Only waste? - Model Holding AG

No. 65 | 2nd Quarter 07
BOX
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Editorial
Waste worlds · Throwaway society
Waste worlds · Environmental protection without boundaries
Lyreco · Recycling: not just from an ecological viewpoint
artistGuide · Products
Rhône-Clichés · Interesting alternative for producing printing plates
Robatech · Ecological packaging solution
STIHL Wil · MODELRecycle
InnoPlastics · Recycling process
Schenk Recycling · The business of recycling – value in waste
Model AG · Exact, fast and clean – the way to process corrugated board
International School Kreuzlingen Konstanz · Preview · Publication details
Only waste?

EDITORIAL
2
Valuable waste?
Almost all the goods we consume end up as
waste. Precisely for this reason, western consumer
societies with their huge consumption
of goods attach great importance to reliable,
clean waste disposal.
In this respect, Switzerland’ has a commendable
record. Whereas in the 1980s and 1990s
waste disposal was a major source of environmental
pollution and a nuisance for many of
our country’s inhabitants, since then Switzerland
has made considerable progress. Although
success in cutting consumption of raw
materials by producing more efficient and
longer-lasting goods is still the exception, government
regulations have drastically reduced
the concentration of harmful substances in
many products. All plastics, for instance, now
have to be cadmium-free.
In the past 20 years the increase in the amount
of waste produced has been contained by separate
collection of different waste fractions.
Alongside waste incineration, refuse separation
is the second prong of Swiss waste management
policy. Better recycling is another important
measure to reduce environmental pollution;
today considerably more raw materials are
returned to the circular flow of goods and services.
In Switzerland, the proportion of recycled
waste from households and small-scale commercial
operations and industry has risen from
approx. 25% in 1988 to some 51% in 2005.
Various factors are behind this success, including
the provisions of the regulation concerning
beverage containers, which threaten the introduction
of a deposit on containers if minimum
recycling quotas are not met. Other important
factors were the introduction of voluntary collection
and funding systems by business, e.g.
for PET drinks bottles, cans and paper; information
provided by communes, waste collection
operators and business; and finally polluterbased
financing, i.e. fees charged for collecting
sacks of non-recyclable refuse. In the final
analysis, this success depends on motivating
all inhabitants to cooperate. Neighboring
countries have different legal provisions, with
the result that further fractions are collected
separately. For instance, in contrast to statutes
in neighboring countries, Swiss legislation
does not solely target packaging: Switzerland
does not have a general regulation governing
packaging, nor is one planned. On the other
hand, there are provisions that apply to specific
packaging types and properties.
As the quality of recyclable raw materials is
currently good, they command good prices in
the market for recovered materials. However,
new product developments (e.g. new product
labels with metal-containing semiconductor
chips) can impair the quality of collected material
and, in turn, upset a well-functioning system.
This needs to be addressed. The aim
should be to ensure that a large part of all
waste flows back into the economy in the form
of cleaned and sorted secondary raw materials.
All of these recycling systems not only help to
reduce environmental pollution – recycling often
uses fewer resources than disposal and
new production –, but recycling also is often
considerably cheaper than disposing of waste
in waste incineration plants. At the same time,
there is no need to recycle at all cost: «Waste
should be recycled if this causes less environmental
pollution than waste disposal and the
corresponding new production. In addition, recycling
needs to have a solid long-term economic
basis.» (Mission statement of the Swiss
Waste Management Industry 1986).
The ban on the direct disposal of non-recoverable
waste and the major improvements in
waste incineration have significantly reduced
environmental pollution. A modern waste incineration
plant can energetically convert waste
into heat and power that can also be used in industrial
processes in the vicinity. Waste recycling
thus makes a key contribution to the sustainable
use of resources. This is a sensible
use of, in particular, refuse that contains compounds
and contaminated and mixed waste.
Furthermore, there are signs that the energetic
potential of other non-recoverable fractions
may soon be put to good use, especially the
processing of green waste, garden trimmings
and possibly wood chips to fuel. Now this
would unexpectedly turn waste into a valuable
asset.
Dr. Hans-Peter Fahrni
Federal Office for the Environment FOEN

Throwaway society
The throwaway society is a phenomenon
of the western industrialized countries.
