Koenig & Bauer News Feed https://www.koenig-bauer.com/ en Koenig & Bauer AG Sat, 23 Oct 2021 15:30:12 +0200 Sat, 23 Oct 2021 15:30:12 +0200 news-2115 Thu, 21 Oct 2021 10:05:46 +0200 Koenig & Bauer presents a new generation of large-format sheetfed offset presses http://dk.koenig-bauer.com/en/news/details/article/koenig-bauer-presents-a-new-generation-of-large-format-sheetfed-offset-presses/
  • Printing speeds of up to 18,000 sheets/hr (Rapida 145) and 17,000 sheets/hr (Rapida 164)
  • Modern, interactive operating concept
  • Extended substrate range and raised foundation
  • Various configurations for cost-efficient inline production
  • Automation features for ultra-fast job changeovers
  • The new Rapida 145 now boasts the same new design as all the latest presses from Koenig & Bauer (1)

    What was originally planned as an international event can only be presented to smaller groups of interested users for the time being – when carrying out print tests or live video demonstrations: Koenig & Bauer is proud to announce the market launch of a brand new generation of its Rapida 145 and Rapida 164 large-format sheetfed offset presses. The new press generation is available with immediate effect.

    The fact that both large-format series now boast the same new innovative design as all the latest Koenig & Bauer presses immediately catches the eye. Along with this, there are also many other new features that will enable the large-format Rapidas to consolidate their position as market leaders in this format class. They handle sheet formats up to 1,060 x 1,450 mm (Rapida 145) and 1,205 x 1,640 mm (Rapida 164) at a standard maximum production speed of 16,000 sheets/hr in board production. Incorporation of a high-speed package raises the top speeds another notch, allowing them to handle 18,000 sheets/hr (Rapida 145) and 17,000 sheets/hr (Rapida 164). Alongside new upgrades to the automation features, they offer the performance parameters of the latest medium-format presses – for twice the print format or even more.

    As is immediately evident here on the feeder head, there are now only very few manual operating elements anywhere on the press. Practically all processes can be controlled by means of touch panels or the main console (3)

    The operating concept has also been given a makeover. Large touch panels on the feeder, on the first printing unit and at the delivery render many buttons and other operating elements superfluous. All routine processes that are normally activated decentrally from the console can therefore be controlled just as conveniently on the press itself. A prominent status indicator at the delivery provides instant updates on the current press status. Different colours are used to signal whether the press is in production, standby or maintenance mode.

    Cameras for inline colour control (centre) and sheet inspection at resolutions of up to 260 dpi check every single sheet during production. Errors and defects are visualised on the wallscreen, and reports are produced to verify the quality (7)

    Digital control and monitoring

    The ErgoTronic console features a touchscreen monitor and a large wallscreen. All relevant information is presented in a clearly structured fashion on both displays. A host of additional functions allow production to be monitored in real time. Production data and other information, such as CO2 emissions, are available at a glance. Autonomous printing of a job list, app-based control of many press functions, access to the CustomerCommunity as a central point of contact between users and the manufacturer, and, of course, a function to start individual press programs using presets based on the data supplied or previously saved – the console is the digital hub for all production processes in the printshop.

    This applies to quality assurance in equal measure. Three different systems combine inline colour control (with the option of grey balance control) with functions for production monitoring (QualiTronic PrintCheck), comparison with the pre-press PDF (QualiTronic PDFCheck) and content inspection (QualiTronic PDF HighRes).

    DriveTronic SPC: fully automatic plate changing with unbent printing plates (5)

    Additional benefits for packaging specialists

    The new Rapida large format generation brings significant improvements for the core application area of packaging printing in particular. Substrate versatility was already very broad in the past, allowing board thicknesses of up to 1.2 or 1.6 mm. Universal gripper systems make this possible. On the new presses, the range of substrates handled can be increased further still – even beyond the 2 mm mark – by simply converting the printing units. For companies that work with heavy board grades or offer post-printing on corrugated board involving printing and finishing a full spectrum in an inline process, the new capabilities represent a quantum leap forward.

    Endless configuration options: this Rapida 145 in the CEC at Koenig & Bauer Sheetfed stands on 555 mm cast blocks and features seven printing units, two coaters, intermediate drying units, a three-section extended delivery with twin-pile capabilities, and fully automatic pile logistics (2)

    Other important changes concern the options to allow increased pile heights. Five variants are available, covering the range from 185 to – as a new option – 925 mm. Raising piles by 185, 370 or 555 mm can also be achieved by placing the press on cast blocks. The additional outlay for special press foundations can then be saved.

