Layout Optimization
The ratio of the area of finished carton blanks to the total area of the sheet from which they are cut determines the material efficiency of the packaging run. Packaging designers use structural CAD layout efficiency to compare different carton orientations and nesting configurations before the die-cutting plates are manufactured. This analysis is performed using specialized software that calculates the most efficient nesting patterns for the blanks.
Design Impact
Even minor changes to the flaps or closure locks of a carton can significantly improve how the blanks nest together on the sheet. This structural CAD layout efficiency is critical for high-volume jobs where a two percent increase in sheet utilization can save thousands of dollars in paperboard costs. The designer must balance the structural requirements of the box with the need to minimize waste in the die-cutting press.
An optimized layout also reduces the amount of stripping scrap that must be cleared from the press.
Yield Improvement
Modern CAD software allows designers to run multiple nesting simulations to find the highest-yielding configuration for a given sheet size. Achieving high structural CAD layout efficiency ensures that the maximum possible number of packages are produced from every sheet of board.