In economies of scarcity – as in
the Third World – people re-use things
over and over again out of necessity.
On the other hand, one advantage of
these economic conditions is the low
level of waste accumulation.
What do we mean by throwaway mentality?
A non-sustainability-based attitude and the
thoughtless disposal of litter (e.g. bottles, paper,
beverage cans, etc.) in the environment, in
the street or in green spaces immediately after
completion of consumption.
The throwaway mentality or throwaway society
is underpinned by the production and consumption
of increasing quantities of unnecessary,
short-dated goods. Today, many high-quality
and correspondingly expensive products
(electronic devices being a case in point) are
often also so designed that even minor defects
cannot be repaired or at a cost out of all proportion
to the price. Critical voices argue that the
only purpose of this is to force the consumer
to buy new equipment, which, in turn, produces
unnecessary waste.
In industrialized countries the term «refuse
emergency» has entered the vocabulary. This
does not describe a state of too much refuse,
but the lack of places to dispose of some or all
of it. It applies in particular to commercial
waste. Meanwhile, in other parts of the world
people are dealing with emergencies of a very
different nature.
Living from and with refuse
For thousands of people rubbish tips such as
Smoky Mountain in Manila in the Philippines
are both home and a source of work and income.
The inhabitants of Smoky Mountain, for
instance, have in effect created functioning recycling
programmes. They convert the «unwanted»
waste into valuable income-generating
materials. So why are the inhabitants being
evacuated? In tropical countries, heavy rains
regularly cause devastating landslides in rubbish
tips. The rainwater also carries noxious
and unsanitary substances. Moreover, the
stench and fumes are injurious to the inhabitants’
health. They suffer from respiratory problems,
nausea, headaches and other complaints.
National and international organizations
are helping to draw up and implement cost-effective
programmes. The goal is not only to
produce less waste, but also to recycle it properly.
However, the emphasis is on measures to
help the inhabitants. Resettlement has deprived
many of them of their source of income.
Hence, they are being trained in the professional
recovery of materials from waste as well
as new possibilities of processing it. More than
100 housewives process old newspapers and
telephone books into tissues and accessories
for sale in the Australian market. A line of fashionable
clothing has also been established to
generate additional jobs.
WASTE WORLDS
Even though older Smoky Mountains have
been grassed over, the dangers associated
with them have not yet been banished. New
rubbish tips are being created. Better organization
has attracted new «inhabitants». The human
race continues to produce increasing
quantities of waste. So, while mothers cultivate
their vegetable patches on what are now
«green mountains», their children play in the
rainwater run-off – completely disregarding the
dangers of waterborne diseases. (Source and
illustrations: Asian Development Bank, Manila,
Rita Festin)
3

WASTE WORLDS
4
Environmental protection
Environmental protection is a topic of
discussion everywhere. However, it is
not managed in the same way in all
countries. The Model Group operates in
various European countries and among
even these there are differences. The
current issue of Model Box highlights
various perspectives. A short description
of the situation in the Philippines
will be found on Page 3. Rules and regulations
are somewhat stricter in
Switzerland. Particular attention is given
to the refuse incineration plant in
the Canton of Thurgau, as this is where
the headquarters of the Model Group
are located. The situation in Poland,
where the problems are different again,
offers another comparison.
Thurgau waste incineration plant KVA
Thurgau – the organization
Environmental protection is a key element in
the corporate culture of the KVA Thurgau Association.
KVA Thurgau operates a business that
is compliant with environmental legislation and
regards itself as a competent, self-critical service
provider in the field of environmental protection.
KVA Thurgau has adopted selective
measures to promote environmental aware-
ness and reduce waste both within its catchment
area and beyond. It employs a safe and
environmentally compatible technology to dispose
of residual materials. KVA Thurgau practises
open dialogue to reinforce the trust of its
member communes, the population, its employees
and its partners.
KVA Thurgau uses a quality and environmental
management system to ensure that its operations
are transparent at all times.
