Abstract:
A method and system for digitally scoring a substrate prior to completing a carton blank is disclosed. After digitally printing a substrate, it is processed through a series of scoring wheels, male on top, female wheel on bottom. The scoring wheels (and transfer belts which help move the substrate through the wheels) are controlled from the same computer file used to create the graphic image. Subsequent to the first scoring sequence, the substrate is turned 90 degrees and a second scoring sequence takes place. After the scoring sequences have been performed, the substrate continues to the laser die cutter where the same computer or digital file determines where to physically cut the sheet into a carton blank.

Description:
[0001]    This claims priority to US Provisional Patent Application Ser. No. 61/723,997, filed Nov. 8, 2012 and hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates generally to cartons and, more particularly, to a system and associated method for digitally scoring carton blanks to be formed into cartons. 
         [0003]    The rapid evolution and globalization of trade around the world creates a significant demand for packaging to transfer and distribute goods to different remote areas of the world. The transport of goods may be done by ships, airplanes, trucks, and so on. The transport of goods may be performed by the manufacturer, different suppliers, individual persons and so on. Further, a significant demand for different packaging also takes part in trade. The different packaging may include paperboard cartons which are formed from carton blanks which may have pre-folds and/or embossing, for example, to assist in forming the carton blank into a carton. 
         [0004]    Packaging takes a major role in the marketing of goods. The package in which the goods are packed and presented, in a store for example, may determine if or to what degree the goods will be appealing to a potential buyer. Thus the packaging appearance can have a direct effect on the sales of merchandise. 
         [0005]    Henceforth, throughout the description, drawings and claims of the present disclosure, the terms package, paperboard box, parcel, box, carton, paperboard box, brochure, flyers, etc. may be used interchangeably. The present disclosure may use the term carton as a representative term for the above group. 
         [0006]    One known preliminary requirement to construct a wide range of cartons, is preparing or purchasing a pre-treated paperboard and/or paper based material. Paper based material may be of different types. Exemplary types include paperboard, waxed paper, cartridge paper, art paper, synthetic paper, etc. Henceforth, throughout the description, drawings and claims of the present disclosure, the terms paperboard, card-stock, display board, corrugated fiberboard, paperboards of different paper based material, folding boxboard, carton, blanks, and so on, may be used interchangeably. The present disclosure may use the term paperboard as a representative term for the above group. 
         [0007]    The pre-treatment of paperboard may include: creating folding lines along the paperboard to ease and provide accurate folding of the paperboard, piercing the paperboard in different areas, creating embossment in different areas of the paperboard, cutting the raw paperboard into predefined shapes, and so on. 
         [0008]    Much attention in the packaging industry currently surrounds digital printing such as the use of computers, digital files and digital print engines, as well as inkjet and electro photographic devices, to position dots of varying sizes and colors onto substrates to create a desired image. And to a lesser, but growing extent, digital die cutting is also gaining momentum. Digital die cutting, in one well known embodiment, makes use of digital files to direct a cutting laser onto a substrate for the purpose of either cutting or perforating the substrate. 
         [0009]    While both digital printing and digital die cutting may be well known, the state of the digital carton making art is, however, lacking in that there is no known way to digitally score or crease substrates with fold lines without degrading the integrity of the substrate. Perforating a substrate with a laser may be used to create a score line, but this technique also cuts through and damages the integrity of the substrate in the process. 
         [0010]    One technique has been introduced by Highcon which it calls “digital die cutting/scoring.” However, this technique requires the creation of a scoring rule from UV curable materials applied by inkjet. In other words, rather than produce steel die rules and bend them in a conventional manner, this Highcon technique generates new die rules from polymers. 
         [0011]    One of the hallmarks of true digital printing is the ability of the print engine to print a different image on every carton, card, or substrate without retooling (i.e. new printing plates, cylinders, etc.) In sum, every image can be different, and there is no added tooling, make ready costs or time delays. The same holds true for digital die cutting. A computer file (i.e., .pdf) can direct a laser to cut each subsequent substrate in a shape that is different from the previous one. 
         [0012]    There is no known technique to provide the ability to score a substrate with infinite variability. Prior systems may cut digitally, but scoring commonly requires shut down and make ready operations for each variation in the desired scoring pattern. 
