The Slovakian print company Tlačiareň Bardejov was founded 25 years ago. It started out – like so many other print companies – as a small private business. Over the years it has grown to become a mid-size packaging specialist with in-house operations catering to all phases of the production process. Tlačiareň Bardejov has always attached particular importance to customer satisfaction. High printing and finishing quality is the focus of all the company’s activities.

By investing in a five-colour Rapida 76 with inline coater, together with an Omega Allpro 90 folder-gluer, the company has boosted its production capacities in preparation for new and future market demands.

Production is primarily on solid and corrugated board substrates. All the presses in use were purchased in recent years in order to stay abreast of the growing challenges in terms of quality, delivery times and packaging design. Tlačiareň Bardejov is committed to providing high-quality services and product finishing options, including both striking coating effects and complex cut-outs.

The company today boasts two sheetfed offset presses, including the Rapida 76, a CtP platesetter, an Omega Allpro 90 line for carton folding and gluing, automatic die-cutters and embossing presses, hot-stamping, laminating and gluing machines, and a whole host of other equipment to round off packaging production.

Perfect for printing on board

The highly automated Rapida 76 in B2 half format was configured specifically for the product portfolio of Tlačiareň Bardejov. It prints board up to a thickness of 0.8 mm and has allowed the company to expand into the production of packaging for wines and spirits, as well as for e-commerce. The fifth printing unit permits the incorporation of spot colours (Pantone, HKS, metallic inks). This ensures most products can be printed and finished in a single pass, which reduces production costs significantly.

When it comes to finishing, the Rapida 76 also shines in the truest sense of the word. The integrated high-flow coater unit handles straightforward inline dispersion coatings and in combination with the last printing unit special multiple finishes as well. The latter option is used to produce matt-gloss refinements and add other visual effects to substrates. The Rapida 76 is equipped with IR and hot-air drying in its extended delivery. This provides for reliable drying even at high production speeds, enabling fast further processing of the printed sheets and correspondingly shorter throughput times for the individual jobs.

Maximising production potential in folding and gluing

Another key element of Tlačiareň Bardejov’s innovation and investment plan was the purchase of an Omega Allpro 90. This folder-gluer maximises production potential – encompassing four- and six-corner cartons, for example, which are two gluing variants that are otherwise difficult to find in Slovakia. Compared to its previous set-up, the company has increased its production capacities for straight-line, crash-lock and double-wall cartons up to fourfold. The LogoTronic system assists Tlačiareň Bardejov with production planning and control, both on the Rapida 76 and on the Allpro 90. Owner Karol Dvorčák: “We recognised that it is currently essential to identify production reserves and to utilise savings potential. That is why we decided to network our production with production planning software.” LogoTronic provides support with planning and control, and supplies reliable data for retrospective evaluation, for example for product costing.

Packaging for domestic and international customers

Tlačiareň Bardejov is based in the town of Bardejov, a location that enables it to supply folding cartons and other print products to customers both all over Slovakia and its neighbouring countries. Numerous jobs are handled for customers from Poland, and in particular from Kraków. Further long-standing business partners are to be found in Switzerland, the United Kingdom and Belgium.

The packaging market has undergone a dynamic development and change over the past few years. Many manufacturers use their packaging as a marketing tool and instrument for communication with their customers. Tlačiareň Bardejov is profiting from this growth. Even so, packaging production is by no means an easy industry, especially when faced with an energy crisis, increasing prices for raw materials, and strict environment protection regulations. “We are very fortunate in that we have been able to attract many new customers,” says Karol Dvorčák, summing up the nevertheless positive situation for his company.

Interesting Website: www.tlaciarenbardejov.sk

To maintain its high level of expertise in creating high-quality packaging for the club store, e-commerce, and quick service food industries, Accurate Box Company, a leading manufacturer of litho-laminated corrugated packaging, installed a new Koenig & Bauer Rapida 164 seven-color printing press to increase its production and throughput. This new investment adds the most advanced printing technology in the industry to Accurate Box’s 400,000 square foot facility in Paterson, NJ, that now houses three Koenig & Bauer presses.

“Our reputation has always been as a world class manufacturer that produces high graphic corrugated boxes,” says Lisa Hirsh, president and CEO of Accurate Box. “As the marketplace continues to rapidly transform, our strategy is to leverage the innovations and advanced technologies available to our market.”

