CONTENTS Volume 49 : issue 9 NEWS
5. Nordenia wins The German Packaging Awards 6. New sales record for Reifenhauser
7. Frito-Lay and Innovia Films resolve patent rights issue 9. tesa reports 13% growth
SLITTING & REWINDING 11. A high spec slitter rewinder with 100% inspection is proving instrumental in meeting the stringent requirements of the pharmaceutical industry
12. When a Chinese packaging films producer decided to double production capacity, it commissioned three 11 meter slitter rewinders to handle the work
15. A flexible packaging operation based in India is now equipped to meet increasing production requirements
SECURITY
17. Low energy UV system delivers increased security 18. Using the example of a tamper evident tape, Mark Miller and Devan V. Padmanabhan discuss how intellectual property creates value for converters
CUTTING SOLUTIONS 21. Responding to customer demand for an operator-friendly core- cutter with fast changeover, Universal Converting Equipment has designed an automated solution
OCTOBER 2012
22. Many converters are seeking a solution to improve efficiency, handle digital sizes and increase output and bridge the gap between smaller rotary knife and wide width sheeters
PAPER & BOARD • FLEXIBLE PACKAGING • FOIL • NONWOVENS • CARTONS • LABELS • FLEXO A Corona System for ‘YOUR’ application!
ROLL HANDLING 25. A speciality films manufacturer is making considerable savings since investing in recycled fiber cradles to protect rolls in transit
26. Operator-friendly reel lifting system takes the strain with the greatest of ease
27. The development of safer roll hanling systems has been assisted by the growth of packaging plants in developing countries
FEATURES: Creating value through patents ❙ Automating the core cutting process ❙ High quality flexo on corrugated ❙ Delivering top quality on demand ❙ Fiber cradles protect with care ❙ Giant moves to business with China ❙ Reaching out to new markets
FLEXO TECHNOLOGY 29. Meeting customer demand for high standards of flexo printing on corrugated or boxboard material
30. Walki invests in cutting-edge ream wrap technology in Poland
COVER Corona Supplies are the only UK manufacturer of corona treatment equipment and supplier of Sherman Treaters products & spares. Corona Supplies is made up of ex- Sherman Treaters employees, including technical and production specialists, who offer a wealth of corona industry experience, years of product expertise and excellent customer knowledge. At Corona Supplies we pride ourselves in solving your corona treatment requirements with a fast and efficient level of service, quality and great value. At Corona Supplies, we manufacture corona treaters and offer complete solutions for plastic film extrusion, (blown film, cast film and wide web extrusion), conversion (printing and laminating), as well as narrow web printing and ozone elimination systems
www.convertermag.co.uk
Editor: Susan Deane Tel: 01242 693380
sdeane@datateam.co.uk Managing Editor: Neil Mead Tel: 01622 699193
nmead@datateam.co.uk Designer: Mike Evans Tel: 01622 699108
mevans@datateam.co.uk Publishing Director: Hannah Dedman
hdedman@datateam.co.uk Online Editor: Jo Pilcher Tel: 01622 699177
jpilcher@datateam.co.uk Advertisement Sales UK&USA: Zoe Revell Tel: 01622 699169 Fax: 01622 757646
zrevell@datateam.co.uk
Advertisement Sales Europe: Sandra Feldmann Tel: 00 49 7221 185 8880 Fax: 00 49 7221 185 8881 e:
f.sandra@
kabelbw.de Production Manager: Claire Noe Tel: 01622 699164
cnoe@datateam.co.uk
Website:
www.convertermag.co.uk
Datateam Business Media Limited, 15A London Road, Maidstone, Kent ME16 8LY Datateam Business Media Ltd 2012. All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, fax, email, recording or otherwise, without prior permission of Datateam Business Media Ltd. ABC average circulation Jan-Dec 2007: 5,262 Subscription 1 year: £72/Euros 90 within Europe, US$160.00 outside UK, airmail delivery. 2 year: £117/Euros 150 within Europe, US$266.00 outside UK, airmail delivery. This journal includes editorial photographs provided and paid for by suppliers
Comment
The internet has been a major tool in doing business for some years now and companies continue to explore more and more innovative ways of harnessing its speed and convenience to ‘sell’ products and services.
their
No less so in the converting industry as suppliers recognise that nothing sells as powerfully as a video clip demonstrating the piece of kit in action - especially when it shows minimal operator intervention, speed and precision.