       SUMMARY OF THE INVENTION 
       [0013]    These and other shortcomings in the prior art are addressed in various embodiments of this invention. Briefly described, the objects of this invention are achieved by a method and system for digitally scoring a substrate prior to completing a carton blank. After digitally printing a substrate in one embodiment, the web is sheeted (or it could start as a sheet) and is sent through a series of scoring wheels, male wheel on top, female wheel on bottom, in one embodiment. The scoring wheels (and transfer belts which help move the substrate through the wheels) are controlled from the same .pdf (or other computer) file that was used to create the graphic image. One aspect of this invention is that a .pdf file with the desired die line is used to score the substrate. This file instructs the wheels, belts and other equipment to position themselves on the X and Y axes and engage/compress the carton substrate for a particular length in a particular place to score the substrate and produce the desired fold lines to erect the resulting carton blank into a carton. 
         [0014]    Subsequent to the first scoring sequence, the substrate is turned 90 degrees, by a gyro-box, a continuous motion robotic arm or other assembly. Because the substrate is typically rectangular, accurately repositioning it 90 degrees in a continuous motion sequence can be accomplished in any one of a variety of ways. 
         [0015]    After the 90 degree turn, the second scoring sequence takes place. Same procedure as the first: belts have been positioned from the .pdf or other computer or digital file, scoring wheels in place, and pressure applied for the appropriate duration of time to the substrate so as to create a score or fold line of a specified length, depth and other parameters. 
         [0016]    After the scoring sequence has been performed, the substrate may continue to the laser or other die cutter where the same .pdf file determines where to physically cut the sheet into a carton blank. 
         [0017]    One aspect of this invention is that score lines along straight lines can be produced. Practically, linear scores or fold lines are utilized in about 99 percent of the folding cartons produced in the world. In various embodiments, four or more score lines in each orthogonal direction can be produced and the score lines may be either parallel or perpendicular to each other. Again, this covers about 95 percent of the world&#39;s cartons under this invention. Most cartons tend to follow some variation of the classic parallel-piped theme, e.g. a refrigerator-housed carton containing twelve cylindrical beverage cans or the like. 
         [0018]    These and other objects, features, and advantages of this invention will become more apparent upon reading this specification in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
           [0020]      FIG. 1  is a flow chart according to one aspect of this invention; 
           [0021]      FIGS. 1A-1C  are plan views of the output from the respective steps of  FIG. 1 ; 
           [0022]      FIGS. 2A-2C  are sequential top plan views a lower bed of one embodiment of a system for digitally scoring of carton blanks according to this invention with an upper bed of the system removed for clarity; 
           [0023]      FIG. 3  is a cross-sectional view taken along line  3 - 3  of  FIG. 2A  showing both the upper and lower beds of the system; and 
           [0024]      FIG. 4  is a block diagram of an exemplary hardware and software environment suitable for implementing the system of one embodiment of this invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]    A system  10  according to various embodiments of this invention is intended primarily for folding cartons which could be used with cans or bottles, and other types of cylindrical containers, used to contain soft drinks, beverages or beer. Other items constructed from paperboard can also readily make use of this invention. According to an embodiment of the invention, the cans are packaged in a carton that is fully enclosed, except for appropriate dispenser or carrying openings. A blank  12  for forming a carton is illustrated in  FIG. 1C  according to one embodiment. The blank  12  is formed from a foldable sheet of material, such as paperboard. Examples of cartons formed from such blanks are disclosed in U.S. Pat. Nos. 8,127,925; 8,118,212; 7,614,543; 5,947,367 and 5,682,984, each of which is incorporated by reference herein. 
         [0026]    Referring to  FIG. 1 , a flow chart showing generally the steps according to one embodiment of this invention is shown. Initially, a substrate  14  is printed, digitally or otherwise,  16  with appropriate graphics  18  on a print side  20  of the substrate. The substrate  14  also has an opposite non-print side  21 . Digital printing on substrates is well known in the art. A next step according to a method of one embodiment of this invention is to digitally score  22  the printed substrate  14  with the appropriate score or fold lines  24  for erecting the desired carton from the carton blank  12 . The process of digitally scoring  22  the substrate  14  into a scored sheet  26  as shown in  FIG. 1B  will be discussed herein below with respect to  FIGS. 2A-3 . In various embodiments of this invention, the fold lines  24  may extend across the entire length or width of the substrate  14 , just at or beyond the perimeter of the carton blank  12  or combinations of these arrangements. 
         [0027]    Those skilled in the art readily appreciate that there is a wide variety of techniques to produce a fold in a substrate such as a sheet of paperboard as one example. 
         [0028]    A good functional fold occurs when the paperboard delaminates in the crease into as many thin, undamaged layers as possible. Ply bond strength must be a compromise, so that delamination occurs easily in a crease while the structure holds together in other areas. 
