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Corrugated Board Processing With Maximum Net Output: Koenig & Bauer Introduces New CutPRO 2.1 Flatbed Die-Cutter
New development shifts focus from theoretical peak values to real-world productivity in daily operations
- Focus on net output instead of theoretical maximum speed
- Advanced technology for optimised material flow
- Intelligent and intuitive HMI, supported by integrated AI
- Delivery and installation of the first prototype scheduled for late 2026, followed by a testing phase
With the CutPRO 2.1, Koenig & Bauer presents a new flatbed die-cutter for corrugated board processing. Developed in joint cooperation within the Group, the machine is specifically designed for production stability and high reliability in practical operation. During the design phase, the primary focus was on optimising net output by minimising unforeseen downtime and micro-stops.
“Our customers are under intense pressure to protect their margins while managing the shortage of skilled workers. With the CutPRO 2.1, we deliver more than just theoretical peak output – we provide a machine that secures true profitability in three-shift operations thanks to its process stability,” outlines Hannah Potrawa, Director Corrugated at Koenig & Bauer. “This is our understanding of a true partnership solution.”
Technological details for continuous production processes
The CutPRO 2.1 processes sheet sizes up to a maximum of 1,300 x 2,100 mm at speeds of up to 7,000 sheets per hour. The range of compatible substrates extends from solid board to corrugated board.
To focus on continuous material transport, gripper movements were harmonised using Varioplan® and Variolever® technology, alongside optimisations to the delivery and non-stop systems. These measures reduce the typical causes of machine stops and micro-stops at high production speeds.
To reduce unproductive downtime during make-ready and maintenance procedures, the machine is also equipped with features, such as an automatic chain tensioner, improved waste routing within the die-cutter, and a safety mechanism for manually moving the die-cutting unit.
In addition, the CutPRO 2.1 offers tool compatibility with existing die-cutting tools. Established tool sets can be seamlessly integrated into new workflows, which reduces changeover costs.
Intuitive design and AI integration to reduce staff workload
In view of the industry-wide shortage of skilled workers, the human-machine interface (HMI) has been completely redesigned. The logical structure of the user interface makes onboarding easier for new employees and shortens the training period. Manual procedures have also been simplified; for instance, a special system allows a single operator to lift the upper frame safely.
For real-time data analysis, the CutPRO 2.1 is integrated into the myKyana software ecosystem and uses AI-supported functions to provide and analyse production data, thereby proactively minimising operating errors.
Practical validation and schedule
The machine was developed in close coordination with customers from the field. The upcoming schedule outlines that Koenig & Bauer will deliver and install the first alpha machine at a pilot customer's site before the end of this year. Immediately afterwards, an intensive testing phase of the prototype will begin in a real, live production environment to finally validate the practical suitability and cost-effectiveness of the flatbed die-cutter.