Koenig & Bauer News Feed https://www.koenig-bauer.com/ en Koenig & Bauer AG Sat, 19 Sep 2020 20:58:26 +0200 Sat, 19 Sep 2020 20:58:26 +0200 news-1803 Tue, 15 Sep 2020 12:23:57 +0200 Bonifatius looking forward to a Rapida 106 X http://www.koenig-bauer.com/en/news/details/article/bonifatius-looking-forward-to-a-rapida-106-x/
  • Eight-colour perfector press with coater and reel-to-sheet feeder
  • 20,000 sph in perfecting mode is a clear competitive advantage
  • Substrate flexibility from lightweight papers to board production
  • Spotlight on digital processes
  • The printing and publishing house Bonifatius in Paderborn/Germany recently ordered a new Rapida 106 X. Its installation is scheduled for early 2021. By investing in this highly automated eight-colour perfector press for 4-over-4 production with additional inline coating, the company has doubled down on its commitment to the medium of print, even in these currently troubled times. Moreover, it is one of the first printing houses in Germany to opt for the new Rapida generation, which was only recently unveiled at the virtual trade fair “Koenig & Bauer Live”.

    Bonifatius will be taking delivery of an eight-colour Rapida 106 X with perfecting unit for 4-over-4 production, inline coating unit and reel-to-sheet feeder in spring 2021 (1)

    Bonifatius makes regular investments in new production equipment. In the past years, a new hall was added to the production complex which today houses a very highly automated 16-page web press. In the meantime, it has also been joined by new post-press machinery. The trend towards ever shorter runs calls for constant optimisation of the way production is structured. The new eight-colour press gives the company the option of printing covers with a high-quality finish in a single pass. Reaching speeds of up to 20,000 sheets per hour, and this in perfecting mode as well, the press is also able to deliver the content for short-run products more economically than its webfed counterpart. This means less waste, faster makeready and greater flexibility in the handling the large number of product variants. The RS 106 reel-to-sheet feeder system allows the same types of paper to be printed on both the sheetfed and webfed presses.

    Replacement investment with added punch

    There were many reasons for the purchase of the Rapida 106 X: After six years of production, the time had come to consider replacing the Rapida 106 that had been used to date. After weighing up different offers and testing the latest technology, the specialists from Bonifatius were impressed by the Rapida 106 X that they went to see at Krüger Druck und Verlag in Merzig. The commanding level of automation and the high production speeds of the new Rapida generation in perfecting mode represent a clear competitive advantage when compared to the other possible alternatives. Moreover, the production chain at Bonifatius is already configured for the use of the Rapida technology. The operating concept for the new series has undergone significant modernisation, yet many elements nevertheless remain familiar to the printers. That will make the transition even easier.

    Looking forward to the new Rapida 106 X (l-r): Tobias Siepelmeyer, managing director of Bonifatius, plant manager Wolfgang Hettlage and Ralf Engels, senior key account manager from sales partner Steuber – together at the Rapida 106 press currently in use (2)

    Managing director Tobias Siepelmeyer and his team particularly value the extremely fast makeready on the Rapida 106 X, not to mention its high production speeds, the fast-reacting inking units, the sidelay-free infeed with DriveTronic SIS, the fully redesigned delivery, the inline colour control system which requires only 3 mm high colour bars, and the fact that the plates no longer have to be bent before mounting. Further praise is given to the quality of service assistance from the company Steuber, which provides local support for users of sheetfed offset presses from Koenig & Bauer in the North Rhine-Westphalia region. The media house has enjoyed a collegial relationship with Steuber over many decades.

    Other outstanding features of the Rapida 106 X are remote-controlled plate stretching using the console (paper stretch compensation), the VariDryBlue IR/hot-air drying systems, simultaneous plate changing using DriveTronic SPC, and the CleanTronic Synchro washing systems that enable parallel washing processes.

    In addition to commercial printing, there are also plans to use the new Rapida 106 X for packaging production. This is why it has been configured with both lightweight and board-handling accessories. The presses currently in use are already printing regular packaging jobs today – including food packaging on substrates up to 600 g/m2. The Rapida 106 X, however, will also ensure that there are sufficient units available for spot colours and coatings.

    Tobias Siepelmeyer in the paper stores. The reels can later be used on both the sheetfed and webfed presses (3)

    Digital and environment-oriented

    The year 2020 has directed a spotlight on digital processes at Bonifatius. In the print section, the new MIS PrintPlus has replaced an analogue production planning system and allows for direct networking with the printing presses. The Rapida 106 X itself incorporates a number of digital solutions ranging from autonomous printing and the LogoTronic Cockpit with displays of performance indicators to a maintenance manager and additional smart services. The company uses smart software to prepare the content for cross-media output and publishes attractive digital content on the Internet in addition to its printed editions.

    Even so, the specialists at Bonifatius are firm believers in the printed product. “It still earns its place in the communication mix,” says Tobias Siepelmeyer, whose conviction is founded not least on experience with his own book and magazine publishing house. Text books and leisure magazines are segments which are continuing to grow. Some 50 per cent of the publisher's products are sold through bookshops, including shops owned by the company itself. Another trend that Bonifatius has recently identified is seeing advertisers beginning to turn their backs on social media. The increasing prices for online ads is one of the reasons for this.