         [0029]    Moreover, the substrate  14  may be subject to various other processes in accordance with embodiments of this invention which may or may not result in a fold, such as embossing. The Paperboard Packaging Council (www.ppcnet.org) defines embossing generally as raising areas of a design above the flat surface of carton blanks. They also define a score generally as a crease along which the adjacent elements of a die cut carton blank are folded without cracking or breaking to form a carton. Likewise, they define creasing generally as the production of the score or folding line in a sheet. These and other terms are collectively referred to herein as a score, scoring or variations of such terms as applied to a substrate which may or may not result in a fold in the carton blank and may or may not include a penetration or cut through the structure of the substrate  14 . 
         [0030]    After the substrate  14  is digitally scored  22 , the scored sheet  26  is, in one embodiment, digitally cut  28  via a laser into the shape of the carton blank  12  as shown in  FIG. 1C . While the sequential steps of printing  16 , scoring  22  and cutting  28  a substrate are shown in one particular order in  FIGS. 1-1C , one of ordinary skill in the art will appreciate that these steps may be performed in a different order, combined and/or additional steps may be included throughout the process according to various embodiments of this invention. 
         [0031]    Referring to  FIGS. 2A-2C , one system  10  for digitally scoring the substrate  14  according to this invention is shown in which the substrate  14  is sequentially processed through the system  10  in  FIGS. 2A-2C . The system  10  includes an upper bed  29  and a lower bed  31  as shown in  FIG. 3  with the substrate  14  passing generally between the beds  29 ,  31 . The lower bed  31  is built upon a generally rectangular frame  30  according to one embodiment with an upstream end  32  of the frame  30  located opposite a downstream end  34  of the frame  30  and lateral side edges  36 ,  36  extending between the upstream and downstream ends. The view of the system shown in  FIGS. 2A-2C  is the lower bed  31  of the system  10  with the upper bed  29  of the system  10  removed in  FIGS. 2A-2C  for clarity. The upper and lower beds  29 ,  31  of the system  10  are shown in the cross-sectional view taken along line  3 - 3  of  FIG. 2A  and  FIG. 3 . A number of shafts  38 ,  40 ,  42 ,  44 ,  46 ,  48 ,  50 ,  52  extend between the opposed lateral sides  36  of the frame  30  and are spaced from the upstream end  32  to the downstream end  34  as shown in  FIGS. 2A-2C . 
         [0032]    The system  10  also includes an upstream conveyor assembly  54  as well as a downstream conveyor assembly  56  for transporting the substrate  14  through the system  10  generally from the upstream end  32  to the downstream end  34 . Each of the conveyor assemblies  54 ,  56  includes a pair of conveyor belts  58   a ,  58   b  and  60   a ,  60   b  which are each trained around upstream and downstream pulleys  62   a ,  62   b ,  64   a ,  64   b ,  66   a ,  66   b ,  68   a ,  68   b . The upstream pulleys  62   a ,  62   b  of the upstream conveyor assembly  54  are each mounted for rotation on the same shaft  38  and the downstream pulleys  64   a ,  64   b  of the upstream conveyor assembly  54  are commonly mounted on the shaft  44 . Similarly, the upstream pulleys  66   a ,  66   b  of the downstream conveyor assembly  56  are mounted on a common shaft  46  and the downstream pulleys  68   a ,  68   b  of the downstream conveyor assembly  56  are commonly mounted on the shaft  52 . Each of the pulleys are positioned on the respective shaft by a carrier belt linear adjustment mechanism  70 ,  72 ,  74 ,  76 ,  78 ,  80 ,  82 ,  84 , each of which is mounted to the adjacent lateral side  36  of the frame  30  as shown in  FIGS. 2A-2C . Each carrier belt linear adjustment mechanism adjusts the lateral position of one of the pulleys as well as the associated conveyor belt trained around the pulley in a lateral position across the width of the system  10 . The carrier belt linear adjustment mechanisms and other operations of the system  10  according to aspects of this invention are controlled by a controller  11  which receives position and other parameters for operation of the system  10  from a digital, computer input file. 
         [0033]    On the upstream shaft  38 ,  46  of each conveyor assembly  54 ,  56 , a conveyor belt drive assembly  114  is mounted on the shaft and the pulleys mounted thereon to drive the conveyor belts in a generally continuous path for advancing the substrate through system  10 . 
