the world's fastest cement sack line - Windmöller & Hölscher
the world's fastest cement sack line - Windmöller & Hölscher
the world's fastest cement sack line - Windmöller & Hölscher
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
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.