Koenig & Bauer Ensures High Profitability in Large Format Packaging Printing: Koenig & Bauer

Seamless networking: Fully automated process from sheetfed offset printing and die-cutting through to the folder gluer
Maximum flexibility: The VariJET 106 digital folding carton press economically handles short runs, relieving the burden on sheetfed offset presses
Effective countermeasure to skilled labour shortages: Easy-to-implement “no-code” robotics solutions will maximize production potential in the future
Integrated brand protection: “protected at print” for market differentiation and the protection of packaging customers' brand equity

User-friendly no-code robotics solutions will increasingly contribute to the smart factory of the future, offering high, measurable efficiency

At the exclusive Executive Day in Radebeul on 8 October, Koenig & Bauer presented the future of seamlessly networked packaging production to industry guests from all over Europe. Under the motto “Large Format End-to-End”, the printing press manufacturer demonstrated live under real production conditions how modern large format technologies transform pressing business challenges – such as the acute shortage of skilled labour, the trend towards increasingly shorter runs, and massive margin pressure – into tangible competitive advantages.

Automation as a response to the skilled labour shortage

Visitors experienced complete end-to-end packaging production in large format live. From sheetfed offset printing on the Rapida 145 and flatbed die-cutting on the Ipress 145 PRO through to gluing folding boxes on the OMEGA Allpro 110, the event convincingly demonstrated how automation and digital workflows have a proven impact on productivity and efficiency.

Many of the presented solutions underline Koenig & Bauer’s pioneering role in large format: they were either introduced to the market for the first time by the company or remain available exclusively from Koenig & Bauer to this day – including on the Rapida 145:

18,000 sheets/h: For maximum output
ErgoTronic FormCheck: Intuitive visual inspection of coating plates and die-cutting forms on the printed sheet to prevent consequential errors in postpress processing
AutoRun: Autonomous printing of a sequence of print jobs, relieving the load on the press operator
AutoGuide: Navigated printing displaying all downstream processes on the control console screen – supporting the machine operator with predictable, trouble-free processes
Mobile assistant panel: Information on the assistant operator's tasks to facilitate communication between the machine, press operator, and assistant
QualiTronic PrintCheck, PDFCheck and PDF HighRes: Sheet inspection and comparison of printed sheets against the PDF for seamless, verified, and documented quality for every single printed sheet
InstrumentFlight: Print image control based on grey balance for significantly shorter colour matching processes alongside a consistent print image across the entire run

Economic short runs and complementary technologies

Shorter runs, seasonal campaigns, short-notice on-demand orders, and a wide variety of versions increasingly characterize the folding carton market. With the VariJET 106, Koenig & Bauer demonstrated live during the event how this digital packaging press operates as a complementary solution to sheetfed offset, producing these items economically and integrating smoothly into existing production workflows.

The direct benefit for the profit and loss statements of printing companies: While long runs are produced quickly and cost-effectively in large format sheetfed offset, the VariJET 106 provides the ideal platform for manufacturing variations in ultra-short to medium runs. This relieves offset presses of less profitable small orders and opens up new business models for packaging manufacturers.

Dietmar Heyduck, SVP Sales at Koenig & Bauer Paper & Packaging Sheetfed Systems, emphasized in his introductory presentation: “We no longer just offer machinery, but integrated complete systems and value-added solutions. With these, we provide concrete answers to current and future trends in packaging production and directly support our customers in achieving their strategic goals – that is precisely what defines a true trusted advisor.”

Brand protection directly in the printing press

Koenig & Bauer’s value proposition extends far beyond mere hardware. The aim is to support customers in growing securely for the future and differentiating themselves in the market. A prime example of this is the ‘protected at print’ initiative, through which Koenig & Bauer Vision & Protection successfully achieves the technology transfer from security and banknote printing into packaging production. Invisible security features are integrated directly into the folding carton’s printing and finishing process without affecting the packaging design. Using the straightforward smartphone app ‘a verification app – ava’, end consumers can also reliably distinguish genuine products from counterfeits. At the same time, brand owners gain complete, end-to-end data to protect their products effectively throughout the supply chain.

The benefit for packaging producers is clear: they differentiate themselves in the market and reliably protect the brand equity of their customers without compromising packaging design in any way.

“Our customers are under intense pressure to handle smaller runs and customized orders profitably,” emphasizes Dietmar Heyduck, SVP Sales at Koenig & Bauer Paper & Packaging Sheetfed Systems. “That is why we no longer just offer machinery, but integrated complete systems and value-added solutions. With these, we provide concrete answers to current and future trends in packaging production and directly support our customers in achieving their strategic goals – that is precisely what defines a true trusted advisor.”

How brands can successfully balance material reduction, cost efficiency, and smart packaging solutions was demonstrated by Uwe Melichar, Vice President of epda ...

... and Thomas Vollmuth, Head of Brand Owner Management at Koenig & Bauer, in their joint keynote

Ecosystems for the future of packaging

In their joint keynote “Packaging in Transition”, Uwe Melichar, Vice President of epda, and Thomas Vollmuth, Head of Brand Owner Management at Koenig & Bauer, provided inspiring insights into how brands can successfully balance material reduction, cost efficiency, and smart packaging solutions.

Furthermore, Koenig & Bauer offered experts and guests a platform for in-depth personal exchange. Beyond the myKyana digital ecosystem, discussions focused on the packaging workflow developed in cooperation with HYBRID Software, additional end-to-end solutions for the entire packaging production value chain, and Flexo Postprinting Solutions in the corrugated sector. Through Koenig & Bauer Service and offerings from the Koenig & Bauer Campus, the printing press manufacturer provides targeted productivity enhancement programs for its customers.

Automated and highly complex packaging production within a smart factory is no longer a distant vision. A special emphasis was placed on three practical use cases for factory and machine automation. Under the banner “Robotics that just works”, user-friendly no-code robotics solutions were brought to life – guests were able to test the simple, intuitive robot controls for themselves. In the near future, these robotics solutions can unlock unused production potential, reduce manual tasks, and turn them into measurable efficiency and profitability.

Martin Dänhardt

Downloads