         [0034]    The upstream and downstream conveyor assemblies  54 ,  56  contact the non-print side  21  of the substrate  14  and advance the substrate  14  through the system  10  from the upstream end  32  to the downstream end  34  of the frame  30 . To ensure appropriate contact and frictional engagement between the substrate  14  and the conveyor belts, each conveyor assembly includes a pair of upstream and downstream hold-down wheels  86   a ,  86   b ,  88   a ,  88   b ,  90   a ,  90   b ,  92   a ,  92   b  mounted on the upper bed  29  of the system  10  as shown in  FIG. 2A  in phantom lines and in  FIG. 3  in cross-sectional view. During operation, the upper bed  29  is lowered toward the lower bed  31  by multiple hold-down screw assemblies  94  extending between the frames of the upper and lower beds  29 ,  31  as shown in  FIG. 3 . Upon actuation of the hold-down screw assemblies  94  and lowering of the upper bed  29  toward the lower bed  31 , the hold-down wheels  86 ,  88 ,  90 ,  92  will sandwich the substrate  14  with the respective conveyor belts  58   a ,  58   b ,  60   a ,  60   b  to securely position and advance the substrate  14  through the system  10 . The hold-down wheels  86 ,  88 ,  90 ,  92  engage the print side  20  of the substrate  14  and the conveyor belts  58 ,  60  engage the non-print side  21  of the substrate  14  in one embodiment of this invention. In alternative embodiments of this invention, conveyor belts may be utilized on both the top and bottom of the substrate  14  or on either the top or bottom of the substrate  14  to advance it through the system  10 . 
         [0035]    As seen in  FIGS. 2A-2C , the upstream conveyor assembly  54  is spaced in a longitudinal direction from the downstream conveyor assembly  56 . A substrate rotating assembly  96  is positioned between the upstream and downstream conveyor assemblies  54 ,  56  as shown most clearly in  FIG. 2A . In response to a signal from the controller  11 , the substrate rotating assembly  96  rotates the substrate  14  approximately 90 degrees as shown by the arrow C in  FIG. 2B . The substrate rotating assembly  96  in various embodiments according to this invention may be a gyro-box such as a Bobst™ mechanism, or a continuous motion robotic arm with or without a pneumatic suction engagement interface. 
         [0036]    To form the scores or fold lines  24  in the substrate  14 , mating pairs of carton scoring wheel assemblies  100  are located on the shafts within the frames of the system  10 . In one embodiment as shown in  FIGS. 2A-2C , four pairs of carton scoring members in the form of wheels  102   a ,  102   b  are located in the upstream portion boa of the system  10  and, likewise, four pair of carton scoring members in the form of wheels  104   a ,  104   b  are located in the downstream portion  10   b  of the system  10 . Each carton scoring assembly  100  includes an upper male scoring wheel  102   c  or  104   c  mounted on a scoring wheel adjustment mechanism  106  for rotation on the upper bed  29  of the system  10 . Each male scoring wheel  102   c ,  104   c  is positioned directly above a complementary female scoring wheel  102   d ,  104   d  on the lower bed  31  of the system  10 . The four carton scoring wheel assemblies in the upstream portion boa of the system  10  can be implemented during the production of carton blanks  12  to produce four distinct and generally parallel score or fold lines  24  in the substrate  14 . Similarly, the four downstream carton scoring wheel assemblies can likewise produce up to four distinct and parallel fold or score lines  24  in the substrate  14 . As is evident in the substrate  14  as shown in  FIG. 2B , after the substrate  14  has passed through the upstream portion boa of the system  10 , four distinct score or fold lines  24  are formed in the substrate  14  and in the exemplary embodiment of the substrate  14  shown in  FIG. 2B , those score or fold lines  24  separate the major panels  110  of the carton blank  12 . 
         [0037]    In alternative embodiments of this invention, the system  10  may have different dimensions (i.e., wider for accommodating wider substrates) than those shown herein and the system  10  may include more or less scoring wheels arranged as needed in the system  10  for generating the desired fold lines in the substrate  14 . 
         [0038]    After the substrate  14  is processed through the upstream portion boa of the system  10 , it is rotated approximately 90 degrees by the substrate rotating assembly  96  and passed to the downstream portion  10   b  of the system  10  for creasing and generating fold lines  24  which are generally perpendicular to those shown in  FIG. 2B . The crease, score or fold lines  24  generated in the downstream portion  10   b  of the system  10  in the exemplary carton blank  12  shown in  FIGS. 1B and 1C  separate the major panels  110  of the blank  12  from carton end flaps  112 . In the embodiment shown in  FIGS. 1B and 1C , only two of the carton scoring wheel mechanisms are utilized to create the fold lines  24  in the downstream portion  10   b  of the system  10 . Note that the inactive carton scoring wheel mechanisms  104   b ,  104   b  are positioned outboard of the substrate  14  passing through the downstream portion  10   b  of the system  10  because only two fold lines  24  are required to be added to the substrate in the orientation of the substrate  14  in the downstream portion  10   b.    