The new Rapida 164 large-format press runs an impressive 17,000 sheets an hour which is 13% faster than Accurate Box’s previous new press that was installed in 2018. Matching the capability of the previously installed press, cameras measure each sheet while printing and automatically adjust the ink for perfect print consistency throughout the run. This is a significant feature that shortens makeready times, minimizes paper waste and guarantees consistent high-quality printing. It reinforces Accurate Box’s facility as a model for quality output and productivity and continues its path as a one-of-a-kind state-of-the-art manufacturer.

Installation of the new press started in July and was in production by August. Accurate Box was well prepared for the installation since one of Accurate Box’s printing team members flew to the Koenig & Bauer facility in Germany for two weeks to receive training on its new press. When the press arrived at Accurate Box’s facility, a Koenig & Bauer team was there for five weeks to train Accurate Box’s entire printing crew. This was critical for Accurate Box in order to have the press up and running quickly and to minimize downtime once it was installed. Training will continue into next year with two Accurate Box employees flying to Germany to get more in-depth training and knowledge on the press.

“One of the key reasons that we have remained extremely successful over nearly 80 years is our investment in our employee base, our equipment, and our customer’s ongoing needs,” says Hirsh. “With a stellar reputation for providing exceptional high quality graphics for corrugated packaging for nationally-recognized brands such as Kellogg’s and Pepsico that line the aisles of big box retailers like Costco and Sam’s Club, we are pleased to continue our strong partnership with Koenig & Bauer and the finest presses on the market.”

Interesting website: www.accuratebox.com

Philipp Zimmermann has assumed responsibility for global sales of web offset and digital printing presses by Koenig & Bauer Digital & Webfed with effect from 1 August 2022. One focus of his tasks as Vice President Sales will be continued expansion of the market presence of the high-performance digital printing press RotaJET in the packaging, decor and book printing segments. Prior experience and know-how in the field of special machine engineering will hold him in good stead in this role. At the same time, Philipp Zimmermann plans to further consolidate the close business relationships with commercial and newspaper printers.

Philipp Zimmermann worked for KraussMaffei Technologies, a leading manufacturer of machinery for the plastics industry, for the past ten years. He joined the company as area sales manager for Asia, and was appointed product and sales manager for composite fibre and surface technologies for reaction process machinery in 2014.

In 2018, he became the head of the business unit that manufactures special machines for lightweight construction and high-end surface technologies, as well as process and system solutions for the manufacturing of industrial components using polyurethane and other reactive materials. For the past two years, Philipp Zimmermann was responsible for the global sales of reaction process machinery and achieved significant market growth in his segment during this time.

Stefan Segger, previously Vice President Sales for the business unit Digital & Webfed at Koenig & Bauer, will in future focus entirely on webfed digital printing, which is such an important segment for the company.

Back in the day, there was a rumour that the printers in the workshops at the Druckerei zu Altenburg (DZA) used silver type for printing. This pays testimony to the quality awareness of the company, which can trace its roots back to 1594 and to this day still operates from premises built in 1870. Metal type – whether silver or lead – is, of course, a thing of the past. What has remained, however, are the quality standards. They are a hallmark of the company which it continues to fine-tune at every opportunity.

And a sterling reputation like this spreads quickly. Art museums, architectural design studios, photographers, publishers and agencies all entrust their work to DZA, especially when it comes to printing catalogues. Many of these jobs are uniquely demanding when it comes to quality, design features and page count. This makes it hardly surprising that, alongside the German customers, there are many companies in Switzerland, as well as a few in Great Britain and the USA, which turn to DZA for their printing needs. Not only that, most of them also come to Altenburg, a more than 1000-year-old former ducal residence in the federal state of Thuringia, to follow the start of their production runs in person.

Quality control all the way down to the last detail

They are able to witness the very latest press technology in action. For a few weeks now, the company has been printing on a brand new Rapida 106 X. With eight printing units, a perfecting unit for 4-over-4 production and an additional inline coater, the medium-format press (max. sheet format 740 × 1,060 mm) is the company’s most extensive sheetfed offset installation to date.

And one which is certainly special, not least because it promises the specialists at DZA significant improvements with regard to quality measurement and control. QualiTronic ColorControl ensures consistent print quality. The system also utilises InstrumentFlight for grey balance control and QualiTronic PDFCheck for a comparison of each printed product with the pre-press PDF.

Special sensors even detect coloured and black substrates both at the infeed and when the sheets are turned in the middle of the press. Jobs requiring substrates like this are rare. Nonetheless, they are requested several times each year, and the press needs to be prepared to handle them when they are.