The KVA Thurgau Association actively provides
information and consulting to promote the
avoidance, reduction and recycling of waste on
the part of residential developments, commerce
and industry. Unavoidable waste is collected
and sorted professionally and recycled
using an environmentally compatible technology
and thermally disposed of and/or deposited
in landfills. KVA Thurgau gives support
to the member communes in all questions related
to waste and coordinates the different activities
among the communes and beyond the
canton’s borders.
Instrumental in achieving clean waste management,
fifty employees work at the waste incinerator
plant in Weinfelden, the RAZ Hefenhofen
regional collection center and the landfills
in Pfyn and Kehlhof.
The Thurgau waste incineration plant entered
into operation in 1997. In the good ten years
since then it has provided a clean, thermal
means of disposing of well over a million
tonnes of waste.
KVA Thurgau values Thurpapier’s
competence in cardboard disposal
For a number of years the KVA Thurgau Association
has collaborated with Thurpapier, a Model
Group company, which recycles a large part of
the recovered paper and cardboard waste.
Dieter Nägeli, divisional head of KVA Thurgau is
very satisfied: «Our cooperation functions perfectly.
We are involved primarily in negotiating
contracts and prices; operational matters are
decided directly between the collecting partners
and recyclers.»
Outsourcing of recoverable paper
collection
In particular, local societies and schools top up
their club or classroom funds by collecting
waste paper and cardboard. Collection is coordinated
directly with Texta AG, St. Gallen and
deliveries are taken to Thurpapier. The residents
of Thurgau collect some 3,600 tonnes of
cardboard a year, equal to 19 kg per inhabitant.
This requires well thought-out logistics. Thanks
to years of cooperation, everything functions
smoothly.
KVA Thurgau also supplies Thurpapier fully with
process steam in order to reduce the combustion
of oil and gas. This results in an excellent
CO2 balance.
Collecting alone is not enough
As Dieter Nägeli points out: «Previously, everything
was waste; today it is clear that besides
waste there are also recyclable materials and
raw materials. As raw materials are used up,
the importance of recycling is growing». As a
producer of recycling articles, Thurpapier plays
a big part in ensuring that the products obtained
from waste are recycled for consumption.
However, consumers also have to shoulder
responsibility: «The cycle only functions if
end users consciously buy and use as many recycled
products as possible.» In other words,
every one of us is called upon to make a personal
contribution to environmental protection.

without boundaries
Waste management in Poland
Waste management policy in Poland is regulated
by Polish and EU law. In other words,
all EU regulations have legal force in Poland.
Of the many guidelines and statutes, those
relating to the following areas are the most
important:
1. The country’s waste management industry
2. Recycling of used cars that have been dis -
posed of
3. Electronic goods and household appliances
4. Packaging and recoverable packaging
5. Waste management law
6. Manufacturer’s obligation (including, among
other things, product and landfill charges)
7. Environmental protection
8. Cleanliness in communes (the smallest,
most immediate level of self-government)
From 2009 onwards, in all countries (with the
exception of Poland, Cyprus and Malta) the
content of recycled material in packaging must
be at least 55%.
A selection of regulations in Poland
In most cases, Poland has adapted its national
ordinances to those of the EU. However,
Poland has, for instance, been given a grace
period until 2014 to introduce stricter regulations
governing the recycling of packaging.
At present, packaging has about 25% recycled
content; this is forecast to rise to 36.6% in
2007.
Poles have to separate waste. Residents of the
country are obliged to dispose of glass, metal,
plastic, paper (all in segregated bags) and biological
waste separately. Furthermore, all citizens
have to take used consumer-goods batteries
to collection points or return them to
dealers or manufacturers. In certain sectors different
principles of waste management apply,
e.g. medicine, electronic appliances, hazardous
materials, excrement, chemicals, etc.
Used cars are an enormous problem. What
should be done with cars that are no longer
roadworthy? To date Poland has imported
some two million very old cars. To impose
some order, all outlets that sell more than 1000
cars a year are obliged to scrap the used cars.
Otherwise they have to pay a fee of about 130
euros per car. The scrapping facility may not be
more than 50 km from the car owner’s registered
address. Facilities responsible for scrapping
or breaking up cars have to recycle 85%
of the car by weight, otherwise they, too, have
to pay fees.
