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Despite opening less than a month after Interpack closed its doors, there was plenty on display to interest packaging converters at the Drupa exhibition in Düsseldorf; from inks to die-cutters and Braille embossers. A number of firms also announced projects aimed at bringing the supply chain closer together and, after a perceived absence at Interpack, the environment was back on the agenda.

There’s been a lot of talk about the environment at the show, and it is greener than previously. But the increase in ‘greenness’ is not considerably more than between, say, 2000 and 2004, says Nigel Tracey, marketing director for folder-gluers at converting equipment manufacturer Bobst. The environment clearly remains a key driver in machinery development – for example by reducing the amount of ink lost during printing, avoiding emissions being given off or lowering the amount of energy used. Bobst says its new Masterfold folder-gluer machine uses 11% less electricity than existing machinery. But it’s also about the impact on the working environment, and the new machines show a 50% reduction in the level of noise they produce, adds Tracey.

The Masterfold is one of a range of folder-gluers, die-cutters and hot foil stamping equipment that Bobst launched at the show. For each of the three machines there are four variants – Nova, Vision, Expert and Master – depending on a firm’s individual requirements. Everyone’s looking to increase performance, but there are different drivers for different customers, says Tracey. He adds that customers in mature markets are looking at areas such as improved speed, differentiation of products and using less labour, while flexibility is the most important factor in emerging markets.

The need for speed
The trend for short production runs is increasing, requiring faster makeready times, says Kilian Renschler, Heidelberg vice president for product management in folding cartons. Following the Interpack launch of its Linoprint technology for packaging decoration, the printing machinery giant launched its Diana X115 folder-gluer at Drupa. Renschler says the key features of the new machine are its open-frame design, providing easy access, and fast changeover times – feeders can be changed within 30 seconds. The machine can deal with cartons ranging from 200 to 900gsm at speeds of up to 650m per minute.

The overall cost of a box needs to be as low as possible to be able to compete with lower-cost economies, but you also need to add value to the product, says Renschler. This trend is driving the sector towards more inline production. You can save money, for example, from cold foiling in one pass, but there is a tooling cost, so it’s important to do your sums and look at the end result.

Michael Zinke, packaging marketing manager in Manroland’s sheetfed presses division, echoes the view that cost per copy is the most important factor as run lengths fall. But he says: We can offer printing and finishing in one pass, but there are limits to how many processes should be integrated on one machine.

Bobst is also adding more processes to its machines. Its Accubraille system can be incorporated on its folder-gluers, but says that because die-cutting is a closed process it becomes more difficult to incorporate other elements. Where it allows better opportunities to add value, such as embossing or quality inspection, there are more and more things going inline, says Tracey.

One example of integrated die-cutting came from German equipment manufacturer Kama. The firm used Interpack to launch the ProCut 53 die-cutter, targeted at short-run digital packaging printers. The machine, also shown at Drupa, was demonstrated in an integrated system with a Xerox iGen3 digital printing press. The system is the product of a partnership between Kama, Xerox and Stora Enso, and is being marketed as the Stora Enso Gallop. It can process substrates up to 800gsm, with extra processes including kiss cutting, cold embossing and Braille.

Inline innovation
The largest ‘inline’ launch at the show was the Gallus ICS 670 carton printing and converting machine (see box), which senior marketing manager Stefan Hagn believes shows the way forward for printing and converting lines. If you look at production in typical offset lines, you have one process, then have to store the product, and then transport it to another machine. With inline production, you can do everything you want in one go and are not waiting for another machine to become available.

But it is not just the actual manufacturing process that is showing signs of becoming more joined up. There are moves to bring the whole supply chain closer together. Drupa 2004 was described as the JDF (job definition format) Drupa because it contained the first real examples of JDF-workflow control applications in the printing industry. Drupa 2008 was the show where JDF-controlled design and processing extended to converting.

Packaging pre-press specialist EskoArtwork has joined forces with Manroland and Bobst and management information system (MIS) designer Dr Lauterbach & Partner, to develop a JDF-based system to control the production of cartonboard packaging from order through to delivery. The impetus for the programme came from a mutual customer who saw the value of all its partners having a good relationship to help bring together the main logistical and financial elements of the packaging supply chain.

Jan De Roeck, EskoArtwork director of solutions management, says: Using JDFs means the whole development process is repeatable, and improves customisation of products. Having a common language makes packaging design a lot easier.
Heidelberg also presented its own JDF-based workflow programme, Prinect, at this year’s show, which the firm said would help improve production speeds and make costing more transparent. With Prinect, it is easy to see the results of a particular phase of production, and if the result is not good you can change it quickly, says Heidelberg’s Renschler.

Shortly before Drupa, KBA announced the creation of KBA Complete to provide a networking programme for JDF-enabled production. Head of marketing Thomas Goeke says the advantage of the KBA internet-based MIS is its compatibility with any interfaced system. It can work with different presses to help standardise communications in the supply chain, he says.

By integrating suppliers, KBA says the system creates a ‘more streamlined flow of information in the supply chain’. We include suppliers and customers because the production chain doesn’t stop at the print shop door, adds Goeke.

DRUPA HIGHLIGHTS
• Ink giant Sun Chemical announced it had joined forces with German firm IMG Digipack to beta test its FastJet press, which it claims is the world's fastest machine for corrugated printing. Sun Chemical's Wetflex, designed for wet-on-wet flexographic printing for the flexible packaging sector, also made its first public outing at the show
• Atlantic Zeiser launched its Braillejet system for short runs in the packaging and pharmaceutical markets. Braillejet uses UV-cured ink to create micro valves to produce the raised bumps, in two lines of text in a single pass
• Epson revealed two new proofers for packaging, spot colour reproduction and contract and remote proofing. The Stylus Pro 7900 and 9900 use a new ink, Ultrachrome HDR, that offers 11 colours, including orange and green
• Fujifilm targeted packaging printers with its new direct laser exposure flexo plate, which it said could cut up to an hour from plate production times as it requires no post-imaging UV exposure or processing
• Chesapeake signed off the purchase of a Manroland HiPrint 700 that will be installed at the cartonboard packaging manufacturer's Frankfurt plant

FLEXIBLE GALLUS FOR FLEXO AND FOIL
Gallus used Drupa to launch its ICS 670 mid-web carton printing and converting machine. The ICS 670 enables packaging printers to go from roll to die-cut pack in just one pass, in the space of 30m and using a variety of processes, says marketing manager Stefan Hagn.

The basis of the ICS 670 is the EVA (Easy Value Add) platform. The modular system can be used to introduce different print processes, such as high-definition flexo, UV screen printing, embossing and hot foil stamping, and the individual modules can be changed without tools.

The machine can process board up to 600gsm at speeds of up to 350m per minute, and can also process 60gsm papers and plastic substrates such as PET. Gallus says the machine is suited to higher-value sectors, such as cosmetics, beauty and healthcare, which typically have smaller packs for high-value products. But it is the adaptability of the machine that Gallus sees as the main reason firms will be attracted to the ICS 670.

It secures investment because firms could start off with an easy configuration, say a simple print run, and add processes as customer demand changes.