Other sites feature interactive tools to help the customer source the most appropriate solution for a particular application. But none of these smart moves would be as effective if the website was not available in the main languages spoken and understood in both existing and emerging markets. So what comes next?
Susan Deane Editor
Follow us on Twitter @convertermag
October 2012
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FOCUS Slitting & Rewinding Delivering top quality on demand
A high spec slitter rewinder with 100% inspection supplied by AB Graphic is proving instrumental in meeting the stringent demands of the pharmaceutical industry
AB Graphic International has installed a 13” (330mm) wide flytec 2010 slitter inspection
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South African and African labels markets. This follows numerous investments made by ACF in the past 12 months including a W&H Miraflex CI printing press. The new slitter will increase capacity in the plant, maximise outputs and provide superior quality due to its high level of technological advancements.
Final inspection
The slitter will be fully operational by the end of the third quarter of the year in
rewinder at New York-based Gintzler Graphics. The full specification machine will be used to convert and inspect high quality labels for the pharmaceutical market. “We made the decision to acquire the flytec 2010 because we wanted to enhance the level of service to our critical care clients,” explains CEO Bryan Scheible. “The market we serve demands perfection and we wanted the latest technology. We needed a platform that could interface with Domino Ink Jet for serialisation during final inspection. A multi-plant facility, we were looking for a vendor that could service all our facilities and offer remote diagnostics.” Key elements of the flytec 2010 at Gintzler Graphics include bi-directional unwind/ rewind and fleyeVision 100% print face inspection equipped with 4096 pixel, greyscale camera capable of detecting defects to a minimum size of .0000465 square inches (0.03 square mm) at speeds up to 22.2f/pm (120m/min.) Labels with static and dynamic 1D and 2D bar codes can be checked to ANSI standards. The system permits labels to be compared against pre- press created PDF files and taught to read the ‘golden image’ data.
ACF Labels DLC has purchased an additional Ashe Converting Equipment Diamond slitter rewinder for its conversion department, showing its ongoing commitment to the
ATB invests in additional flexopress High precision and cost effective slitting
AZCO Corp’s ACU-SLIT, available in both on-line and cut-to-length configurations, is multi-purpose and accurate. Built to last, it can easily replace existing outdated slitter stations or serve as an add-on to any web processing line. The rotary system features a solid,
From left: Alexander Kresik, head of production; Sergey Zykov, marketing director; and Vadim Shevko stand alongside the new Edale Beta
hardened anvil and blade materials are hardened D-2 steel. Each unit is equipped with precision bearings designed to handle high load forces as well as precision machined steel side frame plates. The unit can be mounted on any
www.convertermag.co.uk
ATB Security Technologies based in Minsk, Vilnius has taken steps to increase production capability with the recent installation of a nine- colour 330mm width Edale Beta
modular flexopress with cold foil and hot foil and special options. This joins a five- colour Edale Alpha press on site. Founded in 2002 with a focus on the development of anti-forgery technologies to protect security documents and consumer goods, ATB is now a significant player in the market of protection technologies. The company specialises in the production of security labels including multilayer labels, lottery tickets and access cards alongside tamper-evident labels for a number of sectors but predominantly the high end beverage markets. “We already have an Edale Alpha machine and the easy transfer of processes between the two machines really helped during the transition period,” comments
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production line and perform a variety of tasks from simple slitting to motorised slitter functions that cut dense materials. Shear cut slitters provide clean, precise
AZCO Corp T: 1 973-439-1428
www.azcocorp.com
“This equipment is used to perform the final inspection of the label prior to shipment and has automated the required leader and trailer function needed for each roll of labels shipped,” continues Scheible. “The comparative vision system on the flytec proved superior to its competitors and the software was customised to generate image capturing documentation for client reporting purposes. We were able to work closely with AB Graphic International who set up a full integration team to ensure the machine functions met our unique requirements.” Equipped with pharma control module the flytec 2010 is designed to meet US legislative requirements for pharmaceutical labels, records all operator access and parameters carried out per job and produces all validation documents including IQ, OQ and PQ. Any defect found is recorded in the extended protocol software with photographs to enable subsequent static evaluation.
