Interview with Giacomo Bettini (Senior Sales Representative, MHI EMEA) and Anna Salamandra (Manager, Office Administration, MHI EMEA Dusseldorf Branch).
Giacomo, Anna, nice to meet you. How does MHI’s approach to environmentally friendly solutions differ from that of its competitors?
The Mitsubishi case maker, the EVOL, has always offered advantages in terms of environmental sustainability.
First of all, thanks to its special system for ink changing in the printing units. This unique system generates turbulence of water and air inside the chamber. As a result, EVOL consumes only seven liters of water per ink change per printing unit.
This system allows us to save an average of approximately 750 tons of water every year, depending on the actual number of ink changes required by the customer.
Additionally, only 100 cc of ink is lost per change per printing unit, which equates to approximately ten tons of ink saved annually.
These features already significantly reduce the environmental impact of the machine. In addition to environmental benefits, the ink-change process is highly productive as it takes only two minutes.
Moreover, the special dual slotter (DSL) system enables significant energy savings. The production speed doubles to 42,000 boxes per hour without any substantial increase in energy consumption.
The EVOL equipped with this dual slotter system can produce the same volume as two or even three lines, accommodating various formats and dimensions.
Using only one line reduces the need for multiple sets of peripheral equipment, such as strapping machines, prefeeders and palletizers. This setup saves a considerable amount of energy and operational resources.
Giacomo, what new innovations do you plan to introduce in the near future to improve the line?
We are working on new innovations that are planned to be introduced in spring or summer 2025. At the moment, we prefer not to disclose specific details because some aspects of these innovations still need confirmation and further discussion. But they will be available soon.
We are looking forward to good news. How does the dual slotter application enable an increase in productivity to 42,000 BPH?
By adding two additional slotter shafts, making a total of three, it becomes possible to convert a single box into two boxes. The machine works in the same way as the standard model, with the boxes being separated after the counter ejector.
For instance, the standard EVOL processes 21,000 sheets per hour, but with the dual slotter, this results in 42,000 boxes per hour. This is how we effectively manage to double the production speed of the EVOL machine.
I think we can show this. This is a setup for single-box production, right?
Yes, exactly. In this case, it’s single-box production with the dual slotter unit. In the middle, the shaft is stopped, but the ones on both sides are moving, producing a single box with this setup. This setup is fully automatic.
Then the machine sets up from single-box production to twin-box production. The knives are separated and automatically positioned at the right position to produce twin boxes. You can see how twin boxes are produced when all three shafts are moving.
By using only slotter knives, without the need for die-cutting, the accuracy and quality criteria
remain the same as those of the standard EVOL.
The boxes are separated by a dedicated box slitter supplied by Mitsubishi, ensuring precision after the counter ejector.
This example shows how the system works in principle. Once the boxes exit the counter ejector as twin boxes, they then go to the slitter, where they are cut into two.
Are there any limitations for using the dual slotter application, such as materials, types, or sizes?
There are no significant limitations. The EVOL offers clear advantages over standard methods for twin-box production, such as the two-up operation.
The dual slotter application allows to produce the twin-box using the slotter shafts. So the machine treats the twin-box as one box (sheet) through all its way to counter-ejector.
And then, only after counter-ejector, the twin boxes are separated into two boxes using Mitsubishi’s box slitter. The machine works with a single sheet throughout the process, just like the standard EVOL.
The only limitation is the size:
● For the EVOL 100, boxes with lengths between 190 mm and 475 mm should be produced as twin boxes.
● For the EVOL 115, boxes with lengths between 225 mm and 575 mm should be produced as twin boxes. Other sizes can be processed as single boxes.
Another major advantage of the dual slotter is the use of slotter knives instead of die-cutting, which typically has lower accuracy. Thus, the dual slotter doubles production speed without compromising quality and without die-cutting.
Does the number of operations required to manage the line increase with additional units? How simple is it to operate? For example, how long would it take for a new operator to learn the system?
For operators, there is no difference between the EVOL with the dual slotter and the standard EVOL. The positioning of the slotter knives is fully automatic, so nothing changes for the operator. The learning time is the same across the standard EVOL, and the EVOL with the dual slotter.
How does the EVOL reduce CO2 emissions? Could you share a real-life example of energy savings achieved using this technology compared to traditional machines?
This implementation, already present in many EVOLs worldwide, provides the following benefits:
1. Production speed doubles with only a 5% increase in energy consumption.
2. The working range and specifications of the boxes are expanded.
For example, a customer replaced a mini-line and a mid-line with a single EVOL100 equipped with a dual slotter and Mitsubishi box splitter.
Based on data provided by the customer, this system reduced energy consumption by 43%, saving approximately 147 tons of CO2 annually.
Thank you for explaining. Could you share a success story about the implementation of the dual slotter application? What results have your clients achieved? Perhaps a real-life example?
Yes, we have already completed over 100 installations of this special system worldwide. Many of our customers are highly satisfied with its productivity and energy-saving benefits.
Of course, the actual cash savings from the 43% reduction in electricity consumption depend on the cost of electricity in different countries. However, we are confident this translates into significant financial savings for all our customers.