Automation for fast job changeovers

Given the concentration on mainly short to medium run lengths, the DZA specialists placed particular importance on makeready-saving automation solutions when configuring the new press. This begins with simultaneous plate changing (DriveTronic SPC) and applies equally to the washing systems (CleanTronic Synchro). Parallel processes are standard here. After all, “when there are ultra-short runs of just 250 to 500 copies, the printers have their work cut out to keep pace,” says managing director Peer-Philipp Keller. It is for this same reason that the Rapida106 X seldom runs at full speed.

In combination with extensive inline finishing options, being able to run 4/4 production in a single press pass is a big step forward for DZA. “We have been able to optimise our production processes significantly,” Keller reports. “And this at the same time as improved quality, new possibilities for product refinement and additional strategic options.” If necessary, the press can also use up to eight colours for printing and coating in a straight process. Multiple coatings are similarly possible using the coater and inking units. In addition to protective coatings, DZA can therefore offer a wide range of decorative finishing effects: All-over or spot gloss, silk matt, matt – whatever the customer would like.

“Every product is unique”

Many jobs are printed with FM screening. Optimisations in pre-press and the use of highly pigmented inks enable printing with an extended colour gamut. And spot colours are also used where necessary to achieve specific colour tones and effects.

Versatility is one of the most important hallmarks of the print company. “Every product is unique!” – as is the firm conviction of Peer-Philipp Keller and his 75 employees. And that is also how every print job is treated. Experimenting and testing to realise the creative new ideas that product designers have come up with are daily routine for the production department in Altenburg. This applies not only to their printing services, but also to product finishing and bookbinding.

A string of prizes – most recently at the Druck & Medien Awards 2021 – bears witness to the extraordinary print products made by DZA. A book about artist Meret Oppenheim, for example, received a coveted ‘Golden Letter’, the highest award presented annually by the Stiftung Buchkunst. And this award, in turn, closes the circle back to the proverbial silver type that is said to have been used in the company’s workshops in the past.

Interesting website: www.dza-druck.de 

Koenig & Bauer is continuing to proceed with its transformation from a traditional manufacturer of machinery into an agile technology group. Using global megatrends and intense discussions with customers and industry experts as a basis, the company has defined its strategic direction for the next few years. The course it is already taking towards more digitalisation and a higher degree of modularity will not only lead to more success in Koenig & Bauer’s core business markets, with packaging printing at the forefront – it will also result in less material and energy being used in printing processes, making them more sustainable. In addition, Koenig & Bauer is also setting itself sustainability goals that are even more ambitious with its new Group strategy, ‘Exceeding Print’. Along with its responsibility towards its customers and employees, as a member of the UN Global Compact, the world’s largest sustainability initiative, the Group aims to increase even further its efforts to deliver on its ecological, social and community responsibilities.

A commitment to sustainability goals for the future

“By 2025, we are aiming to reduce CO2 emissions in our production plants by 75 per cent, and intend to be completely carbon-neutral from 2030 on,” as CEO Dr Andreas Pleßke announced. “As the industry’s leading provider of sustainable solutions, we help our customers to reduce their ecological footprint. Solutions based on technology that we developed reduce energy consumption, cut waste, and decrease ink and coating consumption, helping to cut CO2 emissions.” 

Energy efficiency and climate protection

Koenig & Bauer uses an energy management system to prepare the ground for its customers to be more energy efficient in printing operations, and helps them to point their production processes in a sustainable direction. As a member of the 4evergreen Alliance network, Koenig & Bauer can start working with manufacturers of paper and cardboard, folding carton producers, brand owners, technology and material suppliers, along with the collection, sorting and recycling industry, at an early stage to find appropriate solutions. Koenig & Bauer maintains a partnership with ClimatePartner to promote efforts to compensate CO2 emissions by supporting certified projects to protect the climate. Moreover, the company is a partner in the ‘BlueCompetence’ sustainability initiative that is run by the VDMA, and is the first manufacturer of printing machinery to become a member of the ‘Healthy Printing’ network. 

Modularity: The key to more efficiency

Koenig & Bauer is the only manufacturer of machinery worldwide to master all industrial printing process on all substrates in its core markets. Customers benefit from a wide range of products, the experience, and the technical expertise that the company has built up over the more than 200 years of its history. As the oldest manufacturer of printing machinery in the world, Koenig & Bauer has always considered its role to be that of an industry pioneer and an innovative force.

A modular platform for future machine generations offers customers any number of advantages. “Not only are new technologies ready for the market more quickly, but integrated control of machines and systems, and the standardisation of maintenance become possible,” as executive board member and COO Michael Ulverich accentuates. “The modular principle ensures that the customers continue to benefit from tailor-made solutions. The standardisation of a number of elements opens up more opportunities for innovation and individualisation – while maintaining the same high quality at the same time.” Koenig & Bauer intends to maintain its entrepreneurial independence in future by retaining a high level of vertical integration – from the smallest gearwheel to complex units.

