This paper addresses a challenging variant of the two-dimensional variable-sized bin packing problem, characterized by multiple bin sizes, the guillotine-cut constraint, rotatable items, and few item types with high demand quantities. This problem is motivated by industrial application of insulating pressboard cutting in transformers. A hybrid evolutionary algorithm is proposed to solve the problem. The method encodes only sheet types to optimize their usage sequence and generates packing patterns by a heuristic algorithm via processing the encoding. Packing pattern is represented as multitree and constructed using a cutting-based principle. During item placement, a randomization strategy selects from top candidate items to avoid local optima, while compactness is enhanced by replicating individual items. Extensive experiments on three datasets show the proposed approach’s superiority in obtaining high-quality and robust solution. The algorithm substantially outperforms competing metaheuristics, achieving reductions of 4% to 25% across minimum, average, and maximum metrics. Crucially, it exhibits unprecedented solution stability, with standard deviations an order of magnitude lower than competitors. In addition, the randomization strategy yields significant improvements (2.9%-7.2%) over a deterministic variant. Statistical tests confirm all advantages are significant.
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