Capabilities

Reel to pallet, on one site

Nothing is subcontracted between the reel arriving and the truck leaving. One site, one specification, one team answerable for it.

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  1. 01

    Board making

    Reels of liner and fluting are corrugated and laminated into board to the specification the job calls for.

    • Reels held in ten widths from 920 mm to 1690 mm
    • 3 ply and 5 ply, B, C, E and BE double wall
    • The corrugator runs continuously — a long job carries across the shift change rather than stopping
    Fig. reel-storePhotograph pending

    The reel store: paper stacked by width, seen end-on so the scale reads.

    Paper held in ten reel widths, from 920 mm to 1690 mm
  2. 02

    Printing and cutting

    Board is flexo printed and cut in line, so print registration and cut position are set together.

    • Four-colour flexographic printing direct to board
    • In-line slotting and cutting
    • Print approved against the customer's artwork before the run
    Fig. printerPhotograph pending

    The four-colour flexo press mid-run, close on the print unit and a sheet coming through.

    Four-colour flexographic printing, direct to board
  3. 03

    Converting and finishing

    Die-cutting, slotting, folding, gluing and stitching turn cut board into the finished box.

    • Rotary die-cutting for shaped and self-locking work
    • Automatic folder-gluer
    • Stitching for heavy-duty cases
    Fig. convertingPhotograph pending

    Die-cutting or the folder-gluer working, hands and machine together.

    Die-cutting, folding and gluing on the finishing line
  4. 04

    Quality control

    Board and finished product are tested against the specification before anything is released.

    • Grammage, bursting strength and box compression testing on site
    • Dimensional and print inspection against the approved sample
    • Non-conforming product is held, not shipped
    Fig. qc-benchPhotograph pending

    The box compression tester with a carton under load, and the QC record sheet in the same frame.

    Box compression testing on site, recorded against the job
  5. 05

    Packing and dispatch

    Product is bundled, palletised, labelled and loaded on ICZ's own fleet.

    • Bundled and palletised to a counted, repeatable pack structure
    • Own delivery fleet across Lusaka and the line of rail
    • Export consignments prepared with the documentation the corridor requires
    Fig. finished-goodsPhotograph pending

    Palletised finished cartons stacked and banded, shot wide enough to show the volume.

    Bundled, palletised and counted before loading
Fig. dispatchPhotograph pending

A truck being loaded at the dispatch bay, doors open, pallets going on.

Delivered on our own fleet across Lusaka and the line of rail

On the floor

Plant and equipment

  • Corrugator — B, C and E flute
  • Four-colour flexographic printer
  • Rotary die-cutter
  • Automatic folder-gluer
  • Case stitching
  • Box compression tester
  • Bursting strength tester
  • Grammage and dimensional inspection

Specification

Manufacturing range

Manufacturing range
Construction3 ply (single wall) · 5 ply (double wall)
FlutesB · C · E · BE double wall
Reel widths920–1690 mm, in 10 widths
Maximum sheetSheets up to approximately 1 m × 1 m
PrintingFlexographic, direct to board, up to 4 colours
Running patternContinuous — long jobs carry across the shift change
DeliveryOwn fleet, Lusaka and the line of rail

Visit

Come and see the line

The quickest way to judge a packaging supplier is to walk the floor. Buyers are welcome at the plant by arrangement.

Arrange a visitHow we control quality