Simplifying complex carton workflows with inline flexo

Each extra process step, handoff, or machine changeover adds time, cost, and risk. Traditional workflows often involve moving jobs between multiple presses and finishing stations, printing on one machine, embellishing on another, die-cutting elsewhere.

It’s a chain of operations that’s been standard for decades but is increasingly unsuited to today’s fast-moving, high-SKU packaging market.

That’s where modern inline flexographic technology changes the game. With solutions like Edale’s CartonLine platform, carton converters can consolidate every stage of production into one efficient, modular system designed for both day-to-day jobs and premium packaging work.

Conventional folding carton production is typically fragmented. Jobs are printed, then queued for finishing, then queued again for die-cutting or stripping. Each stage requires its own setup, skilled operators, and floor space. This approach works for large, static runs, but when you’re dealing with shorter runs, seasonal SKUs, or premium finishes, the inefficiencies stack up quickly.

Every time a job changes hands, there’s potential for:

For converters working to tight deadlines and margins, these challenges aren’t just operational, they’re strategic.

Single-pass inline flexo production integrates printing, varnishing, embellishing, die-cutting, and stripping into one continuous process. For example, Edale’s CartonLine machines are purpose-built for this type of single-pass efficiency, combining offset-quality print with the flexibility to handle a full range of carton applications

Instead of multiple setups, you have one. Instead of staging work between processes, jobs come off the press retail-ready.

For converters, the benefits are immediate:

One of the biggest myths is that inline flexo is only about speed, not quality. Modern systems like Edale’s CartonLine prove otherwise. High-definition flexo modules produce detail and colour fidelity that rivals offset. Inline embellishments, such as foiling, cast & cure, and tactile varnishes, are built into the process, meaning there’s no need for outsourcing or secondary finishing.

This capability is particularly powerful for premium sectors like cosmetics, spirits, and high-end food, where visual impact drives brand value. It enables converters to offer both speed and shelf appeal in the same job.

When jobs involve multiple SKUs or frequent changeovers, the real efficiency gains come from automation. Edale’s AiiR (Autonomous Inking, Impression and Registration) technology handles setup tasks that used to require skilled intervention, keeping registration tight, waste low, and uptime high.

For converters facing skilled labour shortages, automation is more than a convenience; it’s a necessity.

In a market where packaging complexity is rising, simplifying workflows isn’t just an efficiency measure, it’s a competitive advantage. Single-pass inline flexo streamlines production, protects margins, and opens the door to new work without overloading your factory.

If you’re ready to turn complex carton jobs into simple, profitable ones, the solution isn’t more machines. It’s one smarter, more capable machine.