    Bonifatius worked on a major project to expand its production space in 2017/18. The newly built hall can be seen in the background (4)

    Bonifatius is fully committed to ecological print production. Digital job data increase the efficiency of both makeready and production. Materials consumption, energy input and transport processes can be optimised. That saves natural resources and helps the company to achieve the environmental targets it has set itself. Bonifatius has eliminated industrial alcohol from its production process, and the publishing house, print centre, bookshops and media offices all use green electricity. The environmental management system is certified in accordance with FSC, PEFC and EMAS standards, as well as ISO 9001 and 14001. Bonifatius offers its customers climate-neutral printing (Climate Partner) and is entitled to use the “Blue Angel” ecolabel. A detailed environmental statement provides information on the company’s ecology goals and reports on the results achieved to date.

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    news-1800 Mon, 14 Sep 2020 10:02:53 +0200 Koenig & Bauer Displays Deep Commitment and Leadership to Large Format Press Segment http://www.koenig-bauer.com/en/news/details/article/koenig-bauer-displays-deep-commitment-and-leadership-to-large-format-press-segment/
  • Substantial growth in large-format sheetfed offset press orders 
  • Broad diversity of configurations yields customized solutions
  • Strong commitment to automatization, service, research and development 
  • Only manufacturer to offer neutral consulting with an extensive press portfolio from half-size to large format
  • With more than 200 years of experience and a stellar reputation as the leading innovator among its customers, Koenig & Bauer has maintained its foremost position as a stable innovative partner and continues to be the leader in large format press production. Its successful customers rely on Koenig & Bauer to effectively and profitably produce a wide range of applications from folding cartons and top sheets for the most well-known brands in the world. 

    “We have earned our distinguished reputation as the market leader of manufacturing large-format press models,” says Eric Frank, Koenig & Bauer senior vice president of marketing and product management. “Our large format press models display proven performance and extraordinary print quality. After seeing at least 50% or higher efficiency, productivity, and output on their large format press models, our customers agree with our assertion through their own KPI’s and analytics.”

    Koenig & Bauer large format press models display proven performance and extraordinary print quality

    Large format’s many benefits

    Due to the on-going advancements in new technology on its large format models, Koenig & Bauer has repeatedly sold more large-format models than any other press manufacturer. In part, this is due to its stable of models: the large-format press line runs the gamut from the Rapida 145 57-inch with its production speeds of up to 18,000 to the 64-inch Rapida 164 printing at 17,000 sph.

    Large format customers point to the competitive advantages they receive including 50% or more square inch capacity, reduced make-ready time per box, and the highest production speeds, with the most industrialized customers producing in excess of 90 million sheets per year on a large format press. Everything about a Koenig & Bauer large format press--its high nonstop productivity, less paper waste, shorter makeready times, and simultaneous processes that allows for ultra-fast job changeovers, this in combination with the exceptional print quality, and the highest level of engineering and craftsmanship-- is designed to allow the press to produce the work of two smaller format presses with the investment into one press.

    Due to the broad diversity of configuration options, accessories and automation solutions, the large-format Rapida’s are an efficient means of production for both established and niche markets. They can be equipped with a reel-to-sheet feeder, a double-pile delivery, diverse drying units such as UV and LED, additional printing units after coating and perfecting facilities, as required for the individual application. For packaging printing, they can also be placed on raised foundations and integrated into a fully automatic pile logistics system. Presses with up to 16 printing and finishing units are already in daily use.

    Strong demand

    Koenig & Bauer large format customers have transformed their businesses by investing in solutions that provide high quality, faster turnaround, and increased automated technology. There has been a continuing strong demand for this size press all over the world.

    Litho-laminated corrugated packaging manufacturer Accurate Box chose a new large format Koenig & Bauer Rapida 164 seven-color press to help its elite customers “stand out”, not “blend in” on store shelves. Working with major nationally-recognized brands such as Kellogg's and Pepsico and their specific color schemes, logos, and graphics, it is imperative for Accurate to match those shades and images box-to-box and run-to-run using its new Rapida 164 press configured with new computerized quality systems and enhancements.

    A large format Rapida 164 64-inch eight-color is supporting the explosive demand and growth at Huston Patterson, a privately owned package printing business, that serves such well-known firms as Disney, Pampers, Sony and Coca-Cola. “It is our go-to press,” says Tonya Kowa-Morelli, HP’s president.

    Earlier this year, Oliver Inc. chose its ninth Koenig & Bauer press: a Rapida 145 57-inch seven color serving the food, health and beauty, and pharma package printing niches. This new workhorse press will provide 20% more production and capacity and provide enhanced creative solutions, speed to market, and high-end finishing capabilities. 

    To boost its printing capacity by 40%, Superior Litho in Los Angeles chose a Rapida 145 seven-color coater press, its third large-format press from Koenig & Bauer. Equipped with UV dryers, inline color control and PDF-Check, Superior Litho supplies packaging for the food, electronics and cosmetics industries, as well as for special products. 

    Foster Printing will be adding its fourth large format press from Koenig & Bauer, a new Rapida 164 six-color 64-inch press. Foster proudly installed the unique Koenig & Bauer Rapida 205 81-inch press, the largest ever produced, in 2012 and continues to utilize that extra large format press. “It was and continues to be a workhorse machine for us and supply immense productivity,” says Kris Blackburn, Foster’s vice president of sales.

    Strong commitment

    “While our large format models have many benefits for our customers, we’re proud to act as neutral consultants in which we bring a full press portfolio from half-size to large format,” says Frank.

    “But due to the technology, service, and support of our large format models, customers easily choose one of those models due to their ability to be a profit leader with this format size. Only Koenig & Bauer can customize each press to each customer’s application allowing them to offer a unique printed product for extreme market differentiation. It is important to Koenig & Bauer to be the only press provider that can start and grow with a customer in all format sizes to ensure their long-term success.”