Digitalisation: Group-wide solutions, tailored to the customers

In addition to machines, digital services are becoming increasingly important for networking machines with each other, collecting and analysing data, and controlling processes efficiently. Koenig & Bauer develops digital services based on highly scalable cloud platforms and makes them available to customers via a portal for collaboration. The analysis of machine data forms the basis for evaluating performance, setting benchmarks and industrial analytics scenarios. In combination with machine learning, this renders Koenig & Bauer able to identify potential malfunctions in processes much earlier and more accurately, and to initiate service and maintenance fully automatically. Unplanned downtimes can thereby be reduced, and service intervals can be modified accordingly. 

“Koenig & Bauer made the switch to a cloud-based Customer Relationship Management (CRM) platform, a leading industry product, back in 2010,” adds Ralf Sammeck, executive board member for the Sheetfed segment and CDO. “Across the Group, Sales, Service and Marketing, along with the adjacent functions, all use the CRM application, which also provides performance data for the machines connected within the network.” This allows the employees of Koenig & Bauer to provide advice to customers which satisfies their expectations each and every time they are in contact. “Software is driving our transformation from a manufacturer of machinery to a technology company,” as Sammeck continues. “Our customers benefit from the consistent process integration and from data-optimised job management processes that use data as a basis.”

Short makeready times and flexible processes in packaging printing

High-performance digital presses from Koenig & Bauer offer customers in packaging printing new business models for printing very short runs, rapidly changing requirements, security elements, track-and-trace solutions, as well as personalisation and individualisation. The focus is on the entire value chain with a view to optimise costs. Easy-to-use human-machine interfaces make operation more intuitive for customers. Koenig & Bauer is responding to the trend towards hybrid printing processes in the paper, board, corrugated board and film segments by combining analogue and digital printing and finishing technologies. This allows the advantages of both applications to be exploited optimally, broadening the range of substrates that can be printed on. By entering the food and beverage carton industry, Koenig & Bauer will enable full-colour digital printing on carton packaging in future.

“Digital printing processes will be a catalyst for new business models,” as Christoph Müller, executive board member for the Digital & Webfed segment, is convinced. “We are assuming that most of the companies that will be our customers in future have not even been founded yet.”

We support social responsibility and diversity, and reject discrimination

More diversity within the company in relation to gender, age and internationality has, as a social objective, also been adopted as part of Koenig & Bauer’s strategic blueprint. One key focal point is the advancement of women, for example through mentoring and career programmes, and by introducing wide-reaching measures to reconcile family and career, as well as initiatives to combat discrimination and racism. “Our goal is to be a top employer for everyone,” as Pleßke underscores. As a company with regional roots, Koenig & Bauer has assumed social responsibility from the very beginning. As has been the case for over 150 years, the company continues to train future skilled workers at its own vocational school, and guarantees employment after they have completed their apprenticeships. Koenig & Bauer supports cultural and social institutions at its Group sites and around the world. 

CFO Dr Stephen Kimmich is convinced, “By committing to deliver on our ecological, social and community responsibility, we are sending an important signal to the capital market. Koenig & Bauer is the only manufacturer of printing machinery to master all industrial printing processes on just about every type of substrate – even on corrugated board – and supplies software, systems and service for entire printing and finishing processes. After all, optimising the ‘Total Cost of Process’ forms a key factor, more than ever, for our customers in any decision about which technology to purchase. This also gives the company good reason to consider itself a ‘trusted advisor’ for its customers and an agent of change and innovation within the print industry. ‘Exceeding Print’ will contribute to the achievement of our financial goals for the medium term, which earmarks turnover of €1.3 billion and an EBIT margin of more than 7 per cent.”

“Our ‘Exceeding Print’ strategy allows us to promote sustainability as the greatest challenge that the packaging industry will be facing in future, and uphold our claim to leadership when it comes to digitalisation,” says Dr Andreas Pleßke, summing up the measures that were decided on. “This means organic growth with our own business models and products, but does not rule out growth through acquisitions.” 

The print companies Walter Grieger Offsetdruck in Nettetal and Gieseking in Bielefeld have been operating under the joint name ‘Teamplayer-in-Print’ since 2012, and together are leading service providers for carton products and corrugated board liners. Both companies concentrate on the production of folding carton and display printing products. And both also serve a number of their own end customers, alongside highly flexible production for major European packaging groups.