    Significant improvements in many details

    Many less visible but nonetheless important details have also been overhauled. These include the sheet guiding elements in the delivery and delivery extension (dryer section). Modifications like this have been paramount in realising top production speeds of up to 18,000 sheets/hr with an even broader range of substrates and finishing applications. Thanks to a dynamic sheet brake, visibility and accessibility at the delivery remain unhindered. There is no need for complicated sheet braking systems or delivery grippers.

    Long-life gripper shafts with automatic lubrication and a reduced number of manual lubrication points help simplify maintenance. The same applies to the new AC drive motor of the large-format Rapidas. It is not only practically maintenance-free, but also reduces energy consumption.

    Anilox roller changes can be realised quickly by a single person without the need for tools – thanks to the AniSleeve technology (6)

    High production capacity and flexibility

    All the existing automation and high performance features of the previous models are, of course, still available for the new Rapida generation. This begins with the sheer endless choice of press configurations, with up to 16 printing and finishing units, together with options such as a reel-to-sheet feeder, automatically convertible perfecting, coating and drying units, a double-pile delivery, and extends to a range of non-stop pile changing and logistics components. This means that individual press configurations can be tailored specifically to the very specific requirements of packaging and commercial printers.

    Most Rapida presses for large-format sheetfed offset are equipped with the sidelay-free infeed system DriveTronic SIS (4)

    When it comes to automation, the new Rapida generation sets a new benchmark in large-format printing. The sidelay-free infeed DriveTronic SIS, simultaneous plate changing with DriveTronic SPC, the disengaging of unused inking units as a standard feature, CleanTronic cloth-based washing systems for parallel washing processes, fast coating forme changes with DriveTronic SFC and anilox roller changing with AniSleeve are just a few of the outstanding automation components that enable many processes to run concurrently at job changeover and thereby contribute to the shortest ever makeready times. The dryer modules, too, are manufactured by Koenig & Bauer. After all, dryer systems are one of the company’s core competencies.

    All system components and automation functions serve one goal, namely to provide users with the best possible support, and to enable them to produce efficiently and successfully, whether in packaging or the commercial segment. The large-format Rapidas are therefore the ideal means of production, and ensure print companies are equipped for all current and future challenges. 

    Visit https://www.koenig-bauer.com/de/newdimension/ for more interesting content around the product launch.

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    news-2113 Wed, 20 Oct 2021 10:56:32 +0200 Koenig & Bauer supports UN Global Compact http://dk.koenig-bauer.com/en/news/details/article/koenig-bauer-supports-un-global-compact/ As a participant in the UN Global Compact initiative, Koenig & Bauer actively supports the implementation of the United Nations’ 17 Sustainable Development Goals (SDGs), which define a framework for sustainable economic, ecological and social development. The UN Global Compact is the world’s largest initiative promoting sustainable and responsible corporate activity, and comprises a global network of more than 18,700 participating companies and organisations from 170 countries.

    Koenig & Bauer is a participant of the UN Global Compact and supports its goals through a wide range of activities in the areas of environment, social affairs and corporate governance

    The participants undertake to uphold not only the 17 SDGs, but also the ten UN Global Compact principles relating to human rights, labour standards, environment protection and corruption prevention, and publish annual reports on the progress made within their individual spheres of influence.

    CEO Dr Andreas Pleßke: “Koenig & Bauer has attached a very high importance to social commitments and environmental responsibility ever since it was founded 204 years ago. The principles and goals of the UN Global Compact are fully aligned with the values and philosophy that govern all our business activities. Wherever opportunities arise within the strategic development framework, the companies within our group seek to exert a positive influence and uphold their commitment to their social and ecological responsibilities on the basis of diverse ESG activities and innovations.”

    The 17 SDGs anchored in the Agenda 2030 of the United Nations are aimed at the development of a sustainable global economy. Koenig & Bauer has identified seven of these goals as key targets for its own strategic sustainability initiatives. The SDGs “3 – Good health and well-being”, “4 – Quality education”, “5 – Gender equality”, “8 – Decent work and economic growth”, “12 – Responsible consumption and production”, “13 – Climate action” and “17 – Partnerships for the goals”, in particular, form the focus of the diverse sustainability activities within the group.

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    news-2111 Tue, 19 Oct 2021 09:47:15 +0200 Klingele buys another CorruCUT from Koenig & Bauer http://dk.koenig-bauer.com/en/news/details/article/klingele-buys-another-corrucut-from-koenig-bauer/
  • High levels of quality and performance 
  • State-of-the-art software and hardware 
  • Improved automation features
  • Klingele very satisfied with its first CorruCUT High Board Line Rotary Die-cutter
  • The new CorruCUT is to be installed at the Klingele plant in Werne

    The Klingele Paper & Packaging Group is investing in another CorruCUT High Board Line Rotary Die-cutter from Koenig & Bauer. The new six-colour machine is scheduled to start production at the Klingele plant in Werne in the summer of next year. With a future capacity of almost 200 million square metres of corrugated board, this plant is one of the largest operated by the group. “In recent years, Koenig & Bauer has demonstrated that it has established itself in the market for corrugated board processing. Working together, we have boosted the performance of the first CorruCUT at our plant in Delmenhorst to a high level. This is why we are once again investing in this machinery from Koenig & Bauer with full conviction,” says Dr Jan Klingele, Managing Partner of the Klingele Paper & Packaging Group.     