Ashe Converting T: +44 (0)1473 710912
www.ashe.co.uk
anticipation of the traditional seasonal surge of beverage demand in the fourth quarter. The reliability and productivity of the first Ashe machine made the decision for the second easy for DLC. The Diamond model slitter rewinder has been very well received since its launch at the K exhibition in 2007. The machine features a shaftless unwind with an electric reel lift and digital edge guider. Tension isolation is achieved through Ashe’s vacuum roller design which gives the machine superior flexibility to run a wide range of products. Coreless trim winders will be installed on the Diamond at DLC. The trim winder is an energy efficient solution and eliminates the need for bundling up trip from trim bins. A maximum speed of 500m/min and
features including laser core positioning are said to make the Diamond a highly productive machine.
Automated short run turret rewinder
From left: Michael Leidgschwendner, managing director of AG Graphic International, Germany and Bryan Scheible, CEO of Gintzler
cuts on flexible materials and provide the longest blade life. Crush cut slitters effectively cut thicker, low density materials including filter media and nonwovens. These are convenient units for frequent changeovers. With more than 25 years experience in developing solutions for a wide range of feeding and cutting applications, AZCO offers cutting edge, field-proven systems and components that are easily adapted to meet the needs of the most complex applications, providing the most efficient and cost effective solution for customers.
Vadim Shevko, chief of ATB security printing department. “Production has now moved over entirely to the new Beta and the Alpha is being used solely for R&D purposes. The advantage of staying with Edale was not just the quality of product but that our operators were able to continue printing immediately with no employee downtime.”
October 2012
As well as highly skilled staff, ATB has its own facilities where they carry out their R&D in an effort to further improve their technology to put a stop to the rise in counterfeit products. “I am thrilled that ATB has chosen another Edale special press solution for the production of niche security applications - a field that both companies are leaders in,” concludes Bernhard Grob, Edale’s export sales director.
Edale T: +44 (0)1489 569230
www.edale.com
Low energy UV system delivers increased security
The new energy2cure E2C system from GEW permits full colour, process printing at full
production speed with as little power as 90 W/cm (230W/inch). E2C promises sufficient energy at high production speeds . Delivering dramatic savings in energy consumption and costs, users can expect increased efficiency and profitability per job and less substrate waste from inadequate curing or heat damage with a 42% CO2 reduction in environmental performance.
www.convertermag.co.uk
“We are delivering a transformation in UV curing using the latest technology available that will give our customers print run
security with increased profitability,” says marketing manager David Lyus. “With increasing energy and consumables costs, more complex ink formulations and thinner substrates, spoilage is expensive. It is vital that we offer UV technology that will reduce waste and production costs and a high level of confidence and security to customers.”