Their business concept of providing print services to producers of corrugated packaging makes it imperative to stay one step ahead of potential competitors at all times. For this reason, Walter Grieger Offsetdruck is frequently one of the first users of innovative printing technologies – and ever since the turn of the century, this has meant solutions developed by Koenig & Bauer. The first large-format Rapida for hybrid coating was used for production in Nettetal, as was the first press with direct drives. Now it is the turn of the first of the latest-generation Rapida 164 presses, which is also equipped for production with an extended colour gamut. When it comes to extended colour gamuts, Teamplayer meanwhile considers itself an advisor to the segment. Managing director Wilhelm Drießen explains: “We absorb everything that is happening at the manufacturers.” The distinctly technophile company has therefore also been closely involved with Koenig & Bauer’s market-leading technology developments over the past two decades. A further valuable partner on this journey has been Systemhaus Steuber, the general agency for the sheetfed offset division of Koenig & Bauer in North Rhine-Westphalia.

Significantly enhanced performance

A new Rapida 164 has been boosting print capacities at Walter Grieger for several months now. Production on the seven-colour press with coater and extended delivery is 15 to 20 per cent faster than on the company’s two previous-generation Rapida 164 presses. The same applies to makeready times. This can, in part, be attributed to established automation solutions such as the sidelay-free SIS infeed, CleanTronic multi-function washing systems, including DriveTronic SRW, and pile logistics provisions with automatic non-step pile changing. At the same time, the use of unbent plates, pneumatic ink ducts with EasyClean coatings for fast ink changes, mounting aids for coating plates at the coater tower, and a plate lift up to the level of the gallery also accelerate and improve work processes.

Even the standard configuration of the Rapida 164 prints at speeds of up to 16,000 sheets/h and with sheet formats up to a colossal 1,205 × 1,640 mm. And those aren’t just theoretical values. Its full speed is often demanded in daily production. The pre-series press delivers over four million sheets per month with absolute reliability. That adds up to a sheet area of almost 8 km², an area larger than the whole of Gibraltar – or two-thirds of the area of the Nettetal suburb of Kaldenkirchen, which is where the Grieger plant is located.

Less waste, more quality

A lot has also been achieved in terms of waste savings. QualiTronic ColorControl and PDFCheck are used to configure the ink settings for the enormous sheets, including a comparison with the pre-press PDF. Start-up waste and imperfect sheets can be marked with a tag inserter, so that only the good sheets are shipped and passed on for further processing.

Wilhelm Drießen is also excited by the developments in networking solutions. The LogoTronic PPS from Koenig & Bauer has now become an important module for integration of the presses into an overall workflow. Grieger uses an MIS from Prosecco and a pre-press workflow from Hybrid. All three systems are perfectly coordinated with each other and, thanks to their CIP4 interfaces, establish the necessary end-to-end printshop workflow between the commercial offices and the actual presses. The precise contents of the plates are defined in the MIS. This information is sent to LogoTronic. The operator starts print production, and a fully automatic plate change is carried out as soon as the specified number of sheets is reached. Fewer colour corrections and ink changes are needed, and process reliability is increased.

Packaging and displays in perfection

The prime goal for all automation solutions: they must offer added value for customers. The customers’ production jobs must be handled better, faster and more flexibly. This ensures that they can increase their own level of flexibility, as they receive their packaging or displays in tested quality even at short notice.

Walter Grieger Offsetdruck has been offering print services to display and packaging suppliers since 1988. When the first presses from Koenig & Bauer arrived, the customer base grew to include companies that process solid and corrugated board. Since the early days as a garage business, founded with just DM 500 of initial capital, the production space in Nettetal alone has grown to cover 11,000 square metres. The four sheetfed offset presses in Nettetal and Bielefeld operate 17 shifts per week. The automation systems used for them allow jobs from as few as 100 up to several 100,000 sheets to be printed profitably. And that not just for standard packaging, but even where UV finishing on silver or gold foils is required, such as the type used for cosmetics displays. The typically used substrates range from 170 g/m² to as much as 700 g/m².

Full concentration on print

The list of customers served by Teamplayer-in-Print is equally diverse. They come from all over the German-speaking regions, as well as from the Netherlands, Belgium, Scandinavia and Great Britain. With its 90 employees, Teamplayer processes 35,000 tonnes of paper and board per year. Up to 10 million fresh and printed sheets can be stored at the two locations.