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    news-1799 Thu, 10 Sep 2020 09:05:35 +0200 Koenig & Bauer presents the Rapida 76 for high-end print production in B2 format http://www.koenig-bauer.com/en/news/details/article/koenig-bauer-presents-the-rapida-76-for-high-end-print-production-in-b2-format/
  • Comprehensive automation to shorten make-ready times
  • Versatile configuration and finishing options
  • Application-orientated measuring and control systems
  • Access to a diversity of digital services
  • A new generation of the Rapida 76 from Koenig & Bauer has just been released onto the market. The B2 press (standard sheet format 530 x 750 mm; special format 605 x 750 mm) impresses with its extraordinary level of automation, a minimal footprint and peak printing speeds of up to 18,000 sheets per hour. Boasting a fully revamped and particularly aesthetic appearance, it also stands out visually from its predecessors, and presents itself in the new, award-winning Koenig & Bauer design.

    New and proven automation functions characterise the Rapida 76 as an extremely efficient, high-performance sheetfed offset press. Key features are the DriveTronic dedicated drive components, which eliminate complicated gear systems and provide for both simple handling and parallel processes during job changeovers and make-ready. The full preset capabilities of all press components are a further valuable benefit. In addition to the ErgoTronic console with wallscreen, the Rapida 76 possesses further decentralised touchscreens for maximum ease of operation. For users who are at home in the B2 format class, the Rapida 76 is an ideal means of production.

    The new Rapida 76 is an immediate eye-catcher in the new Koenig & Bauer design (1)

    Broad diversity of configurations

    To cater for as many different applications as possible, up to 11 printing and finishing units can be combined to configure a Rapida 76 which is tailored precisely to individual production needs. That could mean a ten-colour press with an automatically convertible perfecting unit for 5-over-5 production – possibly together with an additional coating tower to allow the printing of covers, for example – or packaging presses with double-coating facilities for the production of pharmaceutical packaging and the like. Further variants incorporate raised foundations to accommodate higher piles with board substrates, or various delivery extensions for coating applications. Ink duct dividers can also be chosen to enable rainbow printing. Thanks to a comprehensive range of measuring systems and optional facilities for inline sheet inspection, the Rapida 76 is ideally prepared for a diversity of special applications, including even the production of security documents.

    The half-format press is no less flexible when it comes to compatibility with different ink and coating systems. It handles both conventional and UV inks and coatings with equal ease. Beside IR/hot-air drying systems, various UV, HR-UV and LED-UV systems are also available.

    With a printing output of up to 18,000 sheets per hour, the Rapida 76 is built for speed (2)

    Specialities “Made by Koenig & Bauer”

    As if that were not enough, the Rapida 76 offers further special features which benefit users in their daily work but are still far from commonplace in this format class:

    as on all Rapida presses, inking units which are not required for a particular job can be disengaged from the press drive. This reduces roller wear and cuts make-ready times. When production is to be resumed, the units concerned are re-engaged at the press of a button.

    The times in which plates had to be bent before loading onto the press are similarly over. On the Rapida 76, unbent plates can also be mounted, irrespective of whether an automated or simultaneous plate changing system is in use.

    Simultaneous SPC plate changing with unbent plates (4)

    The ColorTronic ink ducts, with the bleed-free ink metering which is typical of all Rapidas, guarantee high repeat accuracy. This is achieved with individual ink keys and a special mechanical design which ensures that they are always set to the duct roller with an identical force. With this system, ink duct foils are rendered superfluous. Thanks to the EasyClean duct plate coating, extremely fast ink changes are possible nonetheless.

    With simultaneous plate changing, all the plates on the Rapida 76 can be changed in just 45 seconds. In combination with CleanTronic Synchro, the blankets and impression cylinders – and optionally also the ink rollers – can be washed parallel to plate changing. This shortens make-ready times dramatically and leaves much more time for actual production. The same applies to automated coating forme changes.

    One camera system for up to three functions: colour control, sheet inspection and PDF comparisons (3)

    Wide range of measuring and control systems

    Application-orientated measuring and control systems contribute to faster make-ready, reduced waste, and a consistently high and stable print quality. The Rapida 76 can be configured with systems for register measurement and control, colour control and sheet inspection. All inline systems operate with a common camera, which reduces maintenance requirements and simplifies handling.

    In a full-featured setup, ErgoTronic ICR controls the register by way of a single sheet placed on the console, while QualiTronic ColorControl provides for convenient colour adjustment. The camera system installed after the last printing or coating unit or after the last unit before perfecting automatically determines the optical densities and controls the ink keys without further intervention. As an option, the system can be expanded to implement colour control according to grey balance (QualiTronic InstrumentFlight). QualiTronic PDFCheck carries out inspection of the printed sheets and comparison with the customer’s PDF as the basis for uncompromising quality.

    Semi-automated technology also permits fast coating forme changes on the Rapida 76 (5)

    Digital services at the press of a button

    A multitude of digital services surrounding the Rapida 76 helps to reduce unplanned downtimes, facilitates convenient and barrier-free maintenance of the press, and permits anonymous comparisons of important performance parameters with other presses in identical configurations. The options range from PressCall for optimisation of communication with remote maintenance engineers and VisualPressSupport to enable a better description of the reason for a remote maintenance call using photos (with extensive commenting functions), texts, videos and audio, via Performance Reports and Press Inspection Reports, through to the first instances of predictive services based on methods of artificial intelligence.

