Diana passes the A&R test

In recent months, A&R Carton, in Kriftel, Germany, has been putting Heidelberg's new Diana X 135 folder gluer through its paces. The company readily agreed to a field trial of the machine, unveiled at drupa 2004, which replaced its existing folder gluer.

The modular design of the Diana X 135 has been a "huge benefit" to A&R, enabling it to adapt the machine to its specific requirements for producing a wide variety of complicated packaging designs. The machine operators are said to be impressed by its ease of use - easily handling even the most complex forms of packaging. The machine is also fast and flexible, thanks to its integrated turning module.

Separate servo drive technology in each module has enabled A&R to achieve the optimal configuration for manufacturing a wider range of packaging materials than had previously been possible. The turning module opened up the possibility of manufacturing complex cartons that need to be rotated during processing. Some special cartons that required two separate production steps previously can now be produced in a single pass.

Production

Part of the Swedish A&R Group with more than 40 years in the folding carton business, the Kriftel operation's production comprises two-thirds packaging for confectionery and cosmetics, with the balance split between food and non food. The 150-strong workforce has three 3B and 100x140cm format presses that can produce matt, high gloss, UV and sealer. Further finishing operations include hotfoil stamping and window gluing. A suite of 3B and 100x140cm format flatbed die cutters with folder gluers round off the range of production options.

"Thanks to the Diana X 135, we are able to offer our customers an improved level of service and more efficient production," enthuses plant manager Ralf Schmidt. He says the higher reliability in production provided by add-on units such as the glue line detector and code reader ensures higher output, with an increase of between 15 and 50 per cent over the previous gluer, depending on the type of carton.

During normal operation, the new machine achieves a performance of 650m/min, or 200,000 cartons/hour. With the integrated turning module, it can reach 450m/min. Maximum working width is 1,350mm.

"One of the key advantages for us is the four metre folding section," reveals gluing department manager Michael Beck. "This enables us to process large packaging materials such as Advent calendars quickly and without any problems." The alignment station allows blanks to be aligned to the left or right. An integrated gluing system makes it possible to connect the gluing nozzles through a quick connection system, either in front of or behind the turning module.

A&R covers the entire value added chain from designing the folding cartons, press and post press right through to optimizing the processing of the cartons on the customer's packer. An in-house packaging development team uses CAD to create solutions to customer requirements - and to ensure smooth production.

Supplying around 100 national and international customers and generating annual sales of e35M, the plant operates in three shifts. It is certified to the BRC/IOP hygiene standard and produces up to 20,000t/year of printed folding cartons, in grammages ranging from 180-650g/m².

"The number of units per order is declining," explains Ralf Schmidt. "Our emphasis is on quality rather than quantity."

The company's new 'user friendly' Diana X 135 can be easily accessed from all sides, for easy adjustment. For example, a belt can be replaced quickly at the feeder without removing shafts to facilitate maintenance. A remote control unit allows the Heidelberg machine to be operated from any position.

The folder gluer is set up using the AutoSet positioning system. Production data is stored to save time for repeat jobs; the machine automatically positions the upper and lower roller bars to the correct location. In order to generate the maximum number of folds and prefolds, the version at A&R Carton features a multi purpose 150 module and a lockbottom module, enabling four and six-corner collapsible cartons to be processed.

"We regard the field test as a win-win situation," summarizes Ralf Schmidt enthusiastically. "For our part, we can fully exploit its possibilities to offer our customers greater flexibility and productivity, while Heidelberg gets vital feedback on the machine. It has more than surpassed our expectations and we would like to keep it."

Michael Beck agrees: "Our machine operators really like working with the Diana X 135. They are continually discovering new and easy ways of producing complicated carton blanks."