    The first CorruCUT has now been printing and die-cutting at the Delmenhorst plant for almost two years. Christoph Müller, member of the executive board of Koenig & Bauer AG: “Experience, tradition and the innovative spirit of both companies have contributed to making this machine a further step forward in printing technologies for the packaging sector.”

    Unique features and new technical functions

    Complementing the established features unique to this technology, such as the vacuum-belt feeder without infeed shafts and the anilox roller exchange system, Koenig & Bauer has incorporated a range of new technical functions into the machine. “Thanks to our broad product portfolio, we have been able to integrate different functions from other machines to make the CorruCUT even better,” says Christoph Müller. A series of new software upgrades has also significantly increased  the machine automation. One example is Easy Job Change, which allows automatic preparation of a subsequent job even before completion of the current production run. Amir Mirsakarimi, Plant Manager in Werne: “There are two other topics that were particularly important for us: simplification and optimisation of the interfaces, and live data acquisition during production. In this regard, Koenig & Bauer has shown us some very promising solutions that are completely new to the market.” An innovative control system for die cutting contour also enables incorrectly die-cut sheets to be ejected immediately.

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    news-2101 Fri, 01 Oct 2021 10:05:40 +0200 Rossmann Group invests in Koenig & Bauer CorruCUT http://dk.koenig-bauer.com/en/news/details/article/rossmann-group-invests-in-koenig-bauer-corrucut/
  • Innovative technical functions
  • Enhanced software and hardware features 
  • High level of automation
  • Most cutting-edge and productive Rotary Die-cutter on the market
  • ROMCARTON S.A., a member of the French Rossmann Group, is investing in a CorruCUT from Koenig & Bauer. With seven printing units, it will be the longest CorruCUT made to date. The machine is scheduled for commissioning by summer of next year, when it will begin production in Popesti-Leordeni near the Romanian capital, Bucharest, at one of the largest and most modern box plants in Southeast Europe. “We have been following Koenig & Bauer’s advances in the field of corrugated board processing very closely over the past few years. And we were also able to visit the existing machine installations in Romania and Germany. The expectations of the new machine were clear – the highest possible product quality, short set-up times and a reliable partner at our side. We are proud to work with Koenig & Bauer to further develop the CorruCUT” says Guillaume Grandviennot, Technical Director for the corrugated board activities at ROSSMANN Romania.

    The longest CorruCUT ever will begin production in summer 2022

    Koenig & Bauer has a philosophy of focussing on the expectations that customers have of their machines. Michael Donnert, Senior Sales Manager at Koenig & Bauer Digital & Webfed: “We have been holding close discussions with ROMCARTON since 2019. The new functions and developments incorporated into the CorruCUT impressed ROMCARTON during a visit to experience our technology in action. We are pleased to welcome ROMCARTON S.A. as a new member in our family of users of the newest Rotary Die-cutter on the market.”

    Other new solutions have simplified and perfected the interfaces to peripheral systems even further. At the same time, the CorruCUT is now more compact, while an active air management system has enabled production outputs to be increased by up to 20 % compared to existing solutions when printing coated sheets. 

    Almost 100 years of innovation and progress

    Rossmann Group, one European pioneer of corrugated cardboard packaging will celebrate in 2022 its 100 years. Lucien Rossmann founded its packaging company in Strasbourg 99 years ago, then the group expands all around Europe and Africa by the vision of Mr Bernard Rossmann. The group comprises 23 production sites in Europe and Africa, with 4 paper mills, 10 box plants and 9 sheets plants. More than 3,000 employees generated an annual turnover of almost € 600 million in 2019. All box plants are supplied by the group’s own paper mills. Another member of the corporate group, the company Sorest, collects and recycles the paper and corrugated board waste.

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    news-2092 Thu, 16 Sep 2021 12:28:39 +0200 Koenig & Bauer Durst Enjoys Success and Customer Engagement at SuperCorrExpo in Orlando http://dk.koenig-bauer.com/en/news/details/article/koenig-bauer-durst-enjoys-success-and-customer-engagement-at-supercorrexpo-in-orlando/
  • Koenig & Bauer Durst CorruJET provides digital direct printing on corrugated board sheets
  • Koenig & Bauer Durst Delta SPC 130 FlexLine prints up to six colors on corrugated sheets
  • Koenig & Bauer CorruCUT high board flexo die cutter generates broad interest
  • Koenig & Bauer Durst enjoyed success visiting with show-goers at SuperCorrExpo, one of the most influential corrugated packaging-focused trade shows in the Western Hemisphere, which was held at the Orange County Convention Center in Orlando in August. The firm’s experts were on hand to answer prospective customer questions and provide information on its latest products and developments for the corrugated market.   

