The Challenge
Grupo La Plana, one of Spain's leading corrugated converters, needed to serve growing demand for short-run, high-graphic packaging without adding flexo lines or increasing plate costs.
Jobs below 5,000 sheets were economically unviable on their conventional flexo lines: setup times consumed margins, and plate production for such short runs wasn't cost-effective.
The Solution
They installed the world's first Kento Hybrid® Performer as their first digital investment, integrating it alongside their existing flexo plant at their Onda facility.
The hybrid line took over all jobs under 5,000 sheets, freeing flexo capacity for long runs. Integration was completed without disrupting existing production.
Results
Within six months, they measured the impact across their full production. The reduction in setup times and elimination of plates for short runs transformed their cost structure. The strategic relationship has been reinforced with a Lifecycle OEE+ agreement formalized in March 2026, targeting technical availability close to 95%.
The agreement marks a paradigm shift: from classic maintenance to an OEE+ model that combines operational excellence support, annual and biannual process and maintenance audits, scheduled on-site interventions with dedicated specialists, comprehensive spare-parts management under a Pick & Pay framework, consignment stock at the customer's facilities, remote condition monitoring with unlimited online assistance, and a remote service platform with VPN access, alarms and regular reporting.
More than a service contract, it is a productive partnership: a fixed monthly fee, cost predictability, reduced capital immobilisation in stock, and continuous OEE improvement. Intervention stops being reactive — the team acts when performance begins to drift, not when something fails. Maintenance is no longer a reactive variable; it becomes a strategic lever.
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