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www.wuh-group.com<br />

Customer magazine | <strong>Windmöller</strong> & HölsCHer | volume 9 | Winter 2010 | issue 18<br />

tHe situation today<br />

Sustainability is our main focus<br />

innoVation<br />

The world‘s <strong>fastest</strong> <strong>cement</strong> <strong>sack</strong> <strong>line</strong><br />

greenoVation<br />

World champion in CO 2 avoidance<br />

suCCess stories<br />

VISTAFLEX at JUNG DESIGN –<br />

JUNG VERPACKUNGEN<br />

300th FILMATIC S at Plastienvase S.L.<br />

The world‘s<br />

fasTesT<br />

cemenT <strong>sack</strong> <strong>line</strong>


tHe situation today<br />

sustainaBility<br />

is our main FoCus<br />

(from left) Dr. Jürgen Vutz, Peter Steinbeck, Theodor Determann<br />

2<br />

EXTRA will bE<br />

pRinTEd in A<br />

climATE-nEuTRAl<br />

pRocEss.<br />

The paper you are holding in your hands right<br />

now is more than just a new issue<br />

of our EXTRA Customer magazine. It is actually<br />

ano<strong>the</strong>r mosaic stone in our endeavour<br />

to emphasize <strong>the</strong> sustainability aspect of all<br />

corporate activities, whatever <strong>the</strong>ir nature.<br />

What is this to mean?<br />

When we decided to relaunch EXTRA,<br />

our idea was not only to refresh <strong>the</strong><br />

magazine‘s layout, but to provide our<br />

customers with a modern, yet desirably<br />

unobtrusive and pleasant to read<br />

Customer Magazine reflecting <strong>the</strong><br />

corporate design of our literature and<br />

leaflets without sacrificing individuality.<br />

Ano<strong>the</strong>r objective in redesigning EXTRA<br />

was to give expression to <strong>the</strong> sustainability<br />

aspect not only in regard to contents. In<br />

<strong>the</strong> preceding issue we already presented<br />

to you our “greenovation” logo, which is<br />

meant as an outward sign to signify our<br />

activities and efforts for <strong>the</strong> benefit of<br />

sustainability. As a result, you will find a<br />

new section under <strong>the</strong> heading “greenovation”,<br />

which we are going to publish as<br />

an integral part of EXTRA in all future<br />

issues. This is where you will find relevant<br />

information regarding our continued efforts<br />

towards CO 2 reduction in <strong>the</strong> production of<br />

flexible packaging.<br />

And that’s not all: We will emphasize <strong>the</strong><br />

value we attach to sustainability also in <strong>the</strong><br />

way our Customer Magazine is being<br />

produced. From now on and including this<br />

issue, we are using FSC certified paper,<br />

which means that <strong>the</strong> paper is approved to<br />

be derived from sustainable forestry, which<br />

is certified by <strong>the</strong> Forest Stewardship<br />

Council (FSC) located in Bonn, Germany.<br />

Also, EXTRA will be printed in a climateneutral<br />

process, i.e. printing will be<br />

entrusted to selected printing houses<br />

certified to reduce harming emissions to<br />

<strong>the</strong> very minimum. Unavoidable emissions<br />

are compensated for by <strong>the</strong> purchase of<br />

climate certificates from approved climate<br />

control projects. We hope you will enjoy<br />

reading <strong>the</strong> new EXTRA and are looking<br />

forward to your comments.<br />

In terms of contents, <strong>the</strong> present EXTRA<br />

contains a varied mix of information,<br />

articles on technical and technological<br />

innovations, as well as reports from and on<br />

our international customers. Features<br />

include <strong>the</strong> demonstration of <strong>the</strong> new<br />

<strong>cement</strong> <strong>sack</strong> <strong>line</strong> in Casablanca highlighting<br />

ano<strong>the</strong>r valuable addition to our<br />

converting machinery program, <strong>the</strong><br />

successful commissioning of <strong>the</strong> first<br />

VISTAFLEX at JUNG VERpACkUNGEN,<br />

and an article on <strong>the</strong> 300th FILMATIC S<br />

winder built by W&H, to mention only a<br />

few.<br />

Of course, we take this opportunity to give<br />

a first résumé of k 2010, <strong>the</strong> world‘s<br />

biggest trade show for <strong>the</strong> plastics and<br />

rubber industry, which has just closed its<br />

doors and come out a success. After two<br />

critical years with all markets seeing a<br />

dramatic slump in order input as well as<br />

readiness to invest, <strong>the</strong> trade show set<br />

marked impulses for a positive future<br />

market development. And W&H did not fail<br />

ei<strong>the</strong>r to make its mark with spectacular<br />

accents. Demonstrating <strong>the</strong> sensational<br />

output of 1000 kg/h, W&H presented <strong>the</strong><br />

most powerful blown film <strong>line</strong> to be seen at<br />

<strong>the</strong> show! This is world record and<br />

impressively underscores our position as<br />

technology market leader.<br />

Dr. Jürgen Vutz<br />

Peter Steinbeck<br />

Theodor Determann


innoVation<br />

tHe World‘s Fastest<br />

Cement saCk <strong>line</strong><br />

In early May, <strong>the</strong> focus of attention at<br />

papSac Maghreb, a daughter company of<br />

MONDI Group, located in Casablanca/<br />

Morocco, was on <strong>the</strong> newly developed<br />

W&H <strong>cement</strong> <strong>sack</strong> <strong>line</strong>. During its official<br />

market launch, <strong>the</strong> <strong>line</strong> consisting of <strong>the</strong><br />

