BFT Group retrofits ISOWA jumbo line in Thailand to cut ink usage by 40 percent

Upgrading heavy machinery for the 2026 market

BFT Group has successfully finalised a critical technological upgrade at a prominent Japanese industrial facility located in Thailand. The engineering team executed a comprehensive retrofit on an ISOWA 4600mm jumbo line, systematically replacing the original rubber roller metering mechanisms with advanced carbon fibre chambered doctor blade technology. This intervention targets the exact challenges faced by wide-web corrugated converters operating in 2026, delivering substantial improvements in standardisation, cost control, and print uniformity. The Japanese industrial group required a solution that could immediately modernise the output parameters of the heavy-duty press without necessitating a complete machine replacement.

Engineering for extreme widths

Running corrugated board on a 4.6-metre jumbo press involves navigating demanding physical forces. Traditional rubber roller systems often struggle to maintain a consistent hydrodynamic pressure across such extreme widths. As the rubber wears or flexes under load, operators frequently observe a heavier ink laydown in the centre of the web compared to the edges, compromising print quality on large formats. In jumbo-sized applications, heavy-duty boards are often processed for automotive and industrial transit packaging, demanding flawless ink transfer. By engineering the conversion to a carbon fibre chambered doctor blade, BFT Group has introduced aerospace-grade rigidity into the inking process. The carbon fibre construction prevents mid-span deflection and vibration at higher speeds, ensuring the doctor blade maintains perfectly parallel contact with the anilox roll across the entire 4600mm span.

Economic and environmental returns

The operational data following the installation provides a clear benchmark for machinery upgrades. The facility reported a confirmed 40% reduction in ink consumption immediately after the commissioning phase. In the highly competitive packaging landscape of 2026, where raw material volatility constantly threatens margins, an ink reduction of this magnitude fundamentally shifts the unit economics of the press. Furthermore, applying thinner, more precise ink films facilitates faster drying times, reduces the moisture transferred to the linerboard, and mitigates the risk of warp during subsequent converting stages.

Automation via GT-CORR

Beyond the mechanical metering upgrade, BFT Group heavily focused on process automation. The retrofit included the full integration of the GT-CORR inking and washing system. By stripping away manual interventions, the GT-CORR unit manages the entire fluid cycle automatically. Wash-up times are dramatically shortened, ink recovery is maximised, and the stability of the printing process is no longer reliant on the individual skill level of the operator. In an era where corrugated packaging plants face continuous pressure to reduce their environmental footprint, automated washing systems minimise wastewater generation by injecting precise water dosages strictly to clean the chamber and anilox cells.

Cross-border project execution

Executing a cross-border hardware retrofit requires stringent project management. BFT Group formally acknowledged the management of the Japanese industrial group for their operational transparency during the downtime window. Additionally, the execution heavily relied on the regional expertise of their distributor, UMS Australasia Pty Ltd. Sean Keogh and his team provided the vital logistical and strategic framework to navigate local market complexities, ensuring the massive 4.6-metre components were installed, calibrated, and signed off precisely on schedule.

The strategic lifespan extension of heavy industrial assets through targeted retrofits proves that applied engineering can inject decades of profitability into installed machinery. Does your facility actively evaluate the ROI of component upgrades versus outright machinery replacement for aging wide-web assets? Follow all the latest industry news on www.thepaper.ai