Koenig & Bauer unifies folding carton production with an uninterrupted large-format architecture

On October 8, 2026, during its Executive Day in Radebeul, Germany, Koenig & Bauer presented a fully networked, end-to-end production architecture for folding cartons. Operating under the banner "Large Format End-to-End," the demonstration linked sheetfed offset printing, flatbed die-cutting, and folder-gluing into a continuous automated workflow designed to eliminate traditional manufacturing silos.

The core of the high-volume setup relies on the Rapida 145 sheetfed offset press, which operates at a production rate of 18,000 sheets per hour. This primary printing stage is directly integrated with the Ipress 145 PRO flatbed die-cutter and the OMEGA Allpro 110 folder-gluer. By connecting these stages, the German manufacturer aims to minimize disruptions and reduce the manual material handling that typically bottlenecks large-format packaging production.

To address the growing fragmentation of order sizes, the architecture incorporates the VariJET 106 digital press as a complementary system. Developed in collaboration with Durst, the VariJET 106 absorbs short and medium runs, relieving the burden on the high-speed offset equipment. This hybrid approach allows converters to maintain maximum overall equipment effectiveness (OEE) on the Rapida 145 while handling rapid lead times, versioning, and ultra-short runs on the digital platform.

The workflow is further enhanced by the integration of no-code robotics and advanced data transparency, reducing the reliance on highly specialized manual intervention on the shop floor. Additionally, the system integrates brand protection directly at the printing stage through "Vision & Protection Jobs." This feature embeds security elements and health warnings into the packaging, addressing the increasing regulatory and anti-counterfeiting demands of the global folding carton market.

By consolidating prepress, high-performance printing, and finishing into a single networked ecosystem, Koenig & Bauer provides a structural response to the margin pressures facing packaging converters. The Radebeul demonstration confirms a definitive industry shift toward hybrid, highly automated production floors where offset volume and digital agility operate within the same continuous data stream.