The dual slotter also significantly reduces overall production costs in multiple ways. For example, a single line replaces two or even three lines, which means fewer operators, reduced labor costs, lower maintenance needs, fewer spare parts, and considerable space savings.
I cannot share specific customer names, but this system is very popular and appreciated globally. Our customers have been able to increase both the quality and quantity of production with just one production line, while also cutting overall production costs.
Do you have examples of upgrading existing EVOL 100 and 115 lines with the DSL unit? What
results have your clients achieved?
Yes, we have around 20 to 30 examples of retrofitting existing lines with dual slotter units in Europe and other parts of the world. Essentially, almost any EVOL machine can be retrofitted with a dual slotter.
How does MHI assist its clients in integrating new technologies into their production processes?
Mitsubishi aims to make new technologies retrofittable for the EVOL wherever possible, as we did
with the dual slotter.
The EVOL is designed to last a very long time, so we help customers improve their existing lines by incorporating the most modern technological innovations developed by our engineers in Japan. Of course, we support our customers throughout the entire integration process.
Would you like to share a closing statement for your clients?
We currently have around 700 EVOL machines operating worldwide. Many of our customers already know and appreciate the EVOL.
It has a history of success, delivering increased production, improved accuracy, and reducednproduction costs. It is highly valued, especially by customers who already own one, as they understand its benefits firsthand.
We are always available to speak with new clients and demonstrate how the EVOL can meet their needs. It’s important to highlight that the EVOL is a key player in improving production efficiency and reducing overall operational costs.
Should we also mention and explain the simulation data we normally prepare for the
customers interested in the dual slotter?
Yes, we should. Customers often realize the benefits of the EVOL, especially when they own the machine. For those who do not yet have it, we always demonstrate how the EVOL performs in real production through detailed simulation data prepared by our engineers in Japan.
This data is highly accurate and reflects real production conditions. Customers can see that the theoretical data we provide matches the real results they will achieve with the EVOL. These simulations are very detailed.
Giacomo, could you please explain how the simulations are conducted?
Certainly. In many projects, we replace two or, in some cases, three machines with a single EVOL. We offer customers production simulations based on real production data they provide.
These simulations are highly detailed because they are based on real data. We analyze every order provided by the customer and show them exactly which orders can be moved to the EVOL, as well as how much time the EVOL will take to produce them, considering downtime and other factors.
For example, here is a real customer case. This table lists their existing orders, including details such as sheet dimensions, die cuts, and the number of colors. Each order is manually analyzed by our engineers in Japan.
They evaluate how these orders will be produced on the standard EVOL and the EVOL with the dual slotter, considering different configurations.
This example is just one page, but in reality, the dataset for this particular case consisted of 62 pages of highly detailed analysis. These simulations are provided free of charge to show how production would change if customers switched to the EVOL.
We show this in detail through a long study. Typically, it takes our engineers in Japan at least three weeks, sometimes more, depending on the production data provided by the customer. This allows us to clearly show how much production can be transferred from existing lines to the EVOL. Customers can be 100% confident about the orders that can be moved to the EVOL.
It’s interesting—a real example for clients. It really works.
This graph illustrates the results of the production simulation. We conducted it for the standard EVOL100, the standard EVOL115, and the EVOL versions with the dual slotter.
As shown in the graph, the EVOL—whether in its standard form or with the dual slotter—handles almost the same order volume. Only a few orders fall out of specification and cannot be processed by the EVOL. However, nearly all orders are completed in significantly less time compared to existing machines.
This is particularly important for increasing production volume and reducing overall costs, as we’ve previously explained. With just one EVOL line, customers can often achieve the same production capacity as two or three existing lines, and in less time. This approach appeals to many of our customers who want to replace multiple lines with the EVOL.
We conduct this analysis for all customers, even those with the standard EVOL.
It’s also worth saying that when we perform these analyses, we don’t take maximum EVOL speeds for the calculations. For instance, we make calculations assuming the machine speeds of 300 or 250 sheets per minute instead of 350, which is standard EVOL’s maximum speed .
Additionally, we presume longer setup time and downtime in our calculations, and not just taking two minutes required for regular EVOL setups without die cuts.
Our engineers adopt a “pessimistic” approach, using conservative figures like longer setup times and reduced speeds. Even under these conditions, the EVOL is able to consistently perform better, achieving higher production rates and efficiencies.
This methodology ensures the simulation closely mirrors actual operations at the customer’s site, accounting for potential stoppages or shutdowns by any possible reason.
Let’s emphasize that these simulations are conducted by technicians, not sales teams.
This ensures accountability. We take full responsibility in demonstrating to customers how two or even three lines can be replaced with one EVOL—standard or dual slotter-equipped—based on their specific needs. The simulations are intentionally designed conservatively to guarantee that the results will match the reality once the machine is installed.
Well, that’s everything. Would you like to add anything before we wrap up the interview? I believe we’ve covered everything about the dual slotter application. Additionally, we’ve recently surpassed 100 units sold worldwide, and we’re thrilled to see how much customers value this technology.
We’re committed to continuing this success by providing more machines, retrofitting existing EVOL models with dual slotter upgrades, and offering additional support to meet our customers’ EVOLving needs.
We’d like to thank Konstantin for this interview and extend our gratitude to all our customers for their trust in MHI.
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