Quantities of waste in Poland in 2004
(in million tonnes)
Total 11.802
Biological waste 2.486
Paper and cardboard 2.114
Plastic 1.529
Glass 0.889
Metal 1.521
Forecast quantities of waste (in million t):
2014: 12.290
2018: 12.962
Forecast for recycling in 2007:
paper and cardboard 48% (highest level)
glass 40%
plastic 25%
Quantities of recycling in Poland in 2006
compared to the EU (in million tonnes)
Actual Minimum quantities
quantities for recycling according
2006 to the EU (in 2008)
Plastic 0.070 0.1627
Paper and cardboard 0.825 0.9763
Glass 0.400 0.6686
Based on the national regulation on waste
treatment
5 million tonnes
4
3
2
1
0
1985 1990 1995 2000 2005
WASTE WORLDS
Quantities of waste in Switzerland in 2005
(in million tonnes)
Total 15.671
Building waste 11.9
Residential waste 4.99
of which recycled: 2.41
waste paper 1.24
glass 0.3
electrical and electronic
appliances 0.0825
PET bottles 0.0316
Incinerated waste 3.14
Incineration capacity of waste incineration
plants 2005: 3.377
Situation in Switzerland
Recycling quotas:
Glass: 96%
Paper and cardboard: about 77%
PET beverage bottles > 75%
Total residential waste in Switzerland in 2005: 4.94 million tonnes
Development in collection of separated waste and of residential waste (source: BAFU 2007)
Sep. coll. 51%
2.5 m t
335 kg/inhab.
■ Div. recycling
■ Glass
■ Paper
■ Compost
■ Residential waste
(2.44 m t, 327 kg/inhab.)
5

LYRECO
6
Recycling: not just from
Interview with Erwin Fries, Logistics
Director, Lyreco Switzerland
Founded in 1926, Lyreco AG is a B2B
office supplies company with 11,000
employees worldwide. The former
Büro-Fürrer AG company has been part
of the Lyreco Group since 2005. Its 400
employees in Switzerland generate annual
sales of more than CHF 162 million.
Lyreco is principally concerned
with bundling the flow of goods so as
to simplify the purchasing of corporate
office supply materials.
In Switzerland, Lyreco AG operates under two
brands: for office and coffee supplies under
the Lyreco label, and office furniture under the
Büro-Fürrer label. The company’s clientele is
drawn from across the business spectrum in
Switzerland. Both small firms and large companies
such as UBS order goods from Lyreco. Today,
online orders account for 70% of Lyreco’s
sales. This corresponds to a volume of about
4000 packages a day that are sent all over
Switzerland. To ensure a smooth delivery service,
Lyreco has to have reliable partners and
suppliers – in respect not only of delivery
times, but also of quality and price. Although
certification still plays a subordinate role in our
industry, it is becoming an increasingly prominent
factor.
Customers that place their orders by 5 pm will
have their goods delivered personally by a
driver on the next business day. To make this
happen, more than 110 employees work different
function-based shifts in logistics between
5 am and, as a rule, about 7 pm. The logistics
department divides the day into two shifts:
the blue shift and the red shift.
Blue shift (inbound process)
In the morning the conveyor belt is used to
move new supplies of goods to the storage
area. Merchandise is delivered, controlled and
recorded at an early hour. Then it is placed in
blue-labelled reusable packaging and transported
by conveyor belt to the appropriate
warehousing zones for storage. This simple
procedure ensures that the potential of the
packaging line is optimally exploited and the
«traffic volumes» of the forklift drivers are kept
to a minimum.
Red shift (outbound process)
This afternoon shift deals with customer orders.
Orders are either recorded in the central
SAP ERP system or automatically integrated
from the online shop and then forwarded to
distribution centre control. The first step is to
calculate the volume of the order and assign
the correct packaging to it, which is marked
red. The empty packaging in different sizes is
automatically delivered by conveyor belt to the
various packing stations where the corresponding
articles have been sent by a paperless
procedure. The final step in the packaging line
is quality control. After that, the deliveries are
loaded onto SBB rail wagons, which transport
them to the four hubs in Switzerland (Geneva,
Berne, Ticino and St.Gallen) or directly to the
drivers for local distribution in the region
Zurich, Aargau, Basel and Lucerne. The packages
arrive at their destinations early in the
morning, where they are sorted and delivered
directly to customers by a fleet of trucks.
