Cases24 Ready For The Future With DYSS Digital Cutter And KASEMAKE

Logson Group, DYSS and KASEMAKE


Cases24 is the case making division of Board24, which is in turn part of the Logson group of companies. The Logson Group is a UK based group of corrugated packaging companies employing over 1000 people and turning over £200m annually.

Board24 manufacture high quality corrugated sheet board. The materials produced at Board24 are 100% recyclable, 100% biodegradable and made from 90% recycled or recovered paper.

Cases24 operates four Casemakers at their Coalville manufacturing site. The company caters for trade customers with a minimum order quantity of 5000m2. Cases24 is a market leader in the supply of high volume glued FEFCO style boxes 0200, 0201, 0202, 0203 etc. Packaging can be supplied with up to three-colour Flexographic print.

DYSS X5-1625T

The CAD facility at Cases24 is there to assist customers looking to place an order. Being able to offer a fast turnaround on pre-production samples is key to gaining new business. Jemma Hudson, Board24 Design & Laboratory Manager, uses the CAD cutter mostly for customer samples:

Following an increase in design and sampling activity due to customer growth over the last few years, it became clear that our KM627 cutter wasn’t up to the job. Lead times were sometimes pushed out from 24-48 hours, up to a week, which was unacceptable, especially when a customer has urgent needs.

Board24 Testing Laboratory

The KM627 cutter installed at Cases24 was supplied and maintained by AG/CAD from new. When the time came to start looking at a replacement machine, Cases24 contacted AG/CAD to explore what options were available. Jemma goes on to say:

Since installation, we have not had any down time. This has ensured that we can maintain the fast and efficient service that our customers have come to know us for.

Todays corrugated marketplace is very competitive, being able to approach a customer’s requirements from a technical perspective makes all the difference when it comes to winning an order. At Cases24's laboratory, analysis of the board produced is carried out - testing materials for edge crush, and burst strength etc.

The DYSS X5-1625T was chosen as the perfect match for the technical department at Cases24. Being able to select the most cost-effective material for a specific pack and having the ability to quickly manufacture prototypes, gives customers confidence to proceed to large scale manufacture.

The design and technical departments at Board24 have expanded over recent years. Alex Spencer joined the team in 2018 as an apprentice Lab Technician. Alex says:

It was not long after I started work at Cases24 that the DYSS digital cutter was installed. The DYSS is in regular use. Projects that would have taken a full day to produce on the KM627, are manufactured in a fraction of the time on the DYSS.

Alex goes on to say:

Although the work produced on our four Casemakers is generally FEFCO 0201 styles, we can add hand grips and perforations (rip/tear) using tooling. KASEMAKE gives us the ability to quickly add these details to the packs we design, and when paired with our DYSS cutter, the results closely match work produced on the Casemakers.

The DYSS X5-1625T at Cases24 is supplied with optical calibration sensors. Once the required tools have been selected and calibrated, precise cutting and creasing depths can be set using the KASEMAKE machine control software. With DYSS cutters, any tool can be set to operate at different heights in the X and Y axis, tolerances of up to 100th of a millimetre can be achieved. This is especially useful when working with thinner recycled papers used in corrugated cases. Higher creasing pressures can be applied across the flute and backed off in the flute direction. Having the ability to quickly set up material profiles and edit them on the fly, along with the ability to change creasing wheels without the need to remove the creasing tool, means that high quality cases can be manufactured on the DYSS cutter, without split inner liners. Having optical calibration sensors gives the operator the ability to precisely set the cutting depth, ensuring that only the tip of a blade contacts the machines cutting mat. This increases the longevity of the mat and saves money.

AG/CAD Support

Cases24 has two licenses of KASEMAKE, one of these licenses is installed on the DYSS cutter dedicated workstation. Alex says:

Having KASEMAKE at the workstation means that I can quickly make alterations where required and save these to the network.

If I do have any questions regarding KASEMAKE or the DYSS cutter, I know that I can call AG/CAD and be quickly put through to a member of the Support Team. If necessary, support can dial straight into KASEMAKE or the DYSS cutter using TeamViewer.

Continuous investment

Cases24 has a policy of continuous investment. Being part of an independent group means that decisions can be made quickly. Managing Director of Cases24, Alex Morris, says:

The major qualifying reason for choosing AG/CAD and the DYSS cutter is the perceived view that AG/CAD appear more focused on the corrugated sector than their competitors. AG/CAD are very keen to continue supporting us with their equipment and software into the future. It is our opinion their strong desire to remain partnered with us is a vital facet of supplier relations. The build quality of the DYSS cutter is ideal for our operation and there are enough customisable aspects of it to ensure we have everything we require for efficient case manufacture. And finally, AG/CAD were happy to find a home for our old cutter, which had largely come to end of life.

Cases24 was the first company within the Logson Group to upgrade its ageing KM627 with a fast DYSS X5-1625T digital cutter. Since the installation at Cases24, there has been further digital cutter investment at Boxes and Packaging Manchester and Oxford sheet plant sites. DYSS X5-1625T digital cutters replaced older KM series cutters at both locations.


As the corrugated packaging market becomes more competitive, the benefits gained from the investment in design and designers are clear to see. The sample table has moved on, DYSS digital cutters are not only able to support design departments where the fast turnaround of prototypes is required, they are also 24/7 production machines, earning their keep by doing away with the requirement of bulky tooling and adding the ability to amend customers designs without costly tool changes.

AG/CAD are your partner for industry leading KASEMAKE software and reliable DYSS digital cutter solutions.

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