The special business concept means that both companies are highly streamlined. There are no packaging design offices or extensive post-press departments, because those process steps are handled by the customers themselves. Instead, full concentration is directed at the print process. And with it a workflow that is without equal in terms of process optimisation, throughput times and quality management.

The customers benefit from the high degree of flexibility, a large format process that is especially suited to both one-piece displays and appropriately optimised multi-part products, and the high production capacity with four large-format presses at two locations. From the basic chemical components to the finished product, Grieger produces all the required inks in its own ink kitchen. The same applies to coatings. This also benefits other print companies that find themselves able to obtain their coatings from Nettetal. 

Interesting website: www.teamplayer-in-print.de 

More interesting content relating to the launch of the new Rapida large format generation can be found at https://www.koenig-bauer.com/en/newdimension/

The Model Group is investing in a Rapida 145 with eleven printing and finishing units, as well as two CorruCUT machines from Koenig & Bauer. The Rapida is scheduled to enter production in Opava in the Czech Republic in spring 2022, while the first of the two CorruCUTs is to be installed at a second Czech plant in Nymburk towards the end of next year. “Koenig & Bauer satisfied our high expectations in terms of quality, sustainability and performance in every respect. At the same time, we were looking for a single partner for the whole investment package. The broad product portfolio offered by Koenig & Bauer is therefore a perfect fit for our company,” says Roman Jamnický, COO of Model Obaly. The second CorruCUT is scheduled for installation at the group’s Polish plant in Czosnów near Warsaw. All three machines represent a genuine advance in printing technology for the packaging industry and combine high print quality and precision with market-leading performance.

Innovation and new technical developments
The two CorruCUT machines are the first ones to incorporate a novel presettable rotary die-cutting unit. It allows the die-cutting cylinder that is not in use to be set up for a subsequent job without affecting current production, also allowing fully automatic exchange once the present job is completed. Koenig & Bauer executive board member Christoph Müller: “With these two machines, Koenig & Bauer has finally made its entry into the market of direct corrugated printing. The aim is to achieve a market position that is customary for Koenig & Bauer in the medium term.” In addition, the machines will be equipped with all the established unique features such as anilox roller changing systems and vacuum-belt feeders without feed rollers. Various software upgrades, which raise automation levels yet another notch and greatly simplify work with the machines for the operators, are likewise important and inherent elements of the machine package. “Our team is constantly developing new and innovative technical features for our machines. We listen to our customers and work together with them in partnership. This ensures that the performance of our machines are able to be enhanced further,” Christoph Müller adds. 

Rapida 145 with eleven printing and finishing units
Model Obaly has used a total of twelve sheetfed offset presses from Koenig & Bauer for its operations since 1976. The current line-up comprises a Rapida 145, two Rapida 142 models and a medium-format Rapida 106. 

The new Rapida 145 was purchased to increase print capacities in Opava as of spring 2022. It will be placed on foundations raised by 420 mm to accommodate production with heavy and corrugated board, and has been configured with six printing units, followed by a coater and two intermediate drying units, ahead of a further printing unit, a second coater and a three-section extended delivery. Automation highlights include automatic non-stop systems and pile logistics, the sidelay-free infeed DriveTronic SIS, simultaneous plate changing with DriveTronic SPC and Plate Ident, as well as CleanTronic Synchro washing systems for parallel washing processes. To enable mixed UV/conventional operation, and therefore maximum flexibility in inline product finishing, the press also features UV interdeck dryers and a full complement of IR, hot-air and UV drying systems in the extended delivery. 

Tradition paired with foresight
The Model Group with its headquarter in Switzerland is managed in the fourth generation by Daniel and Elisabeth Model. The company was founded almost 150 years ago and, in the meantime, maintains subsidiaries in seven countries. The Model Group develops, produces and supplies intelligent, innovative and high-quality display and packaging solutions made of solid and corrugated board. Around 4,600 people are employed at the Model Group’s 15 European locations. Last year, they generated a turnover of more than €800 million. Particular importance is attached to the issue of sustainability – for several years, for example, the company has used almost exclusively recycled fibres in its products.

Even more innovative and effective, this is the new performance benchmark in metal decorating.  Seven years after the market launch of the MetalStar 3, of which over 400 printing units have been installed worldwide, Koenig & Bauer is presenting the new MetalStar 4.

The MetalStar 4 presents itself in a new design with innovative, pioneering technology. To meet the growing demands of the metal decorating market even better, the MetalStar 4 offers new functions and improvements in the feeder, state-of-the-art measuring technology and new functions for monitoring production and enhancing ergonomics. What remains unchanged is the proven MetalStar technology, such as the short and dynamic inking and dampening unit and high-precision register printing thanks to the sheet travel in the gripper closure, as well as the extensive automation features that reduce make-ready times to a minimum. 

