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MEX, Switzerland , July 4, 2019 (Press Release) -With the size of its new manufacturing site near Pirmasens in Germany and the equipment installed within it, G & G Preißer is setting new standards in the European market for packaging made out of corrugated cardboard.

To do this, the manufacturer of corrugated board packaging commissioned four new converting machines from BOBST at the beginning of 2018. It only took a few months for the machines – EXPERTLINE 1.6, with five FLEXO 160-VISION print units and hot air intermediate dryers; the specialty folding-gluing machine MASTERFOLD 230; the Inliner FFG 1636 NT and the Miniline FFG 618 Quatro – to be running at full capacity, three shifts a day.

G & G Preißer also upgraded a Midline FFG 924 NT with a pre-feeder and an automatic palletization system, and has already ordered another EXPERTLINE 1.6 and an additional EXPERTFOLD 165 from BOBST. They will be delivered and installed during 2019. G & G Preißer will then have more than seven converting machines from BOBST in its new plant. They will be used to manufacture packaging made of corrugated board, primarily for customers in the food, personal care and cosmetics industries. The production process takes place in a completely clean environment.

“Use of this innovative technology fulfils any requirements our customers may have extremely well,” stated Tobias Preißer who manages the company along with his brother Christof. The three Inliners are still covering about 80% of the production volume. However, the demand from customers for high quality packaging, such as multi-color printed and varnished trays or shelf packaging, is growing steadily. This is why G & G Preißer needs two EXPERTLINE 1.6 lines with high quality FLEXO 160-VISION print units and the hot air intermediate dryers.

Both EXPERTLINE 1.6 lines are also fitted with a LOADER AF sheet-feeder, an EXPERTCUT 1.6 flat-bed die-cutter and a BREAKER blank-separator. Christof Preißer said: “We cannot accommodate our customers with price reductions. However, we can convince them with the quality we are getting from our new machines. The flatbed die-cutting delivers high-quality creasing and cutting and the tolerances for the GAPs and slots are tighter. The nicks can also be smaller or even dispensed with completely. The process also improves the flatness of the flatbed die-cut trays and packaging. There are also no cutting waste between the packaging.” This is all advantageous for the customer’s filling processes.

Using its three Inliners, G & G Preißer is very flexible in the sheet format of the packaging to be manufactured and can pull out all the stops when it comes to color. While the FFG 924 NT covers all formats, with a length of between 600 and 2,490 mm, the FFG 618 Quatro processes sheet lengths of 385 to 1,880 mm and the FFG 1636 NT processes sheet lengths of 700 to 3,690 mm. The FFG 618 Quatro is fitted with dryers and can deliver high-quality print images on sheets at high production speeds, even with four colors. The two other Inliners each have two print units.

To avoid downtime as much as possible, the packaging manufacturer uses the preventive Maintenance Plus program for all of its BOBST machines. In case there should be an issue, a BOBST service technician can remotely access the machine over Helpline Plus and solve problems very quickly. In the future, G & G Preißer plans to tie the machines to the innovative BOBST Connected Services, with the goal of analyzing machine and process data and to gain optimization potentials from the results.

In 2018, G & G Preißer processed about 85 million m2 of corrugated board into folding boxes and die-cut packaging. For 2019, the company is planning to process a volume of 110 million m2. Currently, 1,600 pallets with finished product leave the plant every day. Only ten years ago the yearly volume of processed corrugated board was just 450,000 m2. “With its high performance and reliability, the technology from BOBST is the ideal support for our growth,” said Tobias Preißer. “We will continue our success story.”

MEX, Switzerland , June 11, 2019 (Press Release) -The relationship between Cartonajes Santorromán and BOBST goes back more than 50 years, when they installed the first BOBST flatbed die-cutter.

Since then, many BOBST machines have been installed. These include five flatbed die-cutters – SPO 1575, SPO 160 VISION, two SPO 160 A MATICs and MASTERCUT 1.7 – one PACIFIC folder-gluer, a MASTERFLEX 203 A MATIC flexo post-printing press and two Digital Inspection Tables, which were the first to reach Spain. In addition, a MASTERFOLD 170 will shortly be installed.