    In this context, the Customer Community is a central point of contact bringing all service offers together under one roof. Users and the manufacturer have access to an identical information database, meaning that they are all on the same page when working together.

    In addition to blanket washing, the Rapida 76 possesses a conveniently accessible impression cylinder washing system (6)

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    news-1793 Tue, 08 Sep 2020 13:30:00 +0200 New Koenig & Bauer Rapida 105 PRO Ten-Color Perfector Press Enhances Ultra-Rich Design Capabilities at TPC Printing & Packaging http://www.koenig-bauer.com/en/news/details/article/new-koenig-bauer-rapida-105-pro-ten-color-perfector-press-enhances-ultra-rich-design-capabilities-at-tpc-printing-packaging/
  • New Rapida posts significant 50% increase in output with less machine hours
  • Increased speeds of 30% and reduced make-ready time of 50% due to improved automation  
  • Additional 60% capacity delivered into TPC’s pressroom
  • The perfector and cold foil units add enormous design capabilities for TPC’s world-class consumer retailers and well-known brand names
  • When world-class consumer retailers and well-known brand names require an especially unique luxury package, they turn to TPC Printing and Packaging, a highly-decorated boutique printer with an outstanding reputation for producing a wide range of high-end custom folding cartons and promotional packaging. At its Chattanooga, TN facility, the privately-owned firm operates a stable of automated Koenig & Bauer presses including two Rapida 105 eight-color plus coater presses and its new Koenig & Bauer Rapida 105 PRO 10-color 41-inch perfector press, a specialized versatile model that offers either 10 straight or eight-over-two perfecting, multiple inline curing units, combination LED-UV processes, full automation and color control, and the ability to handle multiple specialty substrates. Since its installation in early 2020, TPC has been generating increased double-digit speed, efficiency, capacity, and faster turnaround for its customers. 

    The new 10-color Koenig & Bauer Rapida 105 PRO perfector press is enhancing ultra-rich design capabilities and reaching new levels of quality and output at TPC Printing & Packaging

    “In the past eight months we have seen enhanced capabilities due to the new press,” says Joseph A. Schmissrauter III, president of TPC Packaging. “We’ve increased speeds and reduced make-ready time using improved automation on this press. The automation and enhanced speed have also helped production efficiency. We have already experienced a significant increase in output with less machine hours. We are showing our customers a lot of unique and innovative in-line cold foil using the inline Eagle cold foil system for eight-over-foil configuration.”

    Limitless designs    

    Schmissrauter and his team specifically designed the press as a perfector since about 60% of its work mix requires inside printing. Its in-line back printing uses the 8/2 configuration in which the press has a perfector between units 2-3 to allow for printing two colors on the backside and eight colors plus coating on the front side--all inline. The new press with perfecting has already seriously reduced the number of impressions through the pressroom, he says. The perfector and cold foil units have added enormous design capabilities for TPC’s luxury packaging customers. In fact, says Schmissrauter, when used in combination with its Scodix E-106 large format variable digital decoration device, the design options are almost limitless. “We are now the only folding carton company in the world to offer in-line cold foil, off line hot foil and off-line variable digital Scodix foil under one roof,” he says.   

    Environmental and sustainable packaging solutions are a growing demand from TPC’s customers. To provide options for these customers, TPC outfitted the new Rapida with a cold foil unit on units 1-2 to allow for in-line cold foil and eight color overprints + coating in-line. The in-line cold foil capability from Eagle has allowed TPC to avoid more expensive and environmentally challenging fully laminated metalized polyester (MPE), explains Schmissrauter. “We can now offer in-line foil transfer and only apply foil where it is needed.”

     TPC decided to partner again with Koenig & Bauer on the new 10-color press purchase because management believes that it is the best printing press in the world for package printing and is manufactured at the highest level of engineering and craftsmanship. “Our expectations were more than met when we installed the 2017 eight-color Rapida,” says Schmissrauter. “The new 10-color installation was complicated by the pandemic but TPC and Koenig & Bauer were able to successfully work through this challenge under some very rigorous conditions. The new Rapida 105 PRO press has exceeded our expectations. We are ready to go to a higher level of quality and output with this new additional press.”

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    news-1791 Tue, 01 Sep 2020 14:13:17 +0200 “All the signs point to growth!” http://www.koenig-bauer.com/en/news/details/article/all-the-signs-point-to-growth/
  • Output expected to increase by 30 per cent
  • Consistently high print quality thanks to QualiTronic PDFCheck
  • Production space continues to grow
  • High degree of social responsibility
  • The raised Rapida 106 packaging press with double-pile delivery in full production. It is operated by Andreas Metz (at the delivery) and his son Alexander (1)

    “All the signs point to growth” – there is no question about that in the mind of Henrik Jung, technical director at packaging producer Heinrich Buhl in Neunkirchen/Siegerland. In fact, the company has developed constantly ever since its founding in the Buhl family home in 1961. “For the past five years, we have seen almost two-figure turnover growth,” Jung says. The workforce has also increased from 40 to 60 over the same period.

    Henrik Jung, technical director at Heinrich Buhl, and Ralf Engels, senior key account manager for print & packaging at Steuber, expect output to increase by 30 per cent compared to the predecessor press (2)

    One important contribution to future positive developments at the company is the installation of a Rapida 106 from Koenig & Bauer, which was commissioned in the spring of this year. Looking back over decades of trustful partnership and cooperation, Heinrich Buhl again chose the printing system house Steuber in Mönchengladbach as the supplier for its new equipment. The two companies have thus added yet another chapter to their joint success story.