GEW (EC) T: + 44 (0)1737 824 500
www.gewuv.com
October 2012 17
“This equipment is built to withstand the normal wear and tear of daily production and can interface with shop floor management systems,”says Scheible. “Throughput speeds are consistent and the accuracy at which the flytec detects non- conforming material is superior to other equipment tested. This enables us to deliver a better quality product. “Our products supply high speed label application lines where label position to the liner edge is ultra-critical. The slitter assembly maintains exact positioning using ultrasonic label edge guide feeding data to the slitter servo to maintain the slitting parameters. This feature has allowed us to keep tighter tolerances on our label to liner edge requirements, reducing in process adjustments by our customers. We are always looking for new technology to improve our process and the flytec has allowed us to exceed expectations; it greatly supports our zero defect initiative.” “Bi-directional operation means that every defect can be checked twice by moving the web backward and forward,” comments Michael Leidgschwendner, managing director of AB Graphic International. “The first allows the operator to check if the defect can be replaced and/or make a repair and the second enables re-inspection to ensure the subsequent operation is error free. Multi-lane, bi-directional operation can
The Alphamatic Turret provides a highly efficient and flexible solution for single person operation short-run work
FOCUS Security
High speed production of RFID plastic cards
At Cartes & IDentification 2012 to be held in Parisin November Melzer will demonstrate high speed production for low cost RFID plastic cards which is quite different from the company’s established solution. MRTD products including e-NID cards or driving licences, border crossing documents or e-passports must have a long lifecycle and are usually equipped with security elements. In addition to the lasered photo security features including CLI/MLI, micro-lettering or latent image must be integrated.
Melzer's inline production equipment combines sheet material with partially very thin reel materials and precision is reliably performed by the only industrial production process available. The material sandwich is laminated for 20-30 seconds at 180-200°C. This patented technology ensures a gentle lamination of the electronics (RFID inlays) and special ink and security thread. Furthermore, the modular system enables control stations or card inspection systems to be integrated. Melzer can provide a fully automatic revolutionary inlay production machine for ID cards and passports based on plated antenna technology with soldering connection at highest yield rates.
Melzer T: +49 2336 92 920
www.melzergmbh.com
Alphamatic Turret. It has been designed for processing sensitive ink jet papers and handling a wide variety of substrates including laminated films. The rewinder runs 2 or 3 inch cores and is rated at 300 m/min with a typical cycle time of 20 seconds for a 50 metre roll. “The Alphamatic Turret provides a highly
efficient and flexible solution for short run work,” explains sales manager Peter Stokley. “It is designed for single person operation – once the unwind reel is loaded into the machine all operations are automatic. “It runs to the length set by the operator, turrets, loads fresh cores, strips the roll from the rewind shaft and is delivered to a roll closing system with ID labelling and bar coding. The finished roll is delivered to a storage table outside the perimeter of the machine guard where the operator can pack as required.” The Alphamatic Turret is available with many levels of automation from semi- automatic versions with manual core loading and removal of finished rolls to full automation. As standard, the winder is supplied with an adhesive-less start (cinching) system. “This is particularly useful for the many applications where adhesive might cause contamination on the next process,” says Stokley, adding that the level of interest in the Alphamatic Turret has been very encouraging across a broad spectrum of substrates. Two orders have already been secured and the first unit is being delivered to a German customer.
AB Graphic International T: +1 909 230 6640
www.abgint.com
October 2012 11
Alpha Converting Equipment T: +44 (0)1767 692244
www.alpha-converting.co.uk
www.convertermag.co.uk
be carried out simultaneously with slitting and inkjet printing for numbering as the machine is equipped with an accumulator that makes it possible to combine these and further finishing steps in one operation. Up to eight ink jet printing heads can be independently controlled.” The flyCut slitting control unit supplied to Gintzler Graphics includes a camera that checks web edge matrix movement and controls the unit to prevent inadvertent damage to labels. A label dispenser unit designed to remove labels from the start or end of the roll creates a blank web to ensure all remaining labels have been inspected. “This is the third system we have supplied for the label converting operation at Gintzler Graphics concludes Leidgschwendner. “The first was a flytec 150 for integration with an inkjet printer and the second and third include the flytec 2010 model and an HSR slitter/rewinder destined for the company’s Texas facility.” Gintzler Graphics produces labels, tags, paperboard packaging and speciality converting for a wide range of industries using both traditional and digital label printing processes. Custom effects include foil, screen and embossing.
Alpha Converting Equipment’s latest addition to its wide range of automatic rewinders is the
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