Jesús Pérez, Technical Manager at Cartonajes Santorromán, explains that “the company's philosophy is to constantly invest in infrastructure and technology for the manufacturing of corrugated board, as well as in any product that can be made using this material. We therefore have four plants in Calahorra, two for production and the other two for services. The total area is over 60,000 m2 and the manufacturing capacity is over 50,000,000 m2 of corrugated board per year, mainly destined for food and drinks packaging. Leopoldo Santorromán, the Manager of Cartonajes Santorromán and current president of the AFCO association, ensures that the philosophy of the four-generation family dynasty with a history of over 100 years is carried on to the next generation.”

This philosophy also favors customer service, which even prevails over production, as it is one of the few companies in the country that can offer services from one day to the next. To be able to do that, Mr. Pérez explains that they are technologically prepared to have 25% manufacturing capacity available to cover this type of order. The inclusion of the new MASTERFOLD 170 responds precisely to the need for more capacity.

“Our aim is to satisfy our customers, so we order the rolls, paper qualities and everything the customer requests. If the machine has to be stopped, so be it, and if waste has to be increased, that too. Our advantage is that we have the necessary means to optimize this different way of working and specialization in service is our strong point,” explains Pérez.

BOBST Digital Inspection Tables

In 2018, Cartonajes Santorromán installed two BOBST Digital Inspection Tables, within three months of each other. Their function is to check the register between printed material, die-cut blank and artwork. It includes the possibility for a user to plug his existing spectrometric solution to the BOBST Digital Inspection Table in order to add the color analysis to be added to the same quality check report. The first BOBST Digital Inspection Table was installed for the company’s MASTERFLEX 203 A MATIC. For Mr. Pérez, the change has been tremendous as all the checks are now grouped together proving that the inspection plan has been carried out properly.

“Before the arrival of the BOBST Digital Inspection Tables, everything was done manually. Working off-line we used Astralon foils, which are transparent drawings for control of the die-cut blank, but Astralon foil would deteriorate over time or be lost. This no longer happens with the BOBST Digital Inspection Tables. It has also been possible to digitize the work flow between the artwork / design department and the production department. This means that all information relating to production – such as the final artwork, colors, the printing presses and the anilox rollers to be used, etc. – can now be included in the customer's quotation. This change has meant that commercial errors are avoided,” explains Pérez.

With the BOBST Digital Inspection Tables, the quality check is digitalized and all the checks are grouped together without the machines having to be stopped. Each table serves two and a half die-cutters, which for the moment is sufficient for the company's five die-cutters. For the Technical Manager of Cartonajes Santorromán, this is a huge step forward as delivery quality can certainly be improved for the customer, and it is guaranteed that what is being printed corresponds exactly to what was agreed.

The BOBST Digital Inspection Table incorporates digital projection for the proofing of printed artwork and die-cut blanks, whilst providing real-time visual representations to match the product with digital proofs. It uses HD projectors to illuminate the product sample with quality control imaging, enabling the operator to easily see if quality standards are matched or compromised. In addition, the layout file can also be projected on to the sheet so that print registration can be checked and adjusted. This removes the need for overlays, print minis and moving the process from paper to digital.

Mr. Pérez explains that it is easy to install and operate the tables. “The BOBST experts installed the Digital Inspection Tables in a couple of days, and after a two-hour instruction, our operators already knew how to operate them. In addition, BOBST has remote access to the tables and that is reassurance for us. We have also been able to reduce the number of machine personnel, from three persons to two persons per shift, freeing up staff time for other tasks. Our expectations are met and the hoped-for benefits in terms of quality and productivity have been achieved. We certainly recommend the table.”

At Cartonajes Santorromán, the operators are using the BOBST Digital Inspection Tables in the following way: First, they check that the print matches the die-cutting layout, and, at the same time, the color is also checked. If needed, the color register is corrected. After that, the warp analysis and color adjustment are performed, as are any checks specified in the inspection plan. The operator simply projects the print onto the printed sheet and in half a minute the sheet is checked.