    Koenig & Bauer Durst enjoyed success visiting with show-goers at SuperCorrExpo, one of the most influential corrugated packaging-focused trade shows in the Western Hemisphere, which was held at the Orange County Convention Center in Orlando in August

    “We were excited to join this event and visit with attendees who came to our booth to explore how Koenig & Bauer can support their corrugated printing needs,” said Jürgen Gruber, Product Manager Digital & Corrugated Printing Technology for Koenig & Bauer US. “Our new CorruCUT HQPP brings a maximum production output of 12,000 boards per hour, including setup while running, integrated remote maintenance for the ultimate uptime, and the easiest machine to operate. It generated a lot of interest at our booth due to its revolutionary new innovations. We are deeply committed to our corrugated customers and are supporting them with our complete portfolio of corrugated products.”

    The booth drew attendees who were especially keen to learn more about the inkjet products from Koenig & Bauer Durst, especially its CorruJET 170 and Delta SPC 130 FlexLine Automatic corrugated production press.

    Developed specifically for the corrugated industry, the brand new CorruJET provides digital direct printing on corrugated board sheets. The CorruJET is engineered for the highly efficient production of corrugated sheets with top-quality digital printing. Operating with a maximum production speed of 5,500 sheets/hour, the CorruJET can process corrugated board up to a thickness of 8 mm.

    The Koenig & Bauer Durst Delta SPC 130 FlexLine Automatic corrugated production press adapts single-pass technology for the corrugated industry. This combines a well-engineered mechanical design with easily accessible sub-assemblies and selected components to guarantee durable quality, high performance and reliability. The Delta SPC 130 is equipped with Durst’s SPC drop-on-demand print head technology and has a non-hazardous ink system and an IR/UV drying process designed for high productivity.

    The Delta SPC 130 can be configured with up to six colors, printing any length of corrugated cardboard or paper media of up to 12mm in thickness. The printing system offers unrivaled versatility, low maintenance requirements and 24/7 dependability.

    “We were pleased to display our joint venture between Koenig & Bauer and Durst at SuperCorrExpo and allow attendees to learn about our all-encompassing portfolio,” says Oliver Baar, senior product manager at Koenig & Bauer Durst. “We had some great conversations with everyone who visited our booth and it was clear that automation and productivity are key talking points in our industry.”

    More information on www.koenig-bauer-durst.com

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    news-2080 Wed, 08 Sep 2021 10:55:53 +0200 Packaging manufacturer Hubert von Carnap launches production on a Rapida 145 http://dk.koenig-bauer.com/en/news/details/article/packaging-manufacturer-hubert-von-carnap-launches-production-on-a-rapida-145/
  • Belated celebration to mark the company’s 150th anniversary
  • Resumption of printing production following a fire
  • Remarkable machinery installation with a tiny footprint
  • Confirmation of succession arrangements
  • The official inauguration of the Rapida 145 by Lothar Irion, Tobias Heinrichs from the municipality of Windeck, Susanne Nordberg, Katharina Steffens and Jürgen Bergmann (from left to right) (3)

    It has only been a few days since the packaging and cardboard processing company Hubert von Carnap, which is based in Windeck, North Rhine-Westphalia, officially launched production on its new sheetfed offset press together with its customers and others who have played a role in the company’s success. And that’s not all: the ceremony provided an occasion to finally celebrate the company’s 150th anniversary, with the celebration that was originally planned having been cancelled following damage due to a fire. Moreover, managing director Jürgen Bergmann and head of sales, Martin Trojca, were able to share good news with employees and business partners alike: Susanne Nordberg and Katharina Steffens will be the new proprietors of the family company, now in its fifth generation. Both this, and the new technology, have given the cardboard processing company a future to look forward to.

    The next generation, Katharina Steffens (second from the left) and Susanne Nordberg, can now call themselves the proprietors of the family company. Managing directors Jürgen Bergmann (left) and Lothar Irion extended their congratulations, knowing that this step will allow the company to continue to thrive (2)

    Process automation with a tiny footprint

    A Rapida 145, which has been raised by 630 mm and which features five inking units, a coater, and three-section extended delivery is now being used for printing at Hubert von Carnap. That’s nothing unusual for a company that specialises in packaging. What is remarkable, however, is the way the press was able to be installed in a very limited space while also featuring extensive, pallet-free logistics along with other components for automation. All the additional components that have been added around the raised press are installed over two levels. This means that the machine operator does not have to cover the same long distances, while also optimising the space available for the anticipated output from the Rapida 145. The close cooperation between the experts at Hubert von Carnap, Koenig & Bauer, the system vendor Heinrich Steuber, and local workshops was pivotal to this remarkable installation.