    The print instruction was met with enthusiasm by all future operators of the Rapida 106 (3)

    The five-colour coater press stands in a brand new hall and has been raised by 675 mm to accommodate the higher piles typical in packaging printing. QualiTronic PDFCheck takes care of inline colour density control, sheet inspection and comparison of each printed sheet with the customer PDF. And that all with a single camera system. The double-pile delivery separates good and waste sheets to ensure that only flawless piles are passed on for further processing.

    For many jobs, this capability is also essential. Some brand owners reject even the tiniest flaws, e.g. deviations in a matt black solid. At the product filling stage – or, at the latest, when making up the trays – each individual folding carton is inspected by hand. The consistently high production quality definitely pays off here.

    Die-cutting formes are valuable assets for every packaging producer. Over 1,200 formes are waiting to be used in the storerooms at Buhl (6)

    Maximum performance under real production conditions

    The company expects the Rapida 106 to boost output by 30 per cent compared to the predecessor press dating from 2011. The outstanding sheet travel capabilities of Rapida presses will play an important role here. Henrik Jung: “We are regularly able to run at speeds of 18,000 sheets per hour, depending on the product and substrate concerned.” Thanks to the EasyClean ink ducts, ink changes are also much faster, without requiring the use of ink duct foils. Flexibility in the drying systems supports the use of blister coatings and demonstrates Koenig & Bauer’s expertise in this field. When it came to the plate changers, however, the specialists at Buhl opted for a less highly automated variant, as its operators spend relatively little time on plate changing compared to their other tasks.

    Even so, make-ready times are now significantly shorter. This is accompanied by increased outputs and reduced waste rates. The new press, the only sheetfed offset press in the company’s print department, is furthermore a paragon of high production stability and reliability. Like the rest of the company, it is fully occupied in a three-shift system.

    With the installation of the Rapida 106 from Koenig & Bauer Sheetfed, Heinrich Buhl has come full circle. Presses built in Radebeul were already delivered to the company in 1987 and 1990.

    One camera system, three functions: QualiTronic PDFCheck takes care of inline colour density control, sheet inspection and comparison of the printed sheets with the customer PDF (5)

    Broad diversity of packaging

    Heinrich Buhl produces folding cartons, blister packs, skin packaging, product backing cards, counter display units and trays. Many of these products can be found in DIY and hardware stores. They are printed on both board and plastic films. The majority of the products are destined for the German market, though numerous customers are also supplied in France, Switzerland, Italy and the Czech Republic.

    Henrik Jung identifies flexibility and punctual deliveries as the most important characteristics of a packaging printer. There are often just 36 hours between receipt of an order and the delivery deadline. During this time, the packaging must be produced from scratch – nothing is held in stock in a warehouse. The perfect functioning of the underlying processes is illustrated by the long-standing partnerships which exist with many customers. Some of these business relationships have been going strong for more than 25 years.

    Heinrich Buhl specialises in packaging production in short and medium runs. The average run length is around 5,000 sheets, but there have also been orders for as many as 200,000 sheets.

    Impressive company headquarters: further investments and extensions are already planned for the coming year (7)

    Start of construction for a new office building

    There can be no doubt about the continued development of Heinrich Buhl: diggers and bulldozers will be back at the site in September. A new office building with modern social facilities is to be built. The plans also include a new car park and charger stations for e-bikes.

    Heinrich Buhl attaches great importance to motivated employees. Most remain loyal to the company over decades, and it is quite possible to meet several generations from one family in the packaging operation.

    Raising of the press foundations by 625 mm permits the handling of piles up to almost 2 metres in height (4)

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    RSS Feed Sheetfed offset Market References & Showcases
    news-1785 Wed, 19 Aug 2020 07:27:07 +0200 Over 100 Rapida printing units in operation at Parksons Packaging http://www.koenig-bauer.com/en/news/details/article/over-100-rapida-printing-units-in-operation-at-parksons-packaging/
  • Rapida 76 boosts sheetfed offset press fleet
  • Rapida sheetfed offset technology valued for ist high productivity
  • Production focus: folding box production
  • Parksons Packaging is one of the biggest packaging solutions providers in India. Alongside its headquarters in Mumbai, the company, which is overseen by chairman Ramesh Kejriwal, operates five ultramodern production plants at locations all over the subcontinent. Only recently, a newly installed Rapida 76 was commissioned. This means there are now exactly 101 printing and finishing units from Koenig & Bauer in production for the Indian packaging giant.

    Impressive dimensions: The Parksons Packaging plant in Chakan, Pune (1)

    The first Rapida sheetfed offset presses started arriving at the company in 2005. At the time, Parksons Packaging was looking for presses to handle UV production. The Rapida 105 with its facility to switch dryer modules between multiple installation points was the industry yardstick in those days, not only at Parksons, but indeed for UV production throughout India. Later, Rapida 106 models joined the line-up – seven-colour and eight-colour presses and others in double-coating configurations. At the beginning of 2020, the company purchased its first Rapida 76 – in a six-colour version with coater and extended delivery.

    Faced with changing market demands, Parksons Packaging decided that it needed to install a half-format press alongside its medium-format Rapidas. The combination of high production speeds and a small footprint tipped the scales in favour of the Rapida 76. No less important were the short job changeover times – especially when using DriveTronic SPC – and an enlarged sheet format.