Empty Lyreco packaging put out by customers
is picked up by the drivers and taken back to
the distribution centres. This combined railand-road
concept has proved to be an optimal
solution, and one that also makes a valuable
contribution to environmental protection.
Where did the idea of using reusable
packaging come from?
Lyreco has always proactively tried to translate
customer needs into performance. In recent
years it has become apparent that customers
have grown more aware of ecological issues.
Customers would also like to cut down on superfluous
material. The choice of five packaging
sizes meets this need. Reusable cartons
also obviate the need for additional packaging
for return and sample consignments. The customer
simply places the returns in the reusable
packaging. Approx. 50% of all dispatch packaging
is sent back with our drivers and more than
30% can be reused in the packaging process.

Cardboard pre-cuts
produced
an ecological viewpoint
Raw materials
procured
Pre-cuts
stored
Waste cardboard
recycled
Materials required
delivered to Lyreco
Reusable box
fed back into
recycling process
Model/Lyreco reusable boxes: ecological cycles
Lyreco’s environmental commitment
In addition to reusable packaging and the general
distribution using SBB (Cargo), Lyreco took
other steps to protect the environment. For instance,
empty toner and inkjet cartridges, batteries,
etc. can be returned free of charge for
proper disposal. All waste that is collected or
produced is sorted and then professionally disposed
of. The product catalogue of more than
480 pages is printed on 100% recycled paper.
Partners as well as employees are encouraged
to actively participate in this kind of environmental
protection. Lyreco in Switzerland is
currently working towards certification to
ISO 14001.
Reusable boxes
returned
Reusable box
produced/assembled
Order delivered
to Lyreco’s
end customer
Customer order
picked &
prepared
What about your employees? What can
they expect from you?
Lyreco has signed on to the Global Compact.
This lays down clear principles in respect of
human rights, social labour standards, environmental
protection and combating corruption.
These principles are regularly reiterated to
employees and actively practised.
Will the company need the services of a
distribution centre in the future as well?
Owing to the spread of globalization, internationally
active customers have a growing interest
in negotiating single buyer contracts for
their worldwide operations. The better in-
LYRECO
formed we are about our customers’ needs,
the better we can advise them and harmonize
volumes and prices on a global basis. Certification
to ISO 9001 and 14001 will further increase
demands on suppliers and logistics.
It remains an exciting market that is bound to
offer a lot in the way of new challenges that
call for new solutions.
7

ARTISTGUIDE
Hengstenberg Bio Display
The Hengstenberg range of organic products
was launched last year. Whether in bags, jars
or displays, the items have a unifying, instantly
recognizable label. This display presents the
entire 12-product Biolinie range in a clear, wellstructured
arrangement in supermarkets and
department stores.
Frucht-Tiger
This Frucht-Tiger (fruit tiger) offers children a
way to quench their thirst. The tiger surrounded
by fruit is an important element of this
packaging. The tiger is flexo printed on the exterior
of the packaging.
The thirst quencher comes in three different
flavors. After opening the package, the consumer
has no problem selecting his choice of
flavor. This solution also has distinct advantages
for dealers. It can, for instance, be transported
without difficulty. At the same time, it
functions as a counter display.
8
Products
Modifast
Slim is the message of
this flexible solution for
Modifast bottles. The
laminated offset
printed display has a
modular construction consisting
of individual trays, a base and a
crowner.
The individual trays are placed directly on the
counter in pharmacies and drugstores. Or the
base can be placed on the floor and the trays
mounted on top to create an attractive, freestanding
display.
Wine boxes for Martel
Martel, a client, required an exclusive-looking,
yet robust wine packaging. A uniform design
has been created for the colorful boxes with inserts
for 6, 3, 2 or 1 bottle. The exterior surface
is printed in two-colored offset design and subsequently
laminated. The interior has a flexoprinted
surface. Delivered as flat packs, the
packaging is quickly converted into practical
boxes that are simple to open and shut.