    Remarkable installation: the individual press units are installed over various levels to save space (5)

    The Rapida 145 has allowed Hubert von Carnap to boost its production capacities significantly. The press for sheets with a format of up to 1,060 × 1,450 mm, and a production of up to 16,000 sheets/hour on substrates up to 1.6 mm thick, has increased output by 40 per cent compared to the predecessor press, which dates from 2002. Automation features such as non-stop systems at the feeder and delivery, sidelay-free infeed DriveTronic SIS, FAPC plate changers and CleanTronic Synchro for parallel washing processes all contribute to higher productivity. Quality control and regulation features are based on inline systems that use QualiTronic ColorControl and PDF check for sheet inspection, as is the comparison of the printed sheet with the customer PDF. These systems are a guarantee of high-quality print products for printers and customers alike.

    Automatic non-stop operation with pallet-free logistics at the feeder (6)

    An exacting range of substrates

    All the new features aside, every effort was made to make the work that printers do easier. This starts with the EasyClean ink duct plates for fast ink changes, and also includes unbent printing plates, the disengagement of individual inking units, and EES to reduce emissions near the delivery area, and even extends to allowing access to virtually every press unit without forcing the operator to climb steps. The production facilities can now also be heated using the heat generated by the cooling units used for the printing press.

    Hubert von Carnap is a producer of packaging, primarily for the food and pharmaceutical industries, but also for tools and hazardous materials such as explosives for use in the mining industry. This range of products places huge demands on the technology, which needs to be able to print, die-cut, and bond thin cardboards, along with flexurally rigid solid boards, and microflute substrates to produce finished packaging.

    A celebration for employees, customers and the company’s supporters. The packaging manufacturer Hubert von Carnap launched production on a new Rapida 145 just a few days beforehand (1)

    More investments and new business areas

    Anything between 160 and 200 tonnes of cardboard is processed by Hubert von Carnap every week. And this looks set to increase: the two new proprietors, Susanne Nordberg and Katharina Steffens, informed their staff of 50 that the installation of the Rapida 145 is the first in a series of future investments. Both intend to keep growing Hubert von Carnap, along with venturing into new business areas to cater to the current demand for packaging made of renewable resources, and will also be focussing on acquiring new customers for their company.

    They also used the occasion to thank employees and customers for their loyalty to the company, which can look back over decades of experience, over what were very difficult months.

    Website of interest: www.hvc.de

    Ralf Engels (right), the system vendor Heinrich Steuber, and Peter Kolle from Koenig & Bauer congratulated the new proprietors Katharina Steffens (second from the left) and Susanne Nordberg on the launch of production on the new press with a picture by artist Conny Wachsmann (4)
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    news-2077 Fri, 03 Sep 2021 12:08:49 +0200 Rapida 145 from Koenig & Bauer puts on a top performance in packaging production http://dk.koenig-bauer.com/en/news/details/article/rapida-145-from-koenig-bauer-puts-on-a-top-performance-in-packaging-production/
  • Fully automated six-colour press with inline coating
  • High level of process automation and individual press customisations
  • Top printing performance saves an entire shift
  • First mover when it comes to product innovations and plastics substitution
  • The coat-of-arms of the Saxon electoral princes is ever-present in Coburg and surroundings. It was in 1353 that Margrave Friedrich III of Meissen inherited the lands which made up the territory known as ‘Pflege Coburg’. The town has only been part of the Free State of Bavaria since 1920. Even so, the fact that a sheetfed offset press built just a few kilometres from Meissen has been in production at Coburger Kartonagenfabrik in Dörfles-Esbach since last year has nothing to do with past traditions.

    Group photo with the team responsible for the installation of the Rapida 145 (left to right): Jörg Liebold, works manager; Daniel Michalik, Koenig & Bauer; Tim Steinke, project manager; Rolf Uting, print production manager; Robert Hein, senior commercial manager; Steffen Theiss, head of product development; Christopher Hugel, sales manager, Koenig & Bauer Germany (everyone on the photo was either fully vaccinated or else tested for coronavirus infection prior to the meeting) (1)

    The investment decision was preceded by an exacting selection process. Senior commercial manager Robert Hein recalls: “Koenig & Bauer did a really good job here. The cooperation was professional and consistent at all times.” After a series of process analyses and print tests, the company opted for a six-colour Rapida 145 with inline coating facilities and a three-section extended delivery. What was already an impressive installation was raised by a further 630 mm to maximise the efficiency of packaging production, and effortlessly handles piles of 1.8 metres and more in non-stop operation. Thanks to fully automatic pile logistics, uninterrupted production is even possible when printing on heavy boards.