AM 8105 tuber and AD 8300 bottomer<br />

impressed <strong>the</strong> international visitors with<br />

shift outputs exceeding 120,000 <strong>sack</strong>s. No<br />

later than one and a half year after <strong>the</strong><br />

spectacular introduction of <strong>the</strong> AD 8300<br />

multi­purpose bottomer with its digital glue<br />

application system, <strong>the</strong> W&H R&D team<br />

was again able to present ano<strong>the</strong>r multiwall<br />

highlight, in this way documenting its<br />

continued strategy to maintain <strong>the</strong> high<br />

rate of new developments of recent years.<br />

The market launch took place under <strong>the</strong><br />

shifT ouTpuTs<br />

EXcEEding 120,000 sAcks<br />

slogan “productivity has Got a New Name”<br />

to express <strong>the</strong> capability of <strong>the</strong> new <strong>line</strong> to<br />

notably reduce unit production costs<br />

through increased productivity. With<br />

output rates of 360 bags per minute, <strong>the</strong><br />

new AM/AD <strong>line</strong> is <strong>the</strong> <strong>fastest</strong> running<br />

<strong>cement</strong> <strong>sack</strong> system currently available in<br />

<strong>the</strong> marketplace world­wide. The boost in<br />

output is tantamount to a 50 per cent<br />

increase in productivity as compared with<br />

multiwall equipment installed ten years<br />

ago!<br />

Cement <strong>sack</strong>s are technically less sophisticated<br />

mass products with a relatively<br />

moderate added value potential. It is just<br />

for this reason that any advance in<br />

efficiency is vital in order to maintain a<br />

competitive edge in <strong>the</strong> target market.<br />

Bearing in mind that it is only <strong>the</strong> bottomer<br />

that turns out saleable products, it is <strong>the</strong><br />

capacity of this <strong>line</strong> component that<br />

dominates <strong>the</strong> efficiency of <strong>the</strong> entire<br />

multiwall plant. Under this aspect it is<br />

obvious that 20 per cent extra output<br />

represents a marked improvement that<br />

counts a lot.<br />

In addition, also <strong>the</strong> output capacity of <strong>the</strong><br />

new AM 8105 tuber has been notably<br />

increased to make sure <strong>the</strong> bottomer will<br />

be adequately supplied with tubes at all<br />

times. As a result, 400 tubes per minute<br />

are available across <strong>the</strong> entire size range.<br />

A smart end­of­roll monitor cuts roll<br />

change times to a minimum, while at <strong>the</strong><br />

same time ensuring minimal residual<br />

material on <strong>the</strong> core of <strong>the</strong> spent roll<br />

(only approx. 4 – 6 meters), resulting in<br />

ano<strong>the</strong>r reduction of <strong>the</strong> already short<br />

makeready time.<br />

Visitors were impressed with <strong>the</strong> perfect<br />

organisation of <strong>the</strong> demonstration show<br />

and, not least, with <strong>the</strong> excellent performance<br />

of <strong>the</strong> equipment <strong>the</strong>y were able to<br />

witness, with all <strong>line</strong> components operating<br />

at maximum speed, without any jams,<br />

production interruptions or rejection of<br />

defective <strong>sack</strong>s.<br />

The new <strong>line</strong> has been operating at<br />

papSac Maghreb for some time under<br />

everyday production conditions and<br />

passed <strong>the</strong> field test with no failure.<br />

Besides <strong>the</strong> AM 8105 tuber and <strong>the</strong><br />

AD 8300 bottomer, <strong>the</strong> <strong>line</strong> features<br />

TRANSYSTEMS tube feeding and storage<br />

elements as well as an ARCOMAT 3<br />

robotic palletizer. With a palletizing rate of<br />

28 <strong>sack</strong> packets per minute, it forms very<br />

flat packets with <strong>the</strong> bottomer running at<br />

maximum speed, resulting in perfect<br />

stacks of <strong>the</strong> finished <strong>sack</strong> packets.<br />

Hicham Jalal, Managing Director of<br />

papSac Maghreb, is more than satisfied<br />

with <strong>the</strong> effective cooperation with W&H<br />

during speedy installation and<br />

commissioning of <strong>the</strong> new <strong>line</strong> as well as<br />

with <strong>the</strong> quality of <strong>the</strong> <strong>cement</strong> <strong>sack</strong>s<br />

produced. “The results so far fully come<br />

up with <strong>the</strong> high expectations MONDI had<br />

specified for this investment”, says<br />

Hicham Jalal.<br />

With 360 bags/min., <strong>the</strong> AD 8300 is <strong>the</strong> <strong>fastest</strong> running valve bottomer in <strong>the</strong> world.<br />

Visitors were also impressed with <strong>the</strong> output of <strong>the</strong> 8105 Tuber of 400 tubes/min.<br />