MASTERFOLD

Another recent purchase by Cartonajes Santorromán is a MASTERFOLD 170 folder-gluer which will shortly be installed. Mr. Pérez explains that such an investment was necessary to have more margin of manufacturing capacity available for carrying out last-minute orders. The MASTERFOLD was chosen because it allows fast make-readies and delivers high productivity, as well as for the good service and reassurance that BOBST is offering. “We were looking for a robust machine at the right size for mid-format production. Our production is now more effective and efficient, because MASTERFOLD enables us to improve programming and maintain the availability percentage. Our aim is to produce 15,000 units per hour with this new equipment.”

For Cartonajes Santorromán, investments enable them to provide better service and quality to the customer, which form the basis of the company. They therefore ensure to continue investing. Consequently, Mr. Pérez is already thinking of incorporating another BOBST Inspection Table for another machine which prints high-quality coated carton and later on an MASTERFLEX-HD flexo post-printing press. “We are convinced that the corrugated board world will continue expanding and that there are many opportunities. But for this, it is necessary to invest, to research new areas of corrugated board use and to offer new services to our customers.”

Pérez says that “finer adjustments of color and the print were previously checked on a computer screen, whereas now it is projected and magnified. The BOBST Digital Inspection Table can even digitally project the bar codes. Without doubt, with a production of 1,700,000 sheets a month and thanks to the BOBST Digital Inspection Tables, a huge amount of time is saved compared to previously, and the quality guarantee is indisputable.”

Cartonajes Santorromán

The family business was created in 1909 in Barbastro as a printing workshop, and then moved location several times until the 1940s when they settled in Calahorra to manufacture corrugated board packaging. Constantly evolving for over 100 years, Cartonajes Santorromán is at the forefront of technology and uses the most efficient processes, while maintaining the values of a family business for four generations, seeking continuous improvement of products, specialization of services, sustainability and communication with customers. They currently have 186 employees who work three shifts a day, producing 50 million m2 a year, and aims to continue growing.

REDDITCH, UK, May 7, 2019 (Press Release) -Innovative cartonmaker, Bridger Packaging, has invested in not one, but two, highly versatile BOBST machines at its Letchworth plant. The site has taken delivery of a folder-gluer VISIONFOLD 110 A2 and a die-cutter NOVACUT 106 E Autoplaten to increase capacity, drive efficiency and further enhance its flexibility.

Focused on innovation since its foundation in 1927, the company leads the way in cartonboard packaging. It accommodates all packaging requirements including specialist stand-out constructional design, bespoke solutions, litho and digital printing combined with detailed and complex on-pack features to add value and boost product sales. The company has a wealth of expertise in catering for a wide range of sectors, such as food & drink, luxury gift, home & garden, healthcare and automotive.

Lawrence Bridger, Managing Director, Bridger Packaging, said: “With brands, retailers and consumers alike looking for sustainability-minded packaging solutions, the demand for cartonboard is continuously increasing. It is a fast-growing market and it is imperative that we are able to meet our customers’ needs now and in the future. Alongside this, brands and retailers require bespoke packaging that responds to consumer demands, often at short notice, so there is a definite need for optimum speed and flexibility.

“We were therefore seeking to invest in our production capabilities with machines that allow us to drive efficiency, whilst continuing to deliver the top-quality, highly creative work we are known for. The two BOBST machines provide us with the enhanced efficiency and capacity we required, allowing us to go above and beyond for our customers, even at short notice.”

VISIONFOLD 110 A2 delivers superb smooth and accurate folding, regardless of size, substrate and run speed. Its ease of set up and effortless repeatability means it delivers the same flawless quality each time a job is run. Capable of processing 8,000 sheets per hour NOVACUT 106 E Autoplaten offers high precision cutting and minimises the need for manual intervention, driving efficiency along the processing line and ensuring consistent quality to optimise the return on investment. Craig McGowan, Area Sales Manager at Bobst UK & Ireland, said: “BOBST combines superb build quality with innovative engineering to ensure its machines are meeting the needs of packaging manufacturers.

“Our commitment is to deliver machines that meet specific customer requirements, delivering the performance enhancements they require. Bridger Packaging has made a significant investment in these two machines to ensure its entire production line is optimised for efficiency and productivity, as the company looks to enhance its capacity and flexibility for its diverse customer base.”