An Integer Programming Solution to the Folding Carton Printing Plate Layout Problem

Folding cartons are used in myriad consumer products. For some products, such as hair dye kits, a very high-resolution printing is required. This is typically done using a technology known as Gravure printing. Gravure printing utilizes engraved cylinders which are very expensive. As a result, the printer often combines multiple products on one set of cylinders to minimize the total number of cylinders used. Since the demand between products varies, this can result in overproduction of the low demand products. This chapter presents an integer programming formulation that assigns products across multiple sets of cylinders in order to minimize this overproduction. Sample problems, their solutions and solution times are presented.