W&H CEO Dr. Jürgen Vutz (l.) is explaining <strong>the</strong> strategy followed in <strong>the</strong> development<br />

of <strong>the</strong> new <strong>cement</strong> <strong>sack</strong> <strong>line</strong>.<br />

extra Winter 2010 | issue 18<br />

3


extrusion<br />

greenoVation //<br />

suCCess stories<br />

World CHamPion in<br />

Sparing usage of raw materials is of vital<br />

importance to <strong>the</strong> commercial effi ciency of<br />

extrusion equipment, while at <strong>the</strong> same<br />

time contributing essentially to sustainability.<br />

What may not, however, be realized<br />

at fi rst glance is <strong>the</strong> fact that <strong>the</strong> thrifty use<br />

of resources also brings about a notable<br />

improvement in regard to <strong>the</strong> carbon<br />

dioxide balance.<br />

While, compared with o<strong>the</strong>r W&H equipment,<br />

our blown and cast fi lm systems<br />

with connected loads of several 100 kW<br />

are <strong>the</strong> most energy­consuming machines<br />

of our product <strong>line</strong>, <strong>the</strong>y yet represent –<br />

because of <strong>the</strong>ir high throughput rates –<br />

<strong>the</strong> machines with <strong>the</strong> lowest power<br />

consumption per kilogram of fi lm<br />

4<br />

eVery day a neW World<br />

reCord!<br />

1000 kg/h – delivered through a 400 mm<br />

die – this sensational output of our new<br />

VAREX 5­layer blown fi lm <strong>line</strong> did not fail<br />

to intrigue visitors to our k stand. Never<br />

before had this output been demonstrated<br />

at a trade show. On top of that, output<br />

rates could be increased still fur<strong>the</strong>r by<br />

ano<strong>the</strong>r 10 kg each day! The novel design<br />

extruder tower turned out to be a real eye<br />

catcher. Boasting a height of 15.50 meters<br />

1000 kg/h wiTh A 400 mm diE!<br />

nEVER bEfoRE hAd This ouTpuT bEEn<br />

AchiEVEd AT A TRAdE show.<br />

and a weight of 85 tons, it towered above<br />

all o<strong>the</strong>rs in Hall 17 and can rightly claim to<br />

be <strong>the</strong> highest and heaviest tower Duesseldorf<br />

fairgrounds have ever seen. The<br />

product was 40­micron tissue fi lm representing<br />

a new generation of polyolefi n<br />

based 5­layer fi lm providing improved fi lm<br />

properties combined with downgauging<br />

potential, as compared to conventional<br />

3­layer fi lm for comparable applications.<br />

produced, in relation to o<strong>the</strong>r systems<br />

used in <strong>the</strong> industry.<br />

What makes <strong>the</strong>m world champion in <strong>the</strong><br />

avoidance of CO 2 emission is <strong>the</strong> added<br />

benefi t of an exceptionally high material<br />

effi ciency, bearing in mind that in order to<br />

extrude plastic resins into fi lm it takes no<br />

more than just one third of <strong>the</strong> energy<br />

needed for producing <strong>the</strong>m. Therefore, any<br />

single kilogram of resin saved with a<br />

VAREX, OpTIMEX, AQUAREX or FILMEX<br />

reduces CO 2 emission by four times <strong>the</strong><br />

CO 2 amount that would have resulted<br />

from its extrusion.<br />

Seen from this viewpoint, our automation<br />

modules OpTIFIL p, EASY­CHANGE, and<br />

pROFILE BOOSTER appear in new light,<br />

since not only do <strong>the</strong>y give <strong>the</strong> fi lm<br />

converter product quality exactly tailored<br />

to <strong>the</strong> end user’s needs and with minimal<br />

resin consumption at that, but also ensure<br />

exceptionally low CO 2 emission values<br />

that are unrivalled in <strong>the</strong> industry. This<br />

message will go down well with your<br />

customers.<br />

The new MAXICONE p die, which debuted<br />

at k, has been specifi cally developed for<br />

<strong>the</strong> innovative fi lm structures. The o<strong>the</strong>r<br />

exhibit showcased in Duesseldorf was a<br />

MIRAFLEX AM 8, <strong>the</strong> youngest model of<br />

our exceptionally successful MIRAFLEX<br />

series of CI fl exo presses, featuring latest<br />

generation press automation modules of<br />

W&H‘s EASY family. The benefi ts and<br />

effi ciency of <strong>the</strong>se systems were successfully<br />

demonstrated live to experts from <strong>the</strong><br />

trade on all days of <strong>the</strong> fair: A complete job<br />

change fi nished and done with in no more<br />

than 15 minutes, including colour matching<br />

– defi nitely ano<strong>the</strong>r spectacular<br />

result of innovative W&H technology with<br />

record­breaking potential. Our k exhibition<br />

program was complemented by numerous<br />

exhibits on show at our in­house EXpO in<br />

Lengerich, with a focus on innovative fi lm<br />

technology and applications. More than<br />

700 customers from 71 countries availed<br />

<strong>the</strong>mselves of <strong>the</strong> opportunity to get an<br />

insight into W&H‘s diversifi ed product <strong>line</strong>.<br />

You will fi nd a more detailed report on<br />

k 2010 and W&H house EXpO in <strong>the</strong> next<br />

EXTRA issue.<br />

Co 2 aVoidanCe The FILMATIC S surface winder has<br />

developed into what can claim to be a top<br />

seller. Following <strong>the</strong> delivery of <strong>the</strong> 200th<br />