    Excellent performance

    Robert Hein and print manager Rolf Uting are full of praise for their printers and the speed at which they have become familiar with operation of the new press. This was not just a change of press model, but also a quantum leap in terms of automation and performance. The sheet output per working hour continues to increase from month to month. Regular performance reports, which include anonymous comparisons with other similar sheetfed offset presses, show that the Rapida 145 at Coburger Kartonagenfabrik is already performing at the top of its league.

    Non-stop operation with pile logistics at the feeder of the Rapida 145 (2)

    This is not least due to the extensive automation solutions and individual press customisations: From its sidelay-free infeed DriveTronic SIS, to the disengagement of individual inking units and automated and therefore exceptionally fast coating plate changes, the Rapida 145 offers benefits that every press operator highly appreciates. Supplementing these features are the EasyClean ink duct coatings to accelerate ink changes, QualiTronic ColorControl for inline inking control, which also extends to the rear edge of the sheet, and ErgoTronic PlateStretch (remote stretching of the printing plates from the console to compensate paper stretch). Using Koenig & Bauer’s plate trolley lift for inspiration, the specialists at Coburger Kartonagenfabrik designed an additional lift to bring the inks to the press. A chute is also provided to enable used washing cloths to be dropped into floor-level waste containers. All these additional functions reduce walking distances and cut the risk of accidents by minimising the need to climb up and down onto the gallery with full hands.

    The new Rapida 145 is responsible for 60 to 70 per cent of the daily production volume. To play out its strengths to the full, it primarily prints on board between 230 and 250 g/m2. A first step saw the high volumes output by the Rapida 145 save one entire production shift on the older press, which is still installed nearby.

    The press delivery is similarly equipped with a full range of logistics components (3)

    Sustainable packaging production

    The Rapida 145 makes successful use of unbent, process-free printing plates. To extend the stability of the plates and to maintain process reliability despite the greater contamination caused by the dampening solution, the intervals at which filters are replaced have been made more frequent. Intensive roller cleaning is also scheduled on a weekly basis.

    This is just one of the company’s measures to make its packaging production sustainable. It is supplemented by a consistent energy management strategy that involves short- and long-term energy savings, continuous investment in energy-saving machinery and infrastructure, and systems for heat and condensate recovery. After all, corrugated board production causes high temperatures, and steam and condensate to form. The Coburg-based packaging experts also pay special attention to checking for leaks, for example from the compressed air systems, for which energy requirements are particularly high.

    At the same time, the company has obtained all the applicable certifications for food and non-food packaging production, from ISO 9001 and FSC to HACCP and energy management.

    A lift brings the plate trolleys up to the press gallery, which has been raised. This reduces walking distances and cuts the risk of accidents compared to manual handling of the large-format plates (4)

    Spectacular installation

    Significant conversion measures had to be carried out on the existing hall to enable installation of the Rapida 145 in its current location, directly at the entrance to the printshop, ensuring it is fully integrated into an end-to-end logistics chain. There used to be a load-bearing column where the feeder now stands. This had to be removed and replaced with a support system to the side of the press, along with a steel roof girder above it.

    The installation of the heat exchanger on the hall roof was another spectacular step within the project. The huge dimensions of the hall required a 220-tonne crane with a jib length extending to more than 80 metres to position the unit on the roof.

    First mover in many fields

    Coburger Kartonagenfabrik produces several million folding cartons every day. Alongside the two sheetfed offset presses, the production floor space of some 40,000 m2 is occupied by laminating machines for single- and double-wall corrugated board, die-cutting machines, more than ten folder-gluers, a window gluing machine and other items of special equipment. The 300 employees process approx. 45,000 tonnes of paper and board each year. Corrugated products dominate, and account for 80 per cent of the final output. The board types used are F-, E- and B-flute, including double-wall variants, and they are used in every conceivable combination.

    Several million folding cartons come off the folder-gluer lines every day (5)

    When it comes to product innovation and the use of renewable resources to replace plastics, Coburger Kartonagenfabrik is one of the industry’s first movers. It derives significant benefits from the current paradigm shift towards renewable resources. Moreover, the company’s machinery base and automation capabilities primarily target high-volume production. Product finishing is one of the standard services that is offered to major customers, along with warehousing services and the shipment of packaging products in batches. Some 16,000 pallet storage bays are available directly on site.

    The company branched into offset printing for double-wall corrugated packaging at an early stage. To this end, it invested in the first of the latest generation of inline corrugated laminating machines. Between 2015 and 2021, the company proceeded with a major investment programme covering not only the building structure and machinery base, but also the entire IT environment. The new Rapida 145 is an integral component of this programme, which, for the most part, is now approaching completion. All the measures that have been realised are clearly aligned with changing market conditions and more exacting customer expectations. 