    At a ceremony to mark the commissioning of the Rapida 76, Dietmar Heyduck, Koenig & Bauer Sheetfed (2nd from right), honoured Ramesh Kejriwal, Parksons Packaging (centre), as an important partner. Also present: Aditya Surana from Koenig & Bauer sales partner Indo-Polygraph Machinery (left), Siddharth Kejriwal (2nd from left) and Subhasis Roy (right), both Parksons Packaging (2)

    Fast job changeovers and high production speed

    The capacity to disengage individual inking units, a feature unique to Rapida presses, also caught Ramesh Kejriwal’s attention: “We can already prepare the unused printing units for the next job while the press is still running the current production job. And as an extra bonus, that also reduces wear on the rollers.“

    Kejriwal is equally impressed by the high productivity of the other Rapida presses: “DriveTronic SPC allows job changeover times to be shortened by 30 to 40 per cent. And the number of jobs which we handle on the new presses has increased by 30 to 35 per cent.“

    On average, it can be said that each new Rapida is able to replace two older models. In addition to the high speeds, waste is also reduced. Parksons is very satisfied with the presses, the print quality and the installation and commissioning process. This is reflective of the fast and comprehensive service provided by Koenig & Bauer sales partner Indo-Polygraph Machinery. And so, with each new press, the company is building up a full package geared to the most important criterion for any type of production technology: Performance.

    It was two years ago that Ramesh Kejriwal, Parksons Packaging (centre), signed the delivery contracts for three seven-colour Rapida 106 coater presses, two of which feature DriveTronic SPC and QualiTronic ColorControl. Here in the photo (left to right): Aditya Surana from Indo-Polygraph Machinery, with Dietmar Heyduck, Bhupinder Sethi and Sascha Fischer, all Koenig & Bauer Sheetfed (3)

    Folding cartons in all dimensions

    All Parksons Packaging plants place their focus on folding carton production. The corresponding jobs can be assigned to a total of 22 offset production lines, 13 of them from Koenig & Bauer, and one digital line. Nevertheless, there are differences between the individual plants and their specialisations. Digital and screen printing are based in Daman, together with the production of pharmaceuticals packaging. Pantnagar is specialised in packaging with high-quality cold foil finishing. And Chakan produces beverage cartons. Additional production plants are located in Sricity and Guwahati.

    This nationwide base allows Parksons Packaging to supply a wide range of packaging products to customers in all corners of the country. Domestic production is complemented by a global export business. The product portfolio includes, among other things: Mono cartons, litho-laminated cartons, liner cartons, transport and retail packaging, shelf-ready displays, promotional and gift packaging, a broad spectrum of custom packaging, beverage cartons and blister packs. One of the company’s specialities is an ingenious slider pack design.

    In 2019, Parksons Packaging recorded a turnover of around €150m ($167m). Almost 18,000 different articles are produced, and approx. 100,000 tonnes of paper and board are processed every year. More than 1,700 employees work in plants with a production floor space totalling almost 100,000m2 (1,075,000sq.ft).

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    news-1778 Wed, 05 Aug 2020 11:52:21 +0200 Poland’s first Rapida RDC 106 rotary die-cutter now being used in production at Top-Pol http://www.koenig-bauer.com/en/news/details/article/polands-first-rapida-rdc-106-rotary-die-cutter-now-being-used-in-production-at-top-pol/
  • Used for in-mould label production
  • Pioneer on the Polish market
  • Production output practically doubled
  • Top-Pol in Zbrosławice is the first print company in Poland to use a Rapida RDC 106 rotary die-cutter from Koenig & Bauer. The machine was purchased as part of a project to allow the printing of innovative IML labels in an offset process, and which received funding support from the EU. The rotary die-cutter aims to guarantee production stability and high cutting speeds, alongside significantly reduced makeready times.

    Top-Pol is a family-run company that has been active on the printing market since 1989, and has become a specialist for the production of labels using non-absorbent substrates – primarily plastics – since the end of the 1990s. Co-proprietor Marcel Topolski: “We were one of the pioneers in the use of UV offset technologies for substrates like this. IML labels soon became our flagship product and currently account for 70 to 80 per cent of our production volume. Another key area is the production of lids and covers made from PE, PS or PP for plastic packaging, for example for yoghurt pots.”

    Top-Pol exports 30 to 40 per cent of its production output. The end customers for the labels are primarily companies operating in the food and construction industries. “The systematic development we are pursuing means we are constantly modernising our production machinery, also with regard to finishing processes,” says Marcel Topolski.

    Marcel Topolski (left) has raised the bar for IML production in Poland with the Rapida RDC 106

    High production speeds, fast makeready

    The maximum mechanical output of the Rapida RDC 106 totals 15,000 sheets per hour. The press enables the die-cutting of substrates in thicknesses from 0.03 to 0.6 mm, and is equipped with numerous solutions that were introduced with the Rapida 106 sheetfed offset printing presses. These include, among others, DriveTronic technology with dedicated drives, the sidelay-free infeed DriveTronic SIS, and a camera system to monitor sheet travel at the feeder and delivery.

    One of the key functions of the machine is automatic adjustment of the die-cutting pressure. The pressure can be set separately for each side of the cylinder with a precision of 1 µm. This results in a high die-cutting quality over the entire length of a run. Fast, tool-free forme changes that use a “click & cut” process enable very short makeready times – as little as 5 minutes for repeat jobs. Smooth delivery of the sheets onto the pallet is realised by the dynamic sheet brake and an anti-static system with an extensive range of functions. This also allows further processing to continue immediately when the next step in the production chain starts. There is no need for time-consuming re-stacking ahead of automated further processing. The die-cutting units are equipped with a magnetic cylinder, to which the individual cutting formes are fixed. As a result, a range of processes can be realised in a single unit – from die-cutting to embossing or perforation, along with hole punching. The Rapida RDC 106 is available in a number of different configurations with one to four units.

