Emballator improves production efficiency with AI

As industry demands change, so do the tools needed to meet them. At Emballator in Ulricehamn, AI has become part of the solution—helping make production more efficient and supporting a more data‑driven way of working.

With support from AI, 5G and self‑driving vehicles, the shift towards Industry 4.0 is already underway. The aim is simple: to streamline production and make improvements where they create the most value.

In Ulricehamn, continuous improvements are already part of everyday work. When an opportunity arose to tap into AI expertise through Emballator’s owner Herenco, one question quickly became central: How can we make the printing press process more efficient and reduce setup time?

Johan Gustafsson, COO at Emballator in Ulricehamn, explains:

“Setup time—the period when a machine is stationary as operators prepare for the next order—depends heavily on the order sequence. Colour changes and plate formats both affect the process. Planning used to be complex, time‑consuming and difficult to optimise.”

AI-supported planning improves production flow

The solution, which has been running since spring 2022, allows planners to select production orders for the coming week. An AI algorithm then calculates the order with the shortest total setup time. Operator knowledge remains essential—AI suggests, and the operators refine and validate.

Jonatan Flyckt, Data Scientist at Herenco, describes the logic:

“It works a bit like the shortest‑path algorithms used in map services. For me, the project has meant learning a lot about the manufacturing process and what it takes to move from an idea to a fully implemented AI solution.”

Clear benefits in day‑to‑day production

The AI‑supported planning offers several advantages. Emballator can produce more units per hour, reduce changeover time, decrease production waste and improve energy efficiency.

“There are fewer uncertainties now and the process is simpler. The operator contributes with their expertise and double‑checks that the planning looks right,” says Johan Gustafsson.

Looking ahead

What comes next?

“AI will affect the industry in many ways. In the short term, I think we’ll see more forecasting tools and better understanding of customer behaviour. We already have several ideas about how AI can support us further,” Johan concludes.