In line for economy

Quality carton producer and specialist in packaging for confectionery, cosmetics, food and luxury goods Model PrimePac of Au, St Gallen, is one of the first companies to invest in Gallus' dedicated platform based, flexo carton press, the KM 510. The machine is the first carton press designed by the St Gallen, Switzerland based label press specialist.

PrimePac sees the main strength of the equipment in the variety of its printing and converting combinations. Applying these printing and finishing processes is the key factor in its successful production of packaging for a series of well known brands. "With this technology we are convinced we will find a lot of new customers for whom we would not have been competitive in the past," says sales manager Jürgen Erhart, explaining why it was decided to add the single substrate, but multi-process press to its machinery armoury. "There are also some existing jobs that can be done on the new press, and others will be jobs from existing customers that we couldn't do before," he added.

The machine at PrimePac is configured to perform up to 16 operations: from flexo (both UV and water based) and screen printing on the front and reverse side of the web without turning, hot foil stamping, varnishing and laminating, embossing, window patching and cutting and creasing in a single pass. But because of its modularity a simpler machine can be supplied and later retrofitted to allow extra processes, reports Gallus. Depending on the configuration cost of investment ranges from SFr1.5–2.5M.

Flexibility of the press is based on the series of platforms. At PrimePac 12 heads can be utilized on the eight platforms. Said Uli Kretzschmar, sales manager folding carton at Gallus: "It is the multi process nature of the press that gives it the advantage. Designed for short runs it offers quick change and added value for the carton converter. It is not trying to be competitive with traditional litho printing of cartons." It scores where the additional processes are needed – processes that would require off line work after the litho process. Basically the more processes are added the longer the run that would be cost effective, but it is usually for jobs under 100,000 where the press can cut costs for the converter.

Recalled Jürgen Erhart: "We had been talking about producing folding boxes like labels for some time. We studied the market and then found Gallus." The equipment was delivered in 2004. "For us it was a new process – it needed a new way of thinking. But I can now say we can assure high quality and there is a low preparation time."

Infeed configuration on the 516mm wide (print width 510mm) KM510 allows for a 1.5m diameter reel of board. Substrates of up to 450g/m² can be easily handled claims Gallus. When Converting Today visited the Model plant, the first job on the press was a 350g/m² board being laminated to a metallized PET film. The substrate was subjected to a double side pre-clean on a Meech unit, through a de-curling device, web tensioning and a final Teknek web clean before passing through to the platforms. In run one the platforms were operating the PET laminating (water based flexo varnish) and five UV flexo units (white coating and four colour printing). Following the print platforms the cartons were flat bed creased, diecut and window punched. In the last section a Fife Controls web guide system is designed to ensure tight registration between print and embossing or die cutting processes. Every single process on each unit has automated registration control, which is easily reconfigured for the next job. Vision inspection is achieved by a BST ProMark. Output was up to 63 blanks/hour (80m/min).

A job change to a cosmetics carton featured a switch to five UV flexo units, glitter varnish printed rotary screen and a water based flexo varnish, flat bed embossing, creasing and die cutting. The change, involving the switch from flexo ink to water based varnish on one platform, from flexo to screen on the eighth platform and the embossing and cutting and creasing flatbed die took two men about 30min.

Since its drupa launch a press has been installed at Eberle Druck Wien, producer of pharmaceutical packaging. "This converter has closed down the sheet fed operation and switched entirely to the in-line press," reported Uli Kretzschmar.

And in the USA health and beauty carton specialist Cadmus has ordered a second KM 510 in-line system for its Whitehall Group location in Charlotte. The new production line will augment a similar Gallus press installed in May, 2004, as the beta site for the introduction to the North American market.

"This technology is a great complement to our offset printing capabilities," said Jay Gibble, Cadmus vp manufacturing. "The 20in mid-web format is perfect for smaller package structures and shorter runs increasingly common in today's market. However, it's the broad range of in-line value added features such as foil stamping, screen printing and film lamination that really put this technology at the head of the class. " The press is scheduled to be installed in October.

"The Gallus KM 510 narrow web in-line system opens up an entirely new dimension in top quality folding carton converting," said Uli Kretzschmar. "The advantages are obvious: improved workflow, simpler materials handling, time savings and increased efficiency."

PrimePac is part of the Model Group, which had record sales of over half a billion Swiss Francs in 2004. The Group has a significant interest in the former Eastern European markets and acquired Cofinec Bohemia in the Czech Republic, consolidating it into the business in 2004. In addition to cartons, the group produces container board and corrugated board. It employs almost 2,700 people and last year invested SFr51M in property, plant and acquisitions