    Enhanced production and productivity

    “Once again, we have assumed a pioneering role, this time by introducing the Rapida RDC 106 onto the Polish market,” says Marcel Topolski. “As we had already been successful using rotary label die-cutting in the past, the purchase was an ideal opportunity to continue to enhance our productivity and production. After all, our products are quite difficult to produce. The IML labels are made of plastic and also feature indentations to make it easier for the end customer to separate them later on. This makes it a perfect opportunity to broaden our knowledge, both for our own and for the manufacturer's benefit.”

    “Special mention must be made of the level of dedication shown not only by the sales team but also by the technical and service departments, both at our local Koenig & Bauer branch office and at the German headquarters. Integration of the press into the new technological process was completed efficiently and on-time during the first quarter of the year. Our operators have nothing but praise for it, especially in regard to the increased level of process stability and the doubling of production output compared to our previous solution.”

    “Our customers in the food industry, along with our customers in other sectors, expect labels of the highest quality. Accordingly, the solutions we use must also represent the highest standards and the best possible performance that the global market has to offer. The latest investment in the Rapida RDC 106 will more than satisfy these expectations, which are becoming more and more demanding due to changes to the market and to consumer tastes. These aspects are all the more important in the current global situation, which has, of course, also impacted our order volume,” Marcel Topolski concludes.

    Jan Korenc, managing director of Koenig & Bauer (CEE) adds: “This is a first-class solution which requires up to 40 per cent less makeready to complete an entire job. This is why we are confident that it will contribute to the continued growth of Top-Pol as one of the leading print companies in Poland, and play a role in the successful implementation of the new technology project for which the Rapida RDC 106 rotary die-cutter was purchased.”

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    news-1771 Wed, 29 Jul 2020 07:15:00 +0200 Koenig & Bauer publishes its H1 report 2020 http://www.koenig-bauer.com/en/news/details/article/koenig-bauer-publishes-its-h1-report-2020/
  • Delivery and pandemic-related revenue decline by 20.1%
  • Order intake 16.2% below prior year, considerably better than industry trend
  • Earnings significantly impacted by low revenue
  • On the cost side, massively counteracted with short-time working from 1 April 2020 and other measures
  • Equity ratio of 32.2%
  • In addition to the general investment restraint on the part of many customers in the corona crisis, travel bans, lockdowns and other restrictions significantly affected the business figures of the Koenig & Bauer group in the first half of 2020. The restrictions caused by the Covid-19 pandemic particularly impeded deliveries of the presses to the international customers as well as the worldwide deployment of the assembly staff and service technicians. At €480.2m, orders were 16.2% lower than in the previous year, although this was better than the sector trend for printing presses published by industry association VDMA. At €404.5m, revenue fell short of the previous year by 20.1%. On the cost side, massive measures were taken to address the effects of the crisis, introducing short-time working from 1 April 2020 alongside other steps. EBIT improved substantially from –€34.9m in Q1 to –€6m in Q2. For the first half of the year, EBIT was –€40.9m after €0.6m in the previous year. At –€44.2m, net earnings as of 30 June corresponds to earnings per share of –€2.68.

    Despite substantially lower trade receivables and higher customer prepayments, the half-year loss and the increase in inventories had major impacts on cash flows from operating activities, which came to –€68.6m (2019: –€96.5m). The equity ratio stood at 32.2% at the end of June 2020.

    The high-end Rapida 106 X press for medium-format sheetfed offset, which was presented at the virtual trade fair Koenig & Bauer Live in June, sets new performance standards in industrial printing (1)

    Segment performance

    Despite the substantial gains with large-format sheetfed offset presses and folder gluers, order intake in the Sheetfed segment declined by 12.9% over the previous year’s figure of €330.6m to €288m due to lower orders for medium and half-format presses. Revenue of €205.5m was 20.6% lower than the previous year’s figure (€258.9m) for delivery-related reasons and due to the effects of the pandemic. With the book-to-bill ratio coming to 1.4, order backlog rose from €261.6m to €265.9m. Due to lower revenue, EBIT of –€17.4m was below the previous year (–€1.3m).

    Order intake in the Digital & Web segment came to €56.7m, down from €89.9m in the previous year, due to lower orders in the web offset press business and for flexible packaging printing. At €51.6m, revenue was down on the previous year (€64.5m). The order backlog contracted from €111.2m to €71.2m. The lower revenue had a significant impact on the EBIT of –€12.1m (2019: –€10.8m).

    The decline in order intake in the Special segment from €175.3m to €150.7m reflects lower orders for security printing, marking and coding as well as glass direct printing. In metal decorating, there was an increase in new business. Revenue fell from €204.9m to €160.1m. The order backlog reached €278.1m after €316m in the previous year. After €6.3m in the previous year, EBIT came to –€10.3m in the first half of 2020 for revenue-related reasons.

    Revenue and orders for the large-format sheetfed offset presses and folder gluers used in the packaging sector also increased during the crisis (2)

    Outlook

    CEO Claus Bolza-Schünemann: “In view of the high volatility and the great uncertainties surrounding the severity and duration of the coronavirus pandemic and the success of health, economic and monetary policies, the further global economic development is uncertain. Given these uncertain underlying conditions, it is currently not yet possible to issue any revenue and earnings guidance for 2020 for our group. The management board is working intensively on the Performance 2024 efficiency programme to increase the operating profitability. We have applied for a KfW loan to supplement the existing syndicated credit facilities. In addition, improvements in working capital and cash flow are at the top of the agenda together with the strategic focus on packaging printing and digital services.”