         [0039]    In a still further embodiment of this invention, the system  10  may include one or more further downstream sections with appropriate substrate rotating assemblies positioned between each pair of adjacent sections for manipulation of the substrate prior to entering the respective downstream section. Moreover, one or more of the sections could be utilized to make non-orthogonal or obtuse fold lines in relation to the fold lines  24  placed on the substrate in the upstream section boa and downstream section  10   b  shown in the  FIGS. 2A-2C . This could be accomplished by rotation of the substrate  14  through an arc of less than or greater than 90 degrees. Movable or adjustable guide rails may be added to the system  10  to enable the placement of obtuse score lines as described. 
         [0040]    In still further embodiments of this invention, each male and female scoring wheel pair  102 ,  104  may function independently of other scoring wheel pairs in the system as needed for a particular application. The controller  11  may have any of the scoring wheel pairs  102 ,  104  engage and/or disengage the substrate  14  independently as required. This may be utilized to produce fold lines on the substrate which are continuous or discontinuous, extend entirely across the substrate  14  or only partially across the substrate  14  or other variations as needed. 
         [0041]    Each carton scoring wheel assembly is operatively coupled to a linear adjustment assembly  108  located laterally outboard of the frame  30  in the system  10  as shown in  FIGS. 2A-2B . Each substrate scoring linear adjustment assembly  108  receives instructions from the controller to adjust the position of the male and female scoring wheel pairs  102 ,  104  laterally on the system  10  to the appropriate position for the desired score or fold lines  24  on the substrate  14 . Two pair of carton scoring wheel assemblies are mounted on a single shaft as shown in  FIGS. 2A-2B . However, the carton scoring wheel assemblies are controlled by individual substrate score linear adjustment assemblies  108  and therefore the position of each carton scoring wheel assembly can be individually adjusted according to the desired position of the resulting fold line  24  in the substrate  14  based on instructions from the controller  11 . 
         [0042]    Now turning to  FIG. 4 , an exemplary hardware and software environment in conjunction with controller  11  is illustrated. For the purposes of the invention, controller  11  may represent practically any type of computer, computer system or other programmable electronic device, and will be referred to hereinafter as a computer for simplicity. It will be appreciated, however, that apparatus  50  may be implemented using one or more networked computers, e.g., in a cluster or other distributed computing system, or may be implemented within a single computer or other programmable electronic device, e.g., a desktop computer, laptop computer, handheld computer, cell phone, set top box, etc. 
         [0043]    Controller  11  typically includes a central processing unit  252  including at least one microprocessor coupled to a memory  254 , which may represent the random access memory (RAM) devices comprising the main storage of computer  11 , as well as any supplemental levels of memory, e.g., cache memories, non-volatile or backup memories (e.g., programmable or flash memories), read-only memories, etc. In addition, memory  254  may be considered to include memory storage physically located elsewhere in computer  11 , e.g., any cache memory in a processor in CPU  252 , as well as any storage capacity used as a virtual memory, e.g., as stored on a mass storage device  256  or on another computer coupled to computer  11 . Computer  11  also typically receives a number of inputs and outputs for communicating information externally. For interface with a user or operator, computer  11  typically includes a user interface  258  incorporating one or more user input devices (e.g., a keyboard, a mouse, a trackball, a joystick, a touchpad, and/or a microphone, among others) and a display (e.g., a CRT monitor, an LCD display panel, and/or a speaker, among others). Otherwise, user input may be received via another computer or terminal. 
         [0044]    For additional storage, computer  11  may also include one or more mass storage devices  256 , e.g., a floppy or other removable disk drive, a hard disk drive, a direct access storage device (DASD), an optical drive (e.g., a CD drive, a DVD drive, etc.), and/or a tape drive, among others. Furthermore, computer  11  may include an interface  260  with one or more networks  262  (e.g., a LAN, a WAN, a wireless network, and/or the Internet, among others) to permit the communication of information with other computers and electronic devices, e.g., one or more client computers  264  (e.g., for interfacing with agents  222 ,  224 ) and one or more servers  266  (e.g., implementing other aspects of  222 ,  224 ). It should be appreciated that computer  11  typically includes suitable analog and/or digital interfaces between CPU  252  and each of components  254 ,  256 ,  258  and  260  as is well known in the art. Other hardware environments are contemplated within the context of the invention. 