    The customers of Coburger Kartonagenfabrik are primarily larger SMEs and major industry players from the German-speaking region and the Benelux countries, and represent a traditionally broad and diversified cross-section of the print market.

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    news-2075 Wed, 01 Sep 2021 13:43:15 +0200 Future-oriented product marking with inkjet http://dk.koenig-bauer.com/en/news/details/article/future-oriented-product-marking-with-inkjet/
  • Intuitive use like a smartphone
  • Modern and industry-standard design
  • Sustainable and cost-efficient in production operation
  • Koenig & Bauer Coding has continued to improve the portfolio of its alphaJET small-character inkjet printers. The reliable inkjet technology with the proven Active Inkflow and Smart Start Technology has been fundamentally modernised in terms of both look and usability. Low consumption and emission values ensure that the alphaJET5 X has the best TCO values.

    The alphaJET5 X features a convincing new design (1)

    Product marking meets different requirements in various industrial sectors. Productivity demands maximum reliability and the greatest possible flexibility from all involved. All inkjet printers in the alphaJET product range possess these capabilities in combination with a large and constantly growing ink portfolio. 

    With the new alphaJET5 X, Koenig & Bauer Coding makes it clear that special attention has been paid to user-friendliness. The design has rounded edges and eliminates raised knobs and switches. High-quality materials such as glass and stainless steel are used for the robust housing. This means that the printer is not susceptible to dirt deposits and can even be used in sensitive environments.

    Trendsetting and industrial design (2)

    Another new feature is the modern user interface, which allows navigation by swiping gestures, just as on a smartphone. Depending on the lighting conditions, a switch can be made between Light and Dark Mode. Depending on the production process, the start screen can be individually configured for the user.

    The alphaJET5 X is also ready for future challenges. Ready-to-use software in many languages and cloud-based systems already provide room for excellent performance. The extensive connectivity of the system opens up all possibilities for managed services and predictive maintenance in production.

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    news-2073 Thu, 26 Aug 2021 12:50:13 +0200 More capacity for sustainable packaging http://dk.koenig-bauer.com/en/news/details/article/more-capacity-for-sustainable-packaging/
  • Individual, highly specialised packaging for brand names
  • Automation for fast job changeovers
  • 20 per cent less waste
  • Flexible production for short and medium run
  • A six-colour Rapida 106 with coating facilities has been used in production at Wittmann Druck & Verpackung since the beginning of the year. The key players in the project recently met up at the press (left to right): managing director Hans Schuster; Gavin Elflein and Ralf Koch, both from Koenig & Bauer Germany; company owner Oskar Wittmann; printer Reiner Schneider; Christofer Hugel, Koenig & Bauer Germany (1)

    Modern, clean and flooded with natural daylight – these qualities characterise the entire company premises of Wittmann Druck & Verpackung in Neumarkt/Oberpfalz. And blue, fast and efficient are attributes that describe the recently installed Rapida 106, which now shoulders all print production for the company. With its inline quality control capabilities, it guarantees both the company and its customers high, reliable and consistent print quality – and ensures this can be done to everyone's satisfaction, because the six-colour coater press now forms the kingpin of a company dedicated to mainly short-run folding carton production. A run of 10,000 copies is already at the top of the range, as managing director Hans Schuster reports. And the print jobs themselves are anything other than routine ones. The company produces very individual and highly specialised packaging for brand owners in sectors such as electronics, writing instruments, confectionery and cosmetics. Advent calendars in a never-ending variety of shapes and forms are one of Wittmann’s specialities.

    View into the bright, light-filled printshop at Wittmann Druck & Verpackung (2)

    High production speeds and fast job changeovers

    The Rapida 106 has brought a number of valuable improvements, especially where short runs are concerned. This is illustrated by the fast and precise colour control, as well as a drastic reduction in the amount of time lost to ink changes at the same time. Key features in this respect are the EasyClean ink duct coatings, which enable exceptionally fast cleaning, and the simplicity of engaging and disengaging individual inking units, which means that production can continue without interruption while the ink is being changed in an unused printing unit.

    The sidelay-free infeed DriveTronic SIS and the fully automatic FAPC plate changers are further benefits spotlighted by Hans Schuster and his printshop manager Stefan Zahn, especially when it comes to packaging production: “The press runs much faster than its predecessor. But even more important for us is that job changeover times have been reduced significantly,” says managing director Schuster. The waste savings associated with the new technology – currently around 20 per cent – align perfectly with the company’s eco-friendly philosophy.