winder, it took us no more than a year to<br />

sell ano<strong>the</strong>r 100 FILMATIC S units – which<br />

clearly testifi es to <strong>the</strong> successful winding<br />

technology and signifi es ano<strong>the</strong>r jubilee.<br />

FILMATIC S No. 300 is going to be<br />

installed downstream of a new VAREX<br />

blown fi lm <strong>line</strong> at <strong>the</strong> Spanish company<br />

plastienvase S.L. in Villarrubia/Córdoba.<br />

plastienvase S.L. was established in 1985.<br />

Business activities include <strong>the</strong> production,<br />

printing and laminating of plastic fi lm for<br />

food packaging applications. The company<br />

is seeing one reason for its success in<br />

<strong>the</strong> use of top­of­<strong>the</strong>­<strong>line</strong> technology<br />

from W&H over many years. Besides<br />

NOVOFLEX fl exographic printing presses<br />

and a HELIOSTAR gravure printing<br />

machine, several VAREX blown fi lm <strong>line</strong>s<br />

as well as a FILMEX cast fi lm system are in<br />

operation at <strong>the</strong> company’s production<br />

plant in Villarrubia. “When considering <strong>the</strong><br />

purchase of a new blown fi lm <strong>line</strong>, it did<br />

not take long until <strong>the</strong> choice fell upon<br />

W&H as <strong>the</strong> supplier of <strong>the</strong> new equipment”,<br />

says General Manager Francisco<br />

Bernal. “Our good experience in <strong>the</strong> past<br />

The highest and most powerful blown film <strong>line</strong> on show<br />

at K was <strong>the</strong> W&H 5-layer VAREX.<br />

Source: Messe Düsseldorf<br />

tHe 300tH FilmatiC s Winder<br />

with expert advice, reliable delivery and<br />

service by <strong>the</strong> W&H team has tipped <strong>the</strong><br />

scales for W&H. Our machines are<br />

operating without problem and producing<br />

superb quality”, adds José Luis Bernal,<br />

president of plastienvase S.L. The 7­layer<br />

VAREX allows <strong>the</strong> company to add to its<br />

current product <strong>line</strong> sophisticated barrier<br />

fi lms and to serve its customers in <strong>the</strong><br />

food industry with an even more diversifi ed<br />

portfolio.<br />

The decision in favour of <strong>the</strong> 1,300 mm<br />

wide FILMATIC S dual winder was easily<br />

taken because of plastienvase S.L.’s good<br />

experience with this winder type so far.<br />

The new FILMATIC S will be commissioned<br />

in Villarrubia soon. Being equipped<br />

with center drive, slitter, and fi nished roll<br />

handling capability, it meets <strong>the</strong> demands<br />

in terms of roll quality and winder<br />

technology. Besides, <strong>the</strong> FILMATIC S is<br />

<strong>the</strong> only winder in <strong>the</strong> world having been<br />

awarded <strong>the</strong> GS mark (GS = approved<br />

safety) for its outstanding safety concept<br />

and, <strong>the</strong>refore, complies in full with <strong>the</strong> job<br />

safety philosophy of plastienvase S.L.<br />

ouR EXpERiEncE in ThE pAsT<br />

wiTh w&h EXpERT AdVicE And sERVicE<br />

hAs bEEn quiTE posiTiVE.


extrusion<br />

suCCess stories<br />

setting neW standards WitH Varex<br />

The production of demanding high quality<br />

multi­layer film such as for food and chilled<br />

food packaging, but also for medical<br />

applications, defines <strong>the</strong> core business of<br />

Bareks plastik Film Ekstrusyon San. Tic.<br />

A.S. (Izmir/Turkey), who will soon be<br />

commissioning a VAREX 3­layer blown film<br />

system. “We are <strong>the</strong> only independent<br />

Turkish company specializing in <strong>the</strong><br />

production of pE films which we sell to<br />

converters both at home and abroad”,<br />

explains Managing Director Mehmet Emin<br />

Bozdagˇ . “With <strong>the</strong> new VAREX added to<br />

our equipment, we will not only extend our<br />

production capacity, but also streng<strong>the</strong>n<br />

our position in <strong>the</strong> market.”<br />

With <strong>the</strong> purchase of <strong>the</strong> new blown film<br />

<strong>line</strong>, Bareks plastik is initiating <strong>the</strong> next<br />

step towards higher output as well as<br />

enhanced quality and efficiency. “Quality is<br />

at <strong>the</strong> top of our priority list”, emphasizes<br />

Mehmet Emin Bozdagˇ . “Our demanding<br />

customers expect us to supply <strong>the</strong>m with<br />

superb quality film. Being ISO 9001­2000<br />

and BRC certified, our products comply<br />

with all standards relevant to food safety in<br />

<strong>the</strong> production of flexible packaging. The<br />

VAREX from <strong>Windmöller</strong> & <strong>Hölscher</strong><br />

completely meets our demands so that<br />

our customers can rely on perfectly<br />

compatible products also in future.”<br />

Bareks plastik was established in 2002<br />

and is a member of Bakiogˇ lu Holding, an<br />

important Turkish business group in <strong>the</strong><br />

flexible packaging sector, with a staff in<br />

excess of 1,000 being employed at ten<br />

locations. The VAREX to be installed at <strong>the</strong><br />

group‘s location in Izmir will be <strong>the</strong> first<br />

W&H machine of <strong>the</strong> Turkish film manufacturer,<br />

and production Manager Serdar<br />

Mutlu is anxious to see <strong>the</strong> first production<br />

results: “We can‘t wait to draw <strong>the</strong> first film<br />

samples.”<br />

Cast Film ProduCtion at its Best<br />

“We are convinced that <strong>the</strong> new FILMEX<br />

cast film <strong>line</strong> is a real investment into <strong>the</strong><br />