Marlboro Travelbox
Working in close cooperation with Model,
Philip Morris created this distinguished packaging
for «Marlboro», the most popular cigarette
brand in the world. Each Travelbox is printed in
red, green and gold and holds ten packets of
cigarettes. Travelboxes are produced exclusively
for sale in duty-free shops.
The outer box is specially glued. On opening
this covered packaging you discover an ingenious
insert and a partition strip that ensure optimal
presentation of the product. Embossing
and UV gloss elegantly highlights the Marlboro
logo. Hot-foil printing is used to tastefully
heighten the contrast with the UV matt finish
of the printed outer box.
Put an end to insects
In many places insects are a
real pest. This counter-top display
has been specially developed
for the German market.
Thanks to the dispenser base,
the display is easy to set up. A
cover placed over the display
protects the «Clean Kill» set
so that it can be easily transported.
An eye-grabbing
crowner catches shoppers’
attention at the point of sale.
Spritzer
Still looking for a light, superior quality,
palatable, low-alcohol drink for that special
occasion? Each of these
small bottles is filled with
27.5 cl of Rimuss to satisfy
the taste of the discriminating
individual.
The distinctive gold-andsilver
design of the fivecolor
flexoprinted pack
containing 12 bottles
has an eye-catching appeal.
The printing is fully lacquered for protection.
In addition to the bottles, Rimuss has introduced
drinks in cans. To attract the attention of
the beverage trade to this new product, the
manufacturer has distributed an amusing
gift pack that contains not only a can of
beverage, but also a glass and a straw.
Thanks to its form, content and offset
laminated printing, this very elegant
packaging has triggered a positive market
reaction.

sia soft
The packaging is intended
to mirror the high-quality finish
of this high-end abrasive
from sia. The once
brown outer wrapping has
been enhanced technically as well as
qualitatively. The emotional element of the design
is consciously heightened. Since sia soft
is used primarily in the automotive industry, the
aim is to transfer people’s emotional bond with
cars to this product. The clear varnish finishings
show a beautiful packaging to superb
advantage.
The Association of Lucerne Carpenters
and Joiners
The Association of Lucerne Carpenters and
Joiners intends to present something special at
the Lucerne Trade Fair. Usually visitors stick
their prospectuses in their rucksacks; this year
the Association wanted an alternative means
of carriage. One condition is that the
customers should spend more time
at the Association's stand. In addition,
the giveaway article should be
durable and attract attention. At the
same time, the visitors should come
into contact with the principal material
of carpentry: wood.
The result is the trolleybox, a combination
of corrugated board
and wood. It is not so
easy to leave with a
trolley as one might
think; it first has to be
assembled. Curiosity
and the positive response
of visitors have even led to
waiting times at the stand.
Afterwards, the trolley
makes a useful container
for a variety of things, for
instance around the house or in a
child’s room, or to distribute mail.
Music stool
Gifts for musicians. Music lovers will find
socks, cups, erasers and other ideas for gifts at
the Kübler music boutique. But there is one
thing they won’t find: musical instruments.
Designed especially for Kübler, the music stool
can be used for decorative purposes by music
stores, or to provide seating at
trade fairs. And of course it can
also be used as a practice stool.
Thanks to its prominent motif,
this idea has high advertising
appeal and strikes a chord with
the defined target group.
HotWheels
Children’s eyes light up
when they catch sight of this
fast racetrack. This attractive display,
which Model designed is an extremely
short space of time, was produced for an
Easter sales campaign. The display was placed
at the POS in Carrefour and Coop stores all
over Switzerland. Various Model businesses
were closely involved in this project. The exterior
sections are litholaminated offset printed.
The display was constructed in Weinfelden
and assembled and stocked with the supplied
products in-house.
Haco Mirador display
You don’t only need spices in
the barbecue season. This
multi-section display presents
Mirador spices in luminous
yellow. Model assembles
and fills the ready-touse
display and delivers it
direct to the regional Migros
warehouse. A litholaminated
offset printed crowner is an
additional eye-catcher.
Haco Subito rice
display
Consumers need to be able
to get these tasty
rice dishes
off the
shelves just as
fast as they can prepare
them. The open display
solution meets this requirement.
And the additional
support construction
also allows for problem-free
transportation.