    Figures at a glance

    The financial statements can be downloaded as a PDF file from here.

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    news-1769 Tue, 28 Jul 2020 12:34:56 +0200 Koenig & Bauer offers Live Remote Video Support App http://www.koenig-bauer.com/en/news/details/article/koenig-bauer-offers-live-remote-video-support-app/
  • Use of different channels for communication
  • Easier communication for fast remote maintenance success
  • Example of consistent implementation of the digitalization strategy
  • Visual PressSupport is an App based live video streaming service that Koenig & Bauer now offers for sheetfed presses and other business units. In addition to audio transmission, it enables live videos to be transmitted directly from a mobile device to the hotline technician during remote maintenance. The success rate of classic remote maintenance methods currently used is 80 percent. It is expected to grow further with Visual PressSupport.

    Visual PressSupport is a cutting-edge tool that makes communication much easier for both users and hotline technicians. The hotline technician sees what the press operator or service technician sees on the press. He can be shown processes and procedures live via video and thus gain a quick and comprehensive overview of the situation at the press. This facilitates communication, saves the need for extensive explanations and reduces the risk of misunderstandings compared to a conventional telephone call.

    Visual PressSupport allows you to broadcast live video, mark up still images and share media

    Communication with added value

    But Visual PressSupport can do even more: both the technician on site and the hotline technician can apply markings to the still images generated live. These markers help to carry out function checks or settings on the correct part or to record the current status separately close-up. In this way, it can help to limit malfunctions or be used to transfer operating and setting aids.

    In addition, the operator or technician at the press can share images from the album on their mobile device with the hotline. These can show certain press behaviour that only occurs sporadically and therefore cannot be picked up on live.

    Data security is guaranteed at the same time as the hotline technician can only see the media that has been shared and no other content.

    Ralf Sammeck – CEO of Koenig & Bauer Sheetfed & Group CDO said “Visual PressSupport is another example of the consistent implementation of our digitization strategy. The focus is on the business benefit for our customers. Everything that contributes to higher availability and productivity and improves communication is of decisive added value for our customers.”

    More details are available at:
    https://www.koenig-bauer.com/en/service/sheetfed/technology-service-select/visual-presssupport/

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    news-1762 Tue, 21 Jul 2020 11:43:34 +0200 Press demonstration facility upgraded into a global Customer Experience Centre http://www.koenig-bauer.com/en/news/details/article/press-demonstration-facility-upgraded-into-a-global-customer-experience-centre/
  • New building boasting more than 3,000m2 of demonstration floor space in Radebeul
  • Packaging lines with seven printing presses and post-press machines, including workflow integration and production data logging
  • One-stop-shop concept for packaging production with fully automated material flows
  • Koenig & Bauer recently opened its new hall and now offers more than 3,000m2 of floor space for print demonstrations at its Radebeul location, near Dresden. The occasion marked the culmination of a project to upgrade the company’s existing demonstration facility into a global Customer Experience Centre (CEC). For customers and other interested visitors, the CEC offers around one-third more space – packed with the very latest equipment – for press and machine demonstrations, application testing, the development of new technologies and for training purposes. The individual sections focus on the specialised areas of packaging, commercial and label production

    Inauguration of the new CEC in Radebeul (left to right): Dirk Winkler, head of print technology, product management and product marketing, Claus Bolza-Schünemann, president and CEO of Koenig & Bauer, Ralf Sammeck, Koenig & Bauer management board member and CEO of Koenig & Bauer Sheetfed, and Thomas Göcke, head of digital business transformation, hand the new building over to its future users (1)

    The new hall, the Packaging Competence Centre within the CEC, will house three packaging lines comprising three printing presses and four post-press machines once fully set up. Koenig & Bauer will then be able to showcase its one-stop-shop concept for packaging production – with flat-bed and rotary die-cutters, folder-gluers and fully automated material flows. Meeting areas with direct views of the production lines, workstations to illustrate digital workflow integration and a full range of modern media equipment contribute to an atmosphere conducive to tests, production trials, demonstrations, discussions and negotiations.

    The machinery that is already installed and ready for demonstrations includes a latest-generation medium-format sheetfed offset press, this being a Rapida 106 X with seven printing units, double-coating facilities, an additional printing unit after the first coater and the coil foil system FoilTronic, as well as an Omega Allpro 110 folder-gluer and a CutPRO X 106 rotary die-cutter. The next step will see the addition of a Rapida 145 and a CutPRO M 144.

    The first machinery – the brand new Rapida 106 is shown here – is ready for individual print tests (2)

    Koenig & Bauer started construction of the new building in the second half of 2018. Since the beginning of the year, the project has continued with the completion of the interior and installation of the machines, which were shown in action for the first time as part of the virtual event series “Koenig & Bauer Live” from 16 to 25 June. In the meantime, 3,500 cubic metres of earth had been dug and 520 cubic metres of concrete had been poured. Other key parameters of the building are its 38 pre-cast columns, a roof construction featuring glulam trusses and a span of 35 metres, and 1,300 square metres of cladding. Some 250 LED lights were fitted on mounting tracks with a length of almost 600 metres, 30,000 metres of cabling were routed through the facility, and a photovoltaic array was installed on the roof.

    Koenig & Bauer is looking forward to intensive use of the new CEC by customers and other visitors from all over the world over the coming weeks.

    The new building now makes one-third more space available to users and interested visitors for individual print tests and press demonstrations (3)

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