Zray ZR-Flex Series Achieves Average 9-Minute Changeover for 200+ SKU Environment

Zray has developed and deployed a customized carton forming solution specifically engineered for high-variety, small-batch production environments, responding to the growing market demand for packaging flexibility driven by e-commerce and personalized product trends. The first installation of the ZR-Flex system was completed at a contract packaging facility in the Czech Republic that services over 40 brand clients with a combined portfolio exceeding 200 carton SKUs.

The facility’s production model presented unique challenges that conventional carton forming machines could not adequately address. Average batch sizes ranged from 500 to 3,000 cartons, with the facility executing 15 to 25 format changes per day. Traditional forming machines required 30 to 45 minutes per changeover, meaning that changeover time frequently exceeded productive run time for small batches. The facility’s legacy machine spent an average of 42% of its available production time in changeover or setup mode.

The ZR-Flex system was designed from first principles for rapid format changeover. All critical adjustment axes—including blank width, length, depth, and folding flap dimensions—are motorized and controlled via servo drives with absolute encoders. Format parameters for each SKU are stored in the machine’s recipe management system and recalled through the HMI. A complete format change is executed by selecting the recipe and confirming the change, after which all 14 adjustment axes reposition automatically and simultaneously.

Machine Architecture and Features

The ZR-Flex is based on Zray’s proven ZR-450 single piece forming platform but incorporates several modifications specific to high-variety production:

• Auto-Indexing Tooling: Critical forming tools, including the folding ploughs and compression belts, are mounted on linear guides with servo-driven positioning. Tool positions are stored as absolute coordinates in the recipe database, eliminating the need for manual measurement during format changes.
• Quick-Release Adhesive Nozzles: The hot melt application system features toolless nozzle change capability, allowing operators to switch between nozzle configurations for different glue patterns in under 30 seconds per nozzle.
• Universal Board Guide System: A segmented guide rail design accommodates board calipers from 0.8 mm to 5.0 mm without manual adjustment, using spring-loaded and pneumatically-actuated segments that self-configure based on the format recipe.
• Inline Format Verification: A laser measurement system mounted at the machine infeed verifies the dimensions of the first blank of each new batch against the selected recipe, providing an automatic cross-check before production begins.

Operational Results

During the first four months of operation, the ZR-Flex processed 1,723 production batches totaling approximately 2.6 million cartons. Key performance data includes:

• Average Changeover Time: 9 minutes and 14 seconds for complete format change, measured from last good carton of previous batch to first good carton of next batch
• Batch Size Range: 350 to 8,200 cartons, with a median batch size of 1,450 units
• Machine Availability: 96.2%, with changeover time excluded from availability calculation
• Format Change Accuracy: Zero format setup errors in 1,723 batch changeovers, attributed to the automated adjustment system and inline format verification
• Operator Training Time: 3 days to independent operation, compared to 8 days for the facility’s previous non-servo machine

“Our business depends on our ability to switch between client jobs rapidly and without errors,” stated the facility’s General Manager. “The ZR-Flex has fundamentally changed our production model. We can now accept orders with minimum quantities as low as 500 cartons without losing money on changeover time. This has opened up new business from small and medium-sized brands that our competitors cannot serve economically.”

Economic Impact

The facility has calculated that the ZR-Flex’s changeover performance has increased its effective production capacity by 78% compared to the legacy machine it replaced, despite having a similar maximum throughput of 45 cartons per minute. This increase is attributable entirely to the reduction in non-productive changeover time.

Additionally, the elimination of manual adjustments has reduced the skill level required for machine operation, allowing the facility to cross-train operators from other production areas. Material waste during batch startup—previously averaging 15 to 20 cartons per changeover due to trial-and-error adjustment—has been reduced to a maximum of 3 cartons, representing annual savings of approximately 18,000 cartons.

Market Interest

Since the Czech installation was publicized through Zray’s European dealer network, the company has received inquiries from seven additional contract packaging facilities in Germany, Poland, and the United Kingdom. Two concept studies are currently underway for potential ZR-Flex installations at UK-based facilities, with procurement decisions expected in Q3 2026.