The following article appeared in the latest issue of International Paper Board Packaging North America:

Partnership Built on Performance:

Why Unicorr Packaging Group Invested in a Second Göpfert RDC 16/28 HBL

For manufacturers of high-quality corrugated packaging, investment decisions are about much more than increasing production capacity. Reliability, print quality, productivity and long-term partnership are equally important. For Unicorr Packaging Group, these factors led to the decision to invest in a second Göpfert RDC 16/28 HBL rotary die cutter for its North Haven, Connecticut facility.

The investment builds on the success of the first RDC HBL, installed at the end of 2018. Over the past several years, the machine has consistently delivered the performance, quality and reliability expected from a world-class rotary die cutter. As Unicorr celebrates its 80th anniversary, the installation of the new seven-colour RDC 16/28 HBL marks another important milestone in the company’s strategy of continuously investing in people, technology and manufacturing excellence.

“When we invested in our first Göpfert RDC HBL in 2018, we were looking for a machine that would support our long-term growth strategy,” says Nick Perkins, Vice President of Operations, Connecticut Container at Unicorr Packaging Group. “Its outstanding performance and reliability made the decision to purchase a second machine remarkably straightforward. This investment is based on proven results.”

Building on Experience

The first RDC 16/28 HBL quickly became an essential part of Unicorr’s production. Equipped with a prefeeder, feed unit, six printing units, transfer unit, rotary die-cut unit, bundle stacker and material handling system, it enabled the company to increase productivity while delivering excellent print quality.

Automation features such as Automatic Print Control (APC), camera-based colour register control and regulation and numerous intelligent machine functions have helped minimise setup times, reduce waste and ensure highly consistent production quality.

Encouraged by this positive experience, Unicorr decided not only to invest in another Göpfert machine but to take the next technological step.

The Next Generation

Installed and commissioned in 2026, the new RDC 16/28 HBL represents the latest generation of rotary die-cutting technology. The line consists of a prefeeder, feed unit, seven printing units, transfer unit, double rotary die-cut unit, bundle stacker and a material handling system supplied by Corrpal Systems.

The additional printing unit provides greater flexibility for sophisticated graphics, while the double rotary die-cut section improves production efficiency and supports increasingly demanding packaging applications. Integrated automation, including APC, intelligent colour register regulation and advanced inspection cameras, ensures consistently high print quality throughout production.

The machine also enables GMI-certified printing for major retailers and consumer brands, allowing Unicorr to meet the growing demand for premium shelf-ready packaging with outstanding graphic quality.

“Packaging has become an essential part of brand communication,” explains Johnny Boykin, Sales Manager at Connecticut Container. “Our customers expect excellent graphics, dependable colour consistency and maximum flexibility. This new RDC enables us to deliver all of that while increasing productivity and supporting future growth.”

The commissioning of the new production line represents one of the largest technology investments in the company’s recent history. During installation, major machine components gradually transformed the production floor into one of the most advanced corrugated printing and converting operations in the region.

Tailored to Unicorr’s Requirements

One of the defining aspects of the project was Göpfert’s willingness to adapt the machine to Unicorr’s specific production environment.

Installing a rotary die cutter of this size inside an existing building with limited height presented a significant engineering challenge. Göpfert successfully developed an installation concept that allowed the complete production line to be integrated into the available space without compromising machine functionality or accessibility.

“The installation required detailed planning and excellent engineering,” says Joe Konicki, Director of Engineering at Unicorr. “Despite the limited building height, Göpfert successfully integrated the complete machine into our existing facility. Their flexibility and problem-solving approach were outstanding throughout the entire project.”

Beyond the installation itself, Göpfert implemented several customised solutions to optimise daily production.

A specially designed access door on the drive side of the machine simplifies the insertion of rotary die-cutting tools, improving ergonomics and reducing setup effort.

Furthermore the machine was prepared to receive Final Flexo Dryers with special features like Color Dry AutoDryer Control and AutoWash Automatic Plate Cleaners by JB Machinery Inc.

“These customised solutions show that Göpfert listened carefully to our operational requirements,” explains Manny DaSilva, Converting Manager at Connecticut Container. “Rather than supplying a standard machine, they adapted the equipment to fit our production environment perfectly. Every modification contributes to greater efficiency and easier operation.”

A Partnership Based on Trust

For Unicorr, the investment in a second RDC HBL is also a reflection of a successful long-term partnership.

Since the first machine was installed in 2018, Göpfert has supported the company with reliable service, engineering expertise and open communication. Throughout planning, installation and commissioning of the new machine, both teams worked closely together to ensure every aspect of the project met Unicorr’s operational expectations.

This collaborative approach was one of the key reasons behind the decision to invest in Göpfert again.

“Technology alone does not make a successful project,” says Perkins. “Equally important is working with a partner who understands our business and is prepared to develop solutions that create real value. Göpfert demonstrated exactly that throughout this project.”

Looking Ahead

With the second Göpfert RDC 16/28 HBL now in production, Unicorr Packaging Group has further strengthened its position as a leading supplier of premium corrugated packaging.

The new seven-colour production line expands manufacturing capacity, enhances graphic capabilities and provides the flexibility needed to meet the evolving requirements of brand owners and retailers. At the same time, it supports Unicorr’s long-term strategy of investing in innovative technology that delivers measurable benefits for customers.

Looking back over nearly eight years of cooperation, Unicorr sees the latest investment as the logical continuation of a successful partnership. The first RDC HBL proved its value every day in production. The second machine builds on that experience with even greater capabilities, advanced automation and customised engineering solutions that fit seamlessly into the company’s manufacturing environment.

For Unicorr Packaging Group, the project is more than the installation of another production line. It is a clear commitment to innovation, operational excellence and a partnership with Göpfert Maschinen GmbH that continues to support the company’s growth and its customers’ success well into the future.