reduces setup time, making short-run orders economically viable.
Heavy-Duty Material Compatibility
The machine processes corrugated cardboard ranging from lightweight E flute (2mm) to ultra-durable AAA flute (16mm thickness, 2400g/sqm density), accommodating 3-ply to 7-ply configurations. With a maximum cardboard width of 3000mm and unlimited length, it handles oversized packaging for industrial clients.
Enhanced Efficiency Features
– 1–6-Second Quick Changeover: Ideal for low-to-medium volume production, the machine switches between box styles rapidly.
– Inline Auto Sharpener & Glue Flap Crush: Ensures consistent cut quality and secure glue flap adhesion.
– Inconsistent Creasing: Adjusts crease depth dynamically for varied cardboard thicknesses, reducing waste.
– 7–21mm Slotting Width: Supports diverse box designs, from standard shipping containers to reinforced industrial crates.
Software-Driven Flexibility
With compatibility for over 150 box styles and freestyle system integration, the BM3000-HD allows PH Flexible Packaging to digitize designs and execute them with pinpoint accuracy, future-proofing their operations.
Implementation & Results: Elevating Custom Box Production Efficiency
GTS Europe Ltd oversaw a seamless installation process, including staff training and workflow integration. Within weeks, the BM3000-HD demonstrated transformative results:
– 50% Reduction in Setup Costs: By eliminating molds, PH Flexible Packaging saved £15,000–£20,000 annually on tooling expenses.
– 30% Faster Order Fulfillment: Complex custom designs that previously took 3–5 days to prototype now ship within 24 hours.
– Expanded Client Base: The ability to process AAA flute cardboard attracted automotive and machinery clients requiring load-bearing packaging.
– Waste Reduction: Precise creasing and cutting decreased material waste by 18%, aligning with sustainability goals.
Client Testimonial
Paul Horobin, Managing Director of PH Flexible Packaging, remarked:
“Investment in new Machinery is continuing at PH Flexible Packaging. Our latest boxmaker the Boxstar from GTS is ideal for short run bespoke boxes. Pictured here making boxes and glueing in line but is capable of a few other tricks.”
Future Vision: Expanding Custom Box Production Capabilities
PH Flexible Packaging plans to leverage the BM3000-HD’s flexibility to penetrate luxury retail and reusable industrial packaging markets. By integrating AI-driven design tools, they aim to automate custom box production workflows, further reducing lead times and costs.
Conclusion
By adopting Aopack’s BM3000-HD, PH Flexible Packaging has solidified its position as a leader in adaptive, high-performance packaging solutions. The machine’s blend of heavy-duty processing, mold-free customization, and rapid production aligns perfectly with the evolving needs of modern industries. For businesses seeking to balance customization with efficiency, this case study underscores the transformative potential of advanced corrugated box-making technology.
Leave A Comment