Exploring the progress and potential of BOBST Connect

Several years on from its launch in 2022, BOBST Connect has evolved into a central pillar of BOBST’s vision for a connected, data-driven packaging industry. What began as a digital platform providing remote access to machine and performance data has become a comprehensive digitalization ecosystem – integrating machines, workflows, quality systems and factory software across entire plants.

So, what has been the real-world impact so far? What have customers gained in practice? Where were the early challenges? And what comes next?

When BOBST Connect was introduced, it marked a decisive shift. For the first time, BOBST made machine data available to customers via the cloud, accessible from any device and location. That move fundamentally changed how packaging converters could interact with their equipment.

In many factories at the time, production data was still being collected manually. Machine connectivity often relied on complex, individually programmed interfaces. There was no universal standard for simple integration. 

BOBST Connect removed much of that complexity, enabling machines to connect to digital systems more easily.

The result was immediate transparency. Production managers could monitor live views, analyze downtime, compare repeat job performance, and access essential machine status information remotely. Simple and easy to use dashboards made any issues visible in real time, supporting faster, data-driven decisions.

From connectivity to measurable performance gains

For early adopters, the benefits in terms of measurable performance improvements soon became clear.

At Stora Enso Packaging in Sweden, the implementation of BOBST Connect across two converting plants delivered tangible operational uplift. Following integration, the company reported a 4.4% increase in production capacity and a 3.3% increase in production efficiency. Machine availability reached 98.5%, alongside reduced downtime and waste.

“We wanted more knowledge of how our machines are running, to maximize our efforts, and we’ve also seen decreased machine downtime and reduced waste,” states Fredrik Wiell, maintenance manager, Stora Enso Packaging. “Digitalization and connectivity are very important for us, and we’ve invested in several training packages from BOBST, tailored to our needs, as well as the comprehensive Maintenance Plus service plan to keep our machines operating at their best.”

Similarly, DS Smith, an International Paper company and long-standing BOBST partner, adopted BOBST Connect across its EMEA facilities to unify machine data and digital services into one connected platform. The system supports improved planning, better-informed decision-making and continuous optimization.

“We have used the BOBST Connect platform since its inception,” notes François Duboin, technical excellence director, DS Smith Packaging EMEA. “Having already seen benefits in terms of performance, we are excited to experience and have access to the wealth of data and the advances in efficiency and productivity that the platform helps us to unlock.” 

These examples illustrate the impact that BOBST Connect is having for customers – enabling performance and productivity gains while reducing downtime and waste. 

Benefiting from continuous innovation 

As the platform has matured, it has expanded into new functional areas. All BOBST Connect users worldwide benefit from continuous innovation. Examples include continuously improved data views of downtime information, efficient performance comparisons of repeat jobs, and the use of AI systems for the recognition of text fields from PDF designs, for automated quality inspection.

Energy transparency has become a priority, particularly as sustainability reporting and carbon footprint reduction gained urgency.

BOBST Connect Energy Monitoring was introduced to measure energy consumption. Selected energy data is displayed per machine, day and per job, thus enabling extended transparency of production on the topic of sustainability. For companies like DS Smith, this supports observation of energy reductions and aligns with broader circular economy ambitions. 

Tool management also emerged as a key focus area. With TooLink, converters can monitor tool performance data to detect wear early, prevent quality defects, and reduce unplanned downtime. This shift from reactive to predictive maintenance reflects the broader movement toward smarter factories.

With Job & Recipe Management, product and job data from ERP systems can be transferred automatically to machine recipes and sent to connected lines, with performance data flowing back after completion. This closes the loop between planning, production, and analysis.

Meanwhile, the integration of BOBST Connect Insight with Remote Service Helpline has significantly improved service responsiveness. Most issues can be resolved via remote assistance, reducing downtime and accelerating problem-solving. 

Quality control at printers’ fingertips 

Quality control has also been transformed. ACCUCHECK is an inline quality control system that inspects every single blank to ensure only zero-fault boxes are delivered. With ACCUCHECK Recipe Management on BOBST Connect, users can create quality control recipes on a PC or tablet remotely, supported by AI-based recognition of text fields from order PDFs, and then send them directly to any ACCUCHECK on the production floor. 

“Using the ACCUCHECK Recipe Management function has greatly improved the setup phase on the ACCUCHECK on our EXPERTFOLD 80 line,” comments Armando Zanini, CEO of paper converting specialist Prealpi srl. “The option to prepare the recipe remotely, and in advance, has demonstrated great advantages in terms of both time savings and better product quality.” 

Structured digital quality reports provide full transparency for each production run. For sectors such as pharmaceuticals, cosmetics and food packaging, where premium presentation and compliance are critical, this represents a significant competitive advantage.

Finally, BOBST also provides integration solutions for the existing installed base, including machines that have been reliably operating for many years, even decades. The BOBST Connect Data Kit enables a standardized connection across all machine types, delivering data transparency throughout the entire plant.

Overcoming the hurdles

Like any digital transformation, the journey has not been without some challenges. Early on, some customers expressed concerns about data security and cloud deployment. However, certified cloud infrastructures and partnerships have proven robust and secure. In many cases, cloud-based systems now exceed the security standards achievable with legacy local installations.

Another hurdle has been cultural rather than technical: moving from manual data collection to automated, standardized data flows requires process change and training. Adoption has therefore been as much about change management as about technology.

What does the future hold?

BOBST Connect continues to evolve and it is fast becoming the backbone of end-to-end digital workflows.

Several years into the journey, the impact is measurable: higher efficiency, improved sustainability, faster service, better quality, and smarter decision-making.

Looking ahead, the next five years will focus on seamless integration of production lines into fully smart factories. High-quality, plant-wide data will provide the foundation for AI-driven optimization, predictive insights, and autonomous decision-support systems.

The next chapter will not just be about connecting machines, but about connecting the entire value chain, BOBST says. This ranges from order creation to final delivery, in a secure, data-rich ecosystem that enables the packaging industry to operate smarter, faster, and more sustainably than ever before.