    Coating plate changes are completed in 2 minutes thanks to the comprehensive automation (3)

    Scoring with flexibility

    With 32 employees and a production area measuring 4,200 m2, Wittmann Druck & Verpackung is actually quite a small packaging company. However, it is nonetheless a force to be reckoned with. Almost ten years ago, it was one of the first companies to use migration-safe inks. The sun has been one of the company’s main energy suppliers since 2015 – thanks to a 285 kW photovoltaic array. Heat recovery – also from the new Rapida 106 – allows more energy savings to be made. And baling presses provide the basis for the return of paper and board waste to the materials cycle.

    Wittmann also scores points with the high level of flexibility made possible by its extremely lean organisation. The response times – from creation of a job, to data collection and through to production and shipping to the customer – are remarkably short. This is in no small way due to an in-house software solution. New and modified designs for complex packaging forms are developed in the company’s own packaging design office.

    High printing speeds and fast job changeovers characterise the Rapida 106 (4)

    Rapida 106 to mark the company’s 125th anniversary

    The full-service production also includes product sorting and filling of the packaging. A mobile shelving system permits up to 1,200 pallets with finished products to be held in intermediate storage. The customers can then have their products delivered at precisely the time when they are needed.

    The company was founded 125 years ago, and Oskar Wittmann represents the 3rd generation at the helm. With the Rapida 106, the company has treated itself to a gift worthy of marking the anniversary. The new press, continued regular investments, and the emerging trend to packaging made from renewable raw materials place Wittmann Druck & Verpackung in an ideal position to master future challenges.

    Following completion of its investment in the Rapida 106, the management at Wittmann Druck & Verpackung can now move on to make other major investments in post-press equipment. For the moment, however, owner Oskar Wittmann is planning the erection of a second production hall in 2022. As he recently announced to the workforce: “I am now, at last, able to realise my long-cherished dream of an additional production hall.”

    Advent calendars and other complex packaging products are specialities of Wittmann (5)
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    news-2069 Thu, 19 Aug 2021 13:31:56 +0200 Ye Sung increases production output with a Koenig & Bauer Allpro 70 http://dk.koenig-bauer.com/en/news/details/article/ye-sung-increases-production-output-with-a-koenig-bauer-allpro-70/
  • Processing of demanding packaging designs
  • Production output increased by 30 per cent
  • Less overtime and better motivated employees

  • Since being founded in 2008, Ye Sung Corp. in Janghang-Dong near the South Korean capital of Seoul has grown to become a highly specialised packaging supplier, whose principal customers are small to mid-size companies that are active in a wide range of market segments, along with major players from the pharmaceuticals industry.

    An Allpro 70 has been used in production at South Korean folding carton producer Ye Sung since March (1)

    A broad spectrum of different folding cartons is produced, including ones for medicines and beauty products, dietary supplements, cosmetics and foods. They frequently include some very complicated designs that push the processing equipment to its limits.

    South Korean employees work longer hours than their counterparts in most other OECD member nations. However, following labour law amendments that came into effect on 1 July 2021, a maximum working time of 52 hours per week now applies in all companies with five or more employees. In order to keep the performance of the operation at a high level, Yesung put the Allpro 70 folder-gluer into operation in March. The new machine contributes to faster turnaround times for individual jobs, and ensures that work processes proceed without problems despite the limited space available.

    Of course, word of such an investment gets around quickly. Since commissioning the Allpro 70, Ye Sung has attracted a whole series of new orders.

    Jaewan Kim, CEO of Ye Sung, is especially pleased with the increased outputs made possible by the Allpro 70 (2)

    Perfect all-rounder with high productivity

    The Allpro 70 is distinguished by its high flexibility in terms of the substrates that can be used. An extensive range of tailored equipment options also allows it to handle an exceptionally broad variety of different folding carton designs, thereby giving free rein to the customer’s creativity. Application-oriented solutions and functions, along with belt speeds of up to 400 m/min, provide for fast makeready and high productivity.

    Even after just a few weeks of use, production output at Ye Sung increased by more than 30 per cent thanks to the new machine. Overtime could be reduced, and employee satisfaction rose in equal measure. Weekend shifts have become a thing of the past.

    Group photo with the young team at Ye Sung (right to left): Haesung Jung, Hongjun Jeon, CEO Jaewan Kim, Junggi Lee, Hyeonu Lee and Hyunho Park, alongside Jaehoon Jo and William Shin from Koenig & Bauer’s branch office in South Korea (3)

    Streamlined work processes

    Jaewan Kim, CEO of Ye Sung Corp., explains: “The additional folder-gluer line has made us better able to group similar carton designs and sizes on individual machines, which saves makeready time and boosts production output.” Work processes have been streamlined to a considerable extent, and the lead time from confirmation of an order through to shipping of the processed products is now also shorter.

    The CEO has full faith in the products made by Koenig & Bauer as one of the leading manufacturers of packaging machines. His philosophy is to embrace the challenging tasks presented by customers, to maintain flexibility, and to work in unison to develop solutions for their products.

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