Some of the biggest innovations of the MetalStar 4 can be found at the feeder. Metal printing-specific updates such as new sensors, newly designed blow pipes and scrapers, and adjustments to the infeed table noticeably increase the reliability of the feeder. Even with challenging materials, the feeder's reliability is convincing. The feeder is rounded off by a new touch panel on which the air setting can be made and stored for each job. For repeat jobs, the last setting can be conveniently loaded and production started directly.

The inline colour measurement and control system MetalControl, which is available for the MetalStar 4, measures the ink densities on each color patch in the print control strip or on individual colour patches and regulates the ink zones fully automatically every 10 sheets. This ensures that the specified target densities are always achieved and maintained within the print run. Independent of the operator or the time of day. In addition, MetalControl supports the operator in color setup for the print job. MetalControl can set up the target densities fully automatically in one print run, utilising a sandwich process. Alternatively, MetalControl can also be used to print individual print runs as usual during set-up. MetalControl then makes a setting suggestion after each print run. 

The new ErgoTronic console is the heart of the MetalStar 4. Thanks to the clear and modern software, the operation of the MetalStar 4 is intuitive. All settings are made via a 23" touch screen. The console can be equipped with a 75" wall screen on which the measuring results of MetalControl and the individual zone openings in each inking unit are displayed. In addition, a live image from one of the observation cameras mounted at neuralgic points on the line can be displayed here. This makes it easy to monitor critical positions live from the ErgoTronic console and intervene if necessary.

In terms of automation, the MetalStar 4 continues to lead the way in the metal decorating market. Features such as parallel washing of the blanket and impression cylinder with CleanTronic Synchro or parallel washing of the inking unit during blanket washing with DriveTronic SRW (Simultaneous Roller Washing) guarantee the shortest make-ready times in metal decorating. The fully automatic plate change FAPC (Fully Automatic Plate Change) is now even faster and has been equipped with a new infeed system that significantly enhances stability.

Each MetalStar 4 is customised directly to the individual needs of the customer and the application. From special equipment packages for UV and UV-LED printing, to a wide range of inline coating options, to the tried-and-tested sheet handling modules and Koenig & Bauer globally proven and highly regarded drying ovens.

All these details and more make the MetalStar 4 the most powerful and efficient MetalStar ever.

Customers have added their voice to the ongoing packaging debate at an ‘inspirational’ second SPC Open House – entitled “New Times, New Challenges and New Opportunities – in Lienz, Austria, organized by Koenig & Bauer Durst.

Jochen Drösel, Chief Sales Officer at Schumacher Group, was a keynote panelist at the event that highlighted future trends, challenges, and opportunities for corrugated board markets, as well as the wider implications for retail and other industries. Breakout sessions at the Durst Innovation Center East also included deep insights into the Delta SPC 130 Automatic single-pass press that uses water-based food-safe inks.

The success of Schumacher Group, an early adopter of Koenig & Bauer’s Delta SPC 130 single pass press for the corrugated packaging market, has led to an investment in a second machine. At the SPC Open House, Mr Drösel shared his perspectives on their relationships with brand owners and digital packaging journey, which Schumacher Group sees as the future for print production in corrugated markets.

Robert Stabler, Managing Director of Koenig & Bauer Durst, said: “This was a truly inspirational event, with real audience interaction and insightful content from leaders in the corrugated industry that generated extremely positive feedback. The perspective brought a new dimension and perspective to the debates we have over the future of packaging. 

“Converters need to be ahead of the regulatory change curve and to be ready for the increased focus of brands on sustainability and have the capabilities and competencies to mass customize without any compromise on quality. Brand owners are demanding that new production methods are reliable, compliant and cost effective. Therefore, in a live setting we were able to look at how single pass digital printing helps converters meet the evolving demands of brand owners in a world of shorter lead times, short run lengths and greater forecast unpredictability.”

Koenig & Bauer Durst will be hosting a third SPC Open House at the Durst East Innovation Center, Lienz, on February 10 2022.

What was originally planned as an international event can only be presented to smaller groups of interested users for the time being – when carrying out print tests or live video demonstrations: Koenig & Bauer is proud to announce the market launch of a brand new generation of its Rapida 145 and Rapida 164 large-format sheetfed offset presses. The new press generation is available with immediate effect.