         [0045]    Computer  11  operates under the control of an operating system  268  and executes or otherwise relies upon various computer software applications, components, programs, objects, modules, data structures, etc., e.g., a call center application  270  (within which, for example, monitoring application  242  may be implemented). Moreover, various applications, components, programs, objects, modules, etc. may also execute on one or more processors in another computer coupled to computer  11  via network  262 , e.g., in a distributed or client-server computing environment, whereby the processing required to implement the functions of a computer program may be allocated to multiple computers over a network. 
         [0046]    In general, the routines executed to implement the embodiments of the invention, whether implemented as part of an operating system or a specific application, component, program, object, module or sequence of instructions, or even a subset thereof, will be referred to herein as “computer program code,” or simply “program code.” Program code typically comprises one or more instructions that are resident at various times in various memory and storage devices in a computer, and that, when read and executed by one or more processors in a computer, cause that computer to perform the steps necessary to execute steps or elements embodying the various aspects of the invention. Moreover, while the invention has and hereinafter will be described in the context of fully functioning controllers and computer systems, those skilled in the art will appreciate that the various embodiments of the invention are capable of being distributed as a program product in a variety of forms, and that the invention applies equally regardless of the particular type of computer readable media used to actually carry out the distribution. 
         [0047]    Such computer readable media may include computer readable storage media and communication media. Computer readable storage media is non-transitory in nature, and may include volatile and non-volatile, and removable and non-removable media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules or other data. Computer readable storage media may further include RAM, ROM, erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid state memory technology, CD-ROM, digital versatile disks (DVD), or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and which can be accessed by computer  11 . Communication media may embody computer readable instructions, data structures or other program modules. By way of example, and not limitation, communication media may include wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of any of the above may also be included within the scope of computer readable media. 
         [0048]    Various program code described hereinafter may be identified based upon the application within which it is implemented in a specific embodiment of the invention. However, it should be appreciated that any particular program nomenclature that follows is used merely for convenience, and thus the invention should not be limited to use solely in any specific application identified and/or implied by such nomenclature. Furthermore, given the typically endless number of manners in which computer programs may be organized into routines, procedures, methods, modules, objects, and the like, as well as the various manners in which program functionality may be allocated among various software layers that are resident within a typical computer (e.g., operating systems, libraries, API&#39;s, applications, applets, etc.), it should be appreciated that the invention is not limited to the specific organization and allocation of program functionality described herein. 
         [0049]    In the embodiment shown in  FIG. 3 , the female scoring wheel  102   d  of each carton scoring wheel assembly  102   a  is in contact with the lower non-print side  21  of the substrate  14  and the male scoring wheel  102   c  of each scoring wheel assembly  102   a  engages the upper print side  20  of the substrate  14 . One aspect of this invention is the ability to modify or change the particular configuration of the male and female scoring wheels  102   c ,  102   d  thereby providing for a variety of different crease and score lines  24 , configurations, widths and geometries on the substrate  14 . Advantageously, the position of the individual carton scoring wheel assemblies can be adjusted on the fly during operation of the system  10  for different scoring patterns for each substrate  14  while avoiding downtime and interruption of production of carton blanks  12 . 
         [0050]    One aspect of this invention allows for the production of a variety of carton blanks  12  based upon algorithms input to the controller  11  whereby every carton for a production run can be slightly different in both print and size, yet still run through standard automatic filling equipment. In other words, random and/or programmed variation can occur within the confines of acceptable process variation, which results in mass production of different dimensioned carton blanks  12 . For example, two adjacent pairs of the major panels no of a carton blank form a first pair of panels and combine to a certain total width and the remaining two of the major panels no of the carton blank combine to form a second pair of panels having the same total width; however, the individual dimensions of each panel in the first pair may be varied and the individual dimensions of each panel in the second pair may be varied from carton blank to carton blank. As such, each carton blank produced according to this aspect of this invention appears to be differently dimensioned from each other carton blank while all of the various carton blanks form a parallel-piped carton configuration and appear to be individually manufactured and not the result of a high-speed continuous digital printing, digital scoring and digital cutting continuous production process. 
         [0051]    From the above disclosure of the general principles of this invention and the preceding detailed description of at least one embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, I desire to be limited only by the scope of the following claims and equivalents thereof.