Envelope machinery revitalized

Universal Envelope Machinery, based in the UK, in association with Dutch company Veldkamp Technische Service, has gained specialist experience in reconditioning and rebuilding both Winkler and Dunnebier envelope manufacturing equipment and Halm overprinting machines. The companies claim this service offers an attractive alternative to investing in new machinery, arguing: “Considering the large investment required to purchase new, the rebuild and refurbish programme gives the end user a viable financial alternative along with the opportunity to customize and upgrade machinery to meet today's challenging manufacturing requirements.”

Two case studies illustrate the possibilities. First is a W+D 328 GSV.38 reel and blank-fed envelope machine, originally manufactured in 1983, which was refurbished last year for a customer in Nigeria. The machine was originally equipped with three flexo printing units and a window cutting section. The condition of the unit was extremely poor and it had been out of production in storage for over 18 months. The project involved the complete stripping of all parts and electrical wiring to expose the original framework of the machine.

Rebuilt

Once completely stripped, the complex process of rebuilding commenced. The framework was sandblasted, treated, primed and re-painted. All removed parts were checked, cleaned, repaired or replaced. All wear and tear parts, including all bearings, belts, chains and rollers, were replaced. The machine was completely re-wired and new control switches fitted. In order to improve print quality, three new FlexoArt doctor blade units were installed, and a Kocher and Beck magnetic window station was introduced for increased speed.

The timeframe to complete the rebuild was 16 weeks. Once complete the machine was fully tested to ensure that maximum operating speeds could be determined. Although the machine was over 20 years old, the original manufacturer's quoted speed of 650 envelopes/min was achieved.

Upon completion of all testing and commissioning, the machine was passed for approval. Universal Envelope's engineers then dismantled and packaged the units ready for shipment to Nigeria.

The second case study is a Halm JP TWOD 6D, two colour, six inch offset printer. Originally manufactured in 1992, it was refurbished in 2004. The machine was in relatively good overall condition, although, some parts were missing and required replacement.

The unit was completely stripped to the original framework, which was then treated, primed and re-sprayed. All rollers, bearings and gears were removed and replaced for new. The equipment was completely re-wired to meet current European safety requirements and standards.

Then it was re-assembled, tested and commissioned. A UV drying system was incorporated into the delivery for improved drying performance. On approval, the machine was packaged for airfreight and shipped to the customer in Thailand.