The fact that both large-format series now boast the same new innovative design as all the latest Koenig & Bauer presses immediately catches the eye. Along with this, there are also many other new features that will enable the large-format Rapidas to consolidate their position as market leaders in this format class. They handle sheet formats up to 1,060 x 1,450 mm (Rapida 145) and 1,205 x 1,640 mm (Rapida 164) at a standard maximum production speed of 16,000 sheets/hr in board production. Incorporation of a high-speed package raises the top speeds another notch, allowing them to handle 18,000 sheets/hr (Rapida 145) and 17,000 sheets/hr (Rapida 164). Alongside new upgrades to the automation features, they offer the performance parameters of the latest medium-format presses – for twice the print format or even more.

The operating concept has also been given a makeover. Large touch panels on the feeder, on the first printing unit and at the delivery render many buttons and other operating elements superfluous. All routine processes that are normally activated decentrally from the console can therefore be controlled just as conveniently on the press itself. A prominent status indicator at the delivery provides instant updates on the current press status. Different colours are used to signal whether the press is in production, standby or maintenance mode.

Digital control and monitoring

The ErgoTronic console features a touchscreen monitor and a large wallscreen. All relevant information is presented in a clearly structured fashion on both displays. A host of additional functions allow production to be monitored in real time. Production data and other information, such as CO₂ emissions, are available at a glance. Autonomous printing of a job list, app-based control of many press functions, access to the CustomerCommunity as a central point of contact between users and the manufacturer, and, of course, a function to start individual press programs using presets based on the data supplied or previously saved – the console is the digital hub for all production processes in the printshop.

This applies to quality assurance in equal measure. Three different systems combine inline colour control (with the option of grey balance control) with functions for production monitoring (QualiTronic PrintCheck), comparison with the pre-press PDF (QualiTronic PDFCheck) and content inspection (QualiTronic PDF HighRes).

Additional benefits for packaging specialists

The new Rapida large format generation brings significant improvements for the core application area of packaging printing in particular. Substrate versatility was already very broad in the past, allowing board thicknesses of up to 1.2 or 1.6 mm. Universal gripper systems make this possible. On the new presses, the range of substrates handled can be increased further still – even beyond the 2 mm mark – by simply converting the printing units. For companies that work with heavy board grades or offer post-printing on corrugated board involving printing and finishing a full spectrum in an inline process, the new capabilities represent a quantum leap forward.

Other important changes concern the options to allow increased pile heights. Five variants are available, covering the range from 185 to – as a new option – 925 mm. Raising piles by 185, 370 or 555 mm can also be achieved by placing the press on cast blocks. The additional outlay for special press foundations can then be saved.

Significant improvements in many details

Many less visible but nonetheless important details have also been overhauled. These include the sheet guiding elements in the delivery and delivery extension (dryer section). Modifications like this have been paramount in realising top production speeds of up to 18,000 sheets/hr with an even broader range of substrates and finishing applications. Thanks to a dynamic sheet brake, visibility and accessibility at the delivery remain unhindered. There is no need for complicated sheet braking systems or delivery grippers.

Long-life gripper shafts with automatic lubrication and a reduced number of manual lubrication points help simplify maintenance. The same applies to the new AC drive motor of the large-format Rapidas. It is not only practically maintenance-free, but also reduces energy consumption.

High production capacity and flexibility

All the existing automation and high performance features of the previous models are, of course, still available for the new Rapida generation. This begins with the sheer endless choice of press configurations, with up to 16 printing and finishing units, together with options such as a reel-to-sheet feeder, automatically convertible perfecting, coating and drying units, a double-pile delivery, and extends to a range of non-stop pile changing and logistics components. This means that individual press configurations can be tailored specifically to the very specific requirements of packaging and commercial printers.

When it comes to automation, the new Rapida generation sets a new benchmark in large-format printing. The sidelay-free infeed DriveTronic SIS, simultaneous plate changing with DriveTronic SPC, the disengaging of unused inking units as a standard feature, CleanTronic cloth-based washing systems for parallel washing processes, fast coating forme changes with DriveTronic SFC and anilox roller changing with AniSleeve are just a few of the outstanding automation components that enable many processes to run concurrently at job changeover and thereby contribute to the shortest ever makeready times. The dryer modules, too, are manufactured by Koenig & Bauer. After all, dryer systems are one of the company’s core competencies.

All system components and automation functions serve one goal, namely to provide users with the best possible support, and to enable them to produce efficiently and successfully, whether in packaging or the commercial segment. The large-format Rapidas are therefore the ideal means of production, and ensure print companies are equipped for all current and future challenges. 

Visit https://www.koenig-bauer.com/de/newdimension/ for more interesting content around the product launch.