ARTISTGUIDE
Toblerone display –
winner of the 2006
WORLDSTAR
After receiving a Swiss
Star last year, the Toblerone
display has now
capped this performance
with a WorldStar.
For its display Kraft Foods
was looking for a solution
that would allow
the existing shelf trays
to function as display
shelves as well. In the solution
developed the trays are suspended in
a column at an angle so that they slant forwards.
Thanks to the tilt, customers have a
clear view of the entire contents and can
easily extract the Toblerone triangles. The
well-designed arrangement provides space
for 60 400g Toblerone bars. Being on a slant,
the contents automatically slide forward
each time a Toblerone is removed.
Every customer immediately associates the
triangular display column with the famous
Toblerone shape.
The Model designers of the display were
proud to accept the WorldStar award in May.
9

RHÔNE-CLICHÉS
Interesting alternative for
producing printing plates
10
Talking to
Frédéric Valz-Blin
Rhône-Clichés has analyzed
all of its customer
orders for the corrugated
board industry
for a year. This study
determined the percent
fraction of waste for
printing plates of solid
photopolymer plastics.
The manufacturer has
searched for new methods
for further development
of the production
process in order to
shorten their production
times.
In parallel with this study,
Rhône-Clichés requested
their customers from the
corrugated board processing
sector to rethink and redefine
their requirements for
plates and their production.
As a result, corrugated board
processing has demanded
an especially cost-effective
plate which should be
specifically adapted to the
individual orders.
Quality should satisfy the
special requirements for
printing corrugated board.
The fact that qualitative
losses in print will not be
accepted in the various
processes (in-line, die-cutting,
off-line presses) goes without saying.
The study demonstrated that those responsible
for printing in the corrugated board industry
expect the following of the printing plates:
Plates should also enable optimum color
transfer to a print substrate consisting primarily
of recycled material.
The plate material must be compressible
enough to also smooth out or lessen the unevenness
and the washboard effect in the
corrugated board.
Plates must be easy to mount and easy to
handle.
The plate material should ideally be workable
in various Shore hardnesses for halftone and
large-format printing on a plate.
In specific cases, printing plates without adhesive
films or sealing of the plate material
on both sides are requested. In compact
assembly, the liquid photopolymer is poured
directly on the Mylar film.
Goals: removal of the photopolymer material
from the Mylar film and prevention of water
penetrating between the film and plate
material.
Possibility of high-quality printing of the corrugated
board without crushing its height due
to the printing pressure and support pressure.
An express production process, in case of
misprints on the printing press.
High stability.
We have performed studies together with our
customers, also including Model Emballages,
and have decided on the production of plates
from the newest generation of liquid photopolymer.
We will then equip these plates
with all of the technical refinements.
What are the technical advantages of liquid
photopolymer?
The most important quality advantages of the
liquid photopolymer are reasonable costs, flexible
production, good print quality and high environmental
compatibility.
Why have you decided on this possibility?
We are firmly convinced that this is an interesting
alternative which can optimally fulfill the
needs of the corrugated board market.
Economic advantages:
Plates are already available after 60 minutes
instead of 180 minutes.
98% of the unexposed liquid photopolymer
can be recycled.
Ecological advantages:
The liquid solvents which were used in prod -
ucing the conventional plates from solid printing
plates are replaced here with a simple
soap solution. This is thus a long-term investment
in environmental protection, ensuring
compliance with the ISO-14000 standard.
Why don't all plate manufacturers resort to
this technology?
Because it requires considerable finances,
90% of which are eliminated in the corrugated
board sector and which have no benefit for
printing soft polyethylene packaging (plastic
bags, films, etc.) – this is thus a realignment in
development strategy. For us, this liquid
process only supplements the engraving lines
which work with solid photopolymer plates
(traditional and digital method). In addition, it
has not yet been possible to run high-definition
four-color print jobs in Masterflex with this procedure,
although tests with somewhat more
viscous materials are currently running in this
area.
How does the printing plate manufacturing
process work with liquid photopolymers?
A Distribution module: phase 1
1. Preparation: the negative film is placed on a
glass plate and is protected with a light dis -
posable film. Now a layer of the liquid photopolymer
can be applied – simultaneously
with the «film substrate».