future”, says Johannes Remmele,<br />

Managing Director SÜDpACk Verpackungen<br />

GmbH located in Ochsenhausen,<br />

Germany. “The outstanding quality of <strong>the</strong><br />

equipment as well as W&H’s engineering<br />

expertise allow us to fully translate our<br />

special film know­how into superb quality<br />

products. Not only is <strong>the</strong> new system more<br />

energy and raw material efficient, but also<br />

provides enhanced quality and increased<br />

output”, adds Johannes Remmele pointing<br />

out that sustainability is among <strong>the</strong> most<br />

important aspects to be implemented in<br />

<strong>the</strong> project.<br />

Vasilij Novoselov (2nd from l.), Managing Director<br />

W&H Vostok, and Reinhard Elting (r.), W&H Sales<br />

Area Manager/East Europe, with representatives from<br />

CHEMPACK, in front of <strong>the</strong> new VAREX.<br />

In <strong>the</strong> production of cast barrier film,<br />

regardless of its width, mixed material<br />

waste strips on ei<strong>the</strong>r side of <strong>the</strong> film web<br />

cannot be avoided. Thanks to <strong>the</strong> major<br />

width of <strong>the</strong> new <strong>line</strong> and to edge<br />

encapsulation capability SÜDpACk has<br />

succeeded in reducing <strong>the</strong> resulting edge<br />

trim waste. In addition, by being able to<br />

run more layers <strong>the</strong>y are able to produce<br />

films with identical or better properties that<br />

could so far be achieved only with heavier<br />

gauge films. As a result, <strong>the</strong>y need less<br />

resin to produce <strong>the</strong> same quantity of film.<br />

On top of that, energy usage of <strong>the</strong><br />

FILMEX has been reduced through <strong>the</strong> use<br />

of drives needing less energy while at <strong>the</strong><br />

When, back at k 2007, representatives of<br />

Moscow based CHEMpACk visited <strong>the</strong><br />

W&H stand for <strong>the</strong> first time, nobody<br />

would have been able to tell that <strong>the</strong><br />

company, founded in 1992, would be <strong>the</strong><br />

proud owner of a 3­layer VAREX by <strong>the</strong><br />

time of k 2010.<br />

Today, CHEMpACk is one of <strong>the</strong> leading<br />

manufacturers of big bags in Russia and,<br />

with two locations and a staff in excess of<br />

one thousand employees, not only<br />

engaged in <strong>the</strong> production of large­size<br />

woven fabric <strong>sack</strong>s, but also runs its own<br />

research and product development<br />

department. Since spring 2010, <strong>the</strong><br />

company has been producing <strong>line</strong>r film for<br />

its big bags on <strong>the</strong> new VAREX.<br />

“CHEMpACk serves <strong>the</strong> most demanding<br />

customers. Consequently, <strong>the</strong> requirements<br />

specified and to be met by <strong>the</strong> W&H<br />

equipment were quite exacting”, says<br />

Reinhard Elting, W&H Sales Area Manager/<br />

East Europe, remembering <strong>the</strong><br />

negotiations. “In constructive dialogue, <strong>the</strong><br />

two parties finally agreed upon a <strong>line</strong><br />

configuration meeting <strong>the</strong> highest requirements<br />

and perfectly matched to <strong>the</strong> task.”<br />

After some months of production experience,<br />

CHEMpACk is fully satisfied with <strong>the</strong><br />

quality and performance as well as <strong>the</strong><br />

output and reliability of its new W&H blown<br />

film <strong>line</strong>.<br />

extra Winter 2010 | issue 18<br />

A handshake seals <strong>the</strong> contract: (from left) Serdar Bulut, MD/W&H Turkey, Thomas Lengenberg, W&H Sales Area<br />

Manager/Europe Middle East, Enver Bakiogˇ lu, MD BAK Ambalaj, Mehmet Emin Bozdagˇ , MD/Bareks Plastik,<br />

Alpan Baran, MD/Baran Ambalaj and Serdar Mutlu, Production Manager/Bareks Plastik.<br />

same time providing enhanced power<br />

efficiency.<br />

“All things considered, <strong>the</strong> system incorporates<br />

a number of technical solutions<br />

which combine into unprecedented<br />

efficiency in <strong>the</strong> production of barrier<br />

film”, explains Dr. Torsten Schmitz,<br />

Manager / Cast Film at W&H. “As an added<br />

benefit, <strong>the</strong> ability to save waste, while at<br />

<strong>the</strong> same time downgauging film thickness<br />

and cutting energy usage, also brings<br />

about a positive ecological effect.”<br />

Johannes Remmele, Managing Director<br />

SÜDPACK Verpackungen GmbH<br />

CHemPaCk Boasts Varex BloWn Film <strong>line</strong><br />

ThE REquiREmEnTs<br />

spEcifiEd foR<br />

ThE w&h EquipmEnT<br />

wERE quiTE EXAcTing.<br />

5


Print and PaCkaging<br />

suCCess stories<br />

6<br />

image-to-Print<br />

After a successful prelude in Russia and<br />

Malaysia, <strong>the</strong> Rotogravure Technology &<br />

Innovation Days committee continued its<br />

tour with events in Bangkok / Thailand and<br />

São paulo / Brazil. Under <strong>the</strong> heading<br />

“Image­to­print”, <strong>the</strong> three partners W&H,<br />

Janoschka and Sun Chemical were<br />

presenting technologies and innovations in<br />

gravure package printing. Visits on <strong>the</strong><br />

second event day to local companies<br />

using state­of­<strong>the</strong>­art W&H technology<br />

and innovations in gravure package<br />

printing proved to meet with special<br />

interest.<br />

More than 100 attendants from all parts of<br />

<strong>the</strong> Sou<strong>the</strong>ast Asian as well as South Asian<br />

region were presented with eight lectures<br />

on technical innovations in <strong>the</strong> field of<br />

wiTh VisTAflEX, wE‘VE goT woRld-lEAding<br />

TEchnology Allowing us To pRoducE<br />

supERb pRinT quAliTy AT mAXimum spEEd<br />

As wEll As giVing us opTimAl flEXibiliTy<br />

wiTh pRinT spEcificATions.<br />

printing press technology, print cylinders,<br />

and inks, before visiting our customer TpN<br />

Foodpack to see for <strong>the</strong>mselves what our<br />

HELIOSTAR GH is able to do and how well<br />

it performs in <strong>the</strong> field. Located in a quite<br />

futuristic production environment, <strong>the</strong><br />

8­colour gravure press was running a job<br />

with a demanding print design for a local<br />

brand producer in <strong>the</strong> food industry, at a<br />

speed of 300 m/min. Visitors were able to<br />

see for <strong>the</strong>mselves <strong>the</strong> superb print quality<br />

produced under real production conditions.<br />

The event in São paulo attracted more<br />

than 100 experts from <strong>the</strong> Latin American<br />

industry. A program highlight on <strong>the</strong><br />

second day was a live demonstration in<br />

<strong>the</strong> highly modern and perfectly organised<br />

production facilities of our customer<br />

“With VISTAFLEX, we‘ve got<br />

world­leading technology<br />

allowing us to produce<br />

superb print quality at<br />

maximum speed as well as<br />

giving us optimal flexibility<br />

with print specifications”, say<br />

Stephan and Claus Jung,<br />

Managing partners of JUNG<br />

DESIGN ­ JUNG VERpACkUNGEN GMBH<br />

based in Steinmauern near Baden­Baden/<br />

Germany. The family enterprise with<br />

business activities <strong>the</strong> world over,<br />

specializes in <strong>the</strong> development and<br />

manufacture of fancy and gift­wrap papers<br />

as well as carrier bags for <strong>the</strong> specialty<br />

retail trade and <strong>the</strong> luxury products<br />

industry. They recently commissioned <strong>the</strong>ir<br />

first VISTAFLEX CM. The machine has a<br />

working width of 1570 mm and is designed<br />

to print high quality paper and film at<br />

speeds up to 600 m/min. “The unique<br />

operating concept of <strong>the</strong> VISTAFLEX with<br />

The VISTAFLEX at JUNG DESIGN prints<br />

luxury gift wrap at speeds up to 600 m/min.<br />

Left:<br />

The HELIOSTAR GH at TPN<br />

Foodpack is operating at 300 m/<br />

min. Technical sales consultant<br />

Bülent Dil (r.) explaining <strong>the</strong><br />

details.<br />

Right:<br />

The Finepack Ltda. operator crew<br />

is proud of <strong>the</strong> new 9-colour<br />

HELIOSTAR SL.<br />

Finepack Ltda. in San pedro. The<br />

HELIOSTAR SL had been commissioned<br />

only shortly before <strong>the</strong> presentation and<br />

convinced <strong>the</strong> attending guests with a<br />

demanding 9­colour print design at a<br />

speed of 400 m/min. With <strong>the</strong> installation<br />

of <strong>the</strong> HELIOSTAR SL, Finepack Ltda. is<br />

launching into <strong>the</strong> gravure sector as a top<br />

provider in <strong>the</strong> Brazilian marketplace.<br />

Because of <strong>the</strong> highly positive response,<br />

a follow­up series of events under <strong>the</strong><br />

heading “Image­to­print” is already being<br />

planned for 2011 and will address important<br />

gravure markets. The main target is to<br />

afford even more gravure printers <strong>the</strong><br />

chance to get an insight into W&H‘s<br />

innovative engineering technologies.<br />

sometHing Very sPeCial<br />

front loading capability has<br />

convinced us from <strong>the</strong> very<br />

beginning, and <strong>the</strong> performance<br />

of <strong>the</strong> press over <strong>the</strong> first<br />

weeks of production has<br />

surpassed our expectations in<br />

terms of output, print quality,<br />

and minimized job change<br />

times.”<br />

The outstanding feature of <strong>the</strong> VISTAFLEX<br />

concept is <strong>the</strong> VISTA­pORT robot allowing<br />

fully automated changeover of plate<br />

man drels, sleeves, and anilox rolls. With<br />

<strong>the</strong> machine running, VISTA­pORT<br />

completes <strong>the</strong> changeover in near to no<br />

time and without <strong>the</strong> operator needing to<br />

intervene, affording him time to attend to<br />

o<strong>the</strong>r work. The result is increased efficiency<br />

and productivity.<br />

Stephan and Claus Jung are happy with<br />

<strong>the</strong> attractive investment into <strong>the</strong> future.<br />

“The VISTAFLEX is something very<br />

special”, Claus Jung puts it briefly. And<br />

this statement is also meant to apply to<br />

<strong>the</strong> superb quality gift wrap now being<br />

printed on <strong>the</strong> VISTAFLEX.


tHe 100tH miraFlex goes to tHe uk<br />

Based Paragon Print & PaCkaging grouP<br />

The MIRAFLEX CM is a true success model.<br />

ThE miRAflEX cm complETEly mEETs<br />

ouR REquiREmEnTs of REducing<br />

sET-up TimE To A minimum.<br />

tHree at one go<br />

Investment projects including more than<br />

just one bagging <strong>line</strong> are not actually<br />

anything out of <strong>the</strong> ordinary. What is out of<br />

<strong>the</strong> ordinary is <strong>the</strong> fact that a renowned<br />

German chemicals company in order to<br />

modernise <strong>the</strong> packaging process for its<br />

specialty products decided to go for <strong>the</strong><br />

entire program of W&H FFS bagging<br />

systems, as has just happened. During <strong>the</strong><br />

project meetings it soon became clear that<br />

because of <strong>the</strong> partly extremely difficult to<br />

handle materials involved, <strong>the</strong> extraordinarily<br />

comprehensive and diversified<br />

spectrum of applications and requirements<br />

to be covered by <strong>the</strong> new packaging<br />

equipment could not be met by just a<br />

single machine type. The perfect solution<br />

proved to be a combination of <strong>the</strong> three<br />

bagging systems DIAMANT, TOpAS, and<br />

OpAL, with <strong>the</strong>ir respective specific<br />

application possibilities and strengths.<br />

The DIAMANT was found to be <strong>the</strong> perfect<br />

solution when it comes to highly aggressive<br />

products, because its bag making<br />

section is separated from <strong>the</strong> filling<br />

section, in this way protecting <strong>the</strong> bag<br />

making process again adverse influences<br />

from <strong>the</strong> product.<br />

As an ideal supplement, <strong>the</strong> OpAL lends<br />

itself to o<strong>the</strong>r demanding products, also<br />

including aggressive fine chemicals which<br />

because of <strong>the</strong>ir toxic or explosive<br />

properties or due to <strong>the</strong>ir heavy flowing<br />

nature are difficult to handle and cannot be<br />

adequately bagged with conventional FFS<br />

technology. Designed in full compliance<br />

with ATEX standards, <strong>the</strong> OpAL features<br />

an auger feed system. The product is fed<br />

into <strong>the</strong> bag from <strong>the</strong> bottom up – with <strong>the</strong><br />

chute outlet positioned below <strong>the</strong> filling<br />

level – which eliminates dust during <strong>the</strong><br />

filling process.<br />

TOpAS, <strong>the</strong> third machine included in <strong>the</strong><br />

investment scope, is designed for <strong>the</strong><br />

packaging of hygroscopic (i.e. moisture<br />

absorbing) polyamides making special<br />

demands on <strong>the</strong> bagging process and <strong>the</strong><br />

bag material being used. To protect <strong>the</strong><br />

product against <strong>the</strong> ingress of moisture<br />

even over long transport distances, <strong>the</strong><br />

bags are made out of aluminium laminate,<br />

with air evacuation taking place after filling.<br />

Even with such critical bag wall materials,<br />

<strong>the</strong> TOpAS guarantees perfect seal quality<br />

and maximum efficiency of <strong>the</strong> bagging<br />

process.<br />

paragon Flexibles, a division of <strong>the</strong><br />

paragon print and packaging Group,<br />

located in Gainsborough Lincolnshire has<br />

ordered <strong>the</strong>ir third MIRAFLEX CM since<br />

purchasing <strong>the</strong> first at Drupa in 2008.<br />

“print quality, performance and a customer<br />

service model of excellence are what<br />

define our business. We demand <strong>the</strong> same<br />

high standard from our suppliers and <strong>the</strong>ir<br />

products. The decision to buy our third<br />

MIRAFLEX CM was made with <strong>the</strong>se<br />

criteria in mind. We are confident we have<br />

purchased what is likely to be <strong>the</strong> best<br />

selling central impression flexo press<br />

available today.” Mark Lapping MD<br />

paragon print & packaging Group.<br />

paragon Flexibles is a fast growing flexible<br />

packaging company that embodies <strong>the</strong><br />

paragon print & packaging Group model<br />

of excellence ethos.<br />

Uk Market leaders in supplying optimised<br />

filmic solutions to <strong>the</strong> fresh and chilled<br />

food market sector. paragon Flexibles<br />

have built an enviable reputation for quality<br />

and service in <strong>the</strong> Uk, supplying packaging<br />

materials for sectors such as<br />

produce, Cooked meat and convenience<br />

OPAL, <strong>the</strong> bagging system specially designed for demanding products.<br />

extra Winter 2010 | issue 18<br />

food. Due to <strong>the</strong>ir demanding service<br />

proposition, paragon Flexibles needed a<br />

machine combining rapid changeover<br />

ability while delivering superb print quality<br />

that does justice to <strong>the</strong>ir paragonHD<br />

reprographic capability . “The MIRAFLEX<br />

CM completely meets our requirements of<br />

reducing set­up time to a minimum<br />

and can deliver our industry leading<br />

paragonHD print quality expectation”,<br />

says Mark Lapping.<br />

Numerous EFTA awards won by paragon<br />

Flexibles testify to <strong>the</strong> excellent print<br />

quality of <strong>the</strong> MIRAFLEX CM press. The<br />

new 8­colour MIRAFLEX CM with in­<strong>line</strong><br />

unit is scheduled to commence production<br />

at <strong>the</strong> paragon Flexibles Gainsborough<br />

facility in spring 2011.<br />

7


extra Winter 2010 | issue 18<br />

Breaking neWs<br />

neWs From tHe W&H grouP<br />

Polyrex noW a garant ProduCt<br />

Since August 2010, our subsidiary Garant<br />

Maschinenhandel has been entrusted with<br />

<strong>the</strong> complete product <strong>line</strong> of pOLYREX<br />

plastic bag machines as ano<strong>the</strong>r supplement<br />

to Garant‘s program of new machines.<br />

With <strong>the</strong> addition of <strong>the</strong> pOLYREX,<br />

Garant is now in charge of W&H‘s complete<br />

bag making machinery program.<br />

Customers can, <strong>the</strong>refore, rely on continued<br />

competent and comprehensive advice<br />

and service for <strong>the</strong>se machines also in<br />

future. Following earlier transfer to Garant<br />

of <strong>the</strong> paper bag machines TRIUMpH and<br />

MATADOR as well as of <strong>the</strong> SOLOFLEX<br />

flexo printing press and <strong>the</strong> ALINA 700<br />

tail­end printer, which are today being<br />

built, marketed and serviced by Garant<br />

under licence from <strong>Windmöller</strong> & <strong>Hölscher</strong>,<br />

<strong>the</strong> transfer of <strong>the</strong> pOLYREX product <strong>line</strong><br />

was a logical follow­up step.<br />

8<br />

dr. falco paepenmüller<br />

The filmEX team: (from l.) david finnemore, markus stumpf,<br />

dr. Torsten schmitz, and Robin Roy barman.<br />

Dieter Schallenberg, MD Garant (l.), is happy with <strong>the</strong> extended product range. Customers interested in <strong>the</strong><br />

POLYREX are being competently looked after by Silvia Ventker and Ulrich Kühne.<br />

Effective 1 September 2010, dr. Falco Paepenmüller<br />

has been nominated manager of <strong>the</strong> W&H business unit<br />

‘extrusion equipment’ as well as managing Director of<br />

W&H subsidiary Klaus Reinhold maschinen- und<br />

Gerätebau GmbH & Co. KG.<br />

After finishing studies in mechanical engineering and<br />

subsequent doctorate at RWTH Aachen, Dr. Falco<br />

Paepenmüller joined W&H in September 2007 and has<br />

since been responsible for <strong>the</strong> film winder product <strong>line</strong>.<br />

Also effective 1 September 2010, david Finnemore has<br />

joined <strong>the</strong> FILmEX team as technical sales consultant/<br />

cast stretch, which is headed by Dr. Torsten Schmitz.<br />

Born in <strong>the</strong> UK, <strong>the</strong> graduated engineer was employed as<br />

Vice President/Sales at Gloucester Engineering Europe<br />

GmbH with business location in Vienna/Austria. Along<br />

with Dr. Torsten Schmitz, markus Stumpf, and Robin Roy<br />

Barman, he will be your contact when it comes to<br />

economical solutions for <strong>the</strong> production of high quality<br />

flat film. The reinfor<strong>cement</strong> of our cast film team signifies<br />

<strong>the</strong> importance we attach to this product <strong>line</strong>.<br />

windmöllER & hölschER<br />

Postfach 16 60<br />

49516 Lengerich/Germany<br />

telephone: +49 5481 14-0<br />

telefax: +49 5481 14-2649<br />

e-mail: info@wuh-group.com<br />

www.wuh-group.com<br />

publisher:<br />

Management Board<br />

WINDMÖLLER & HÖLSCHER KG<br />

Editor:<br />

Elisabeth Braumann, M. A.<br />

Postfach 16 60<br />

49516 Lengerich/Germany<br />

telephone: +49 5481 142929<br />

telefax: +49 5481 143355<br />

e-mail: extra@wuh-group.com<br />

Languages: German, English,<br />

Spanish, French, Italian, Russian,<br />

Chinese, Portuguese<br />

No part of this publication may<br />

be reproduced or published<br />

without <strong>the</strong> publisher’s approval.<br />

© WINDMÖLLER & HÖLSCHER<br />

Printed in <strong>the</strong> Federal Republic<br />

of Germany<br />

production:<br />

Blattschuss – Agentur für<br />

Aufmerksamkeit GmbH & Co. KG<br />

ISSN 1610-5672<br />

(English ed.-Print)<br />

ISSN 1611-0625<br />

(English ed.-Internet)<br />

AD, AM, AQUAREX, ARCOMAT,<br />

DIAMANT, FILMATIC, FILMEX,<br />

GREENOVATION, HELIOSTAR,<br />

MIRAFLEX, MULTICOOL,<br />

OPAL, OPTIFIL, OPTIMEX,<br />

TOPAS, TRANSYSTEMS, VAREX<br />

and VISTAFLEX are registered<br />

trademarks of WINDMÖLLER &<br />

HÖLSCHER KG in some<br />

countries.<br />

ALINA, MATADOR, POLYREX,<br />

SOLOFLEX and TRIUMPH<br />

are registered trademarks of<br />

Garant Maschinenhandel GmbH<br />

in some countries.

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