2. Exposure: rear and front exposure. In liquid
photopolymers technology, the UV light
sources from above provide for rear exposure,
and the light sources from below provide
for front exposure. All of the transparent
negative parts transmit the UV light and
cure the exposed polymers. The unexposed
areas remain liquid and can be recycled.
B Engraving module: phase 2
Following exposure, all processing proceeds in
the engraving module. The procedure can be
subdivided in 3 steps:
1. Recovery of unexposed polymers: the protective
film is removed and the uncured liquid
polymers are removed with hot compressed
air. This enables recycling of up to
98% of the unused material. Using solid
printing plates, the material in the uncured
areas would have been lost. The liquid
photopolymer recovered in this way is returned
to the «main tank» and can be recycled
up to 100%.
2. Washing out: the last residual liquid is
washed out with soap water (concentration:
approx. 2%).
3. Surface treatment: irradiation with UVC and
UVA completely eliminates the «tacky» surface.
The plate can now be further processed.
Production time: 60 minutes.
Tests and development are ongoing. The continuing
development of new technologies is
highly important to meet both ecological as
well as economic and technical requirements.

Ecological
packaging solution
Interview with Loan Kutter, Marketing
Assistant, and Ruedi Brun, Marketing
Head.
Robatech, a Swiss family-owned enterprise,
is one of the world’s largest
manufacturers of gluing application
equipment and systems. The Robatech
Group operates in more than 38 countries
and has vast experience in the
application of adhesives and sealants.
What is so special about Robatech
equipment?
The machines we produce in our own factories
are always tailored to the customer’s needs.
They all produce an excellent performance. Regardless
of the manufacturing date and the unit
model, the components of the individual machines
are mutually compatible. Customers are
trained to use new machines. Once a customer
knows how to use our units, very little
training is needed for other machines, as the
programming and maintenance is very similar
for all our equipment.
At the start of the process, we make a point of
consulting intensively with our customers in
our experimental laboratory. This enables us to
evaluate the customer’s requirements and, together
with the customer, test different approaches
to solutions on the spot.
How important is packaging for your
machines?
The common characteristic of all our products
is high quality. Thanks to our global network,
these are sent all over the world, which is why
it is of fundamental importance that we can
rely on the equipment reaching the recipient in
perfect condition. In addition, we also have to
be cost-efficient in our use of packaging.
Tell us about your packaging system?
Instead of using environmentally harmful filling
material, our packaging solutions are made exclusively
of corrugated board. It took a lot of
time and effort on the part of Model to develop
the current – very satisfactory – solution. The
core element of the packaging is its ingenious
base. It locks the machines in position on the
floor and guarantees that the machines arrive
in perfect condition. Empty spaces are filled
with small boxes that also serve as packaging
for auxiliary material. The stable base and lid
sections are sized to fit europallets, which enables
us to stack several boxes of machinery
on top of one another for transport. The packages
are so stable that our partners can re-use
them without any difficulty to forward items to
the end-user.
It simplifies matters that we sat down with
Model and standardized packaging sizes. Thus,
although we need different base inserts for the
various machines and components, it is only
one base and one top section for each packaging.
Model helped us to optimize our warehouse.
What do you look for in your partners?
Our partners have to be recognized within their
own industry and customer-oriented. We attach
importance to cost-effectiveness in the industrial
process. To achieve the targets we
have set ourselves we depend on our partners,
because our machines only function if the raw
materials are absolutely free of defects.
Another not insignificant factor is the ratio between
price and performance. In addition, we
have to keep the logistics of integrating the
raw materials delivered to us simple. To
achieve this, we use the so-called Kanban system
in our dealings with our suppliers.
(Editor’s remark: see
Model Box 61)
What contribution
can you make in a
time of scarce raw
materials?
The Robatech company
develops entire
systems for the application
of adhesives.
ROBATECH
Of course, we are an interesting partner for our
customers only inasmuch as we develop units
and application nozzles that use less glue to
achieve the same adhesive strength. For this,
however, we depend on the research and development
of adhesive manufacturers. And in
the final instance, our customers will prefer our
systems only if they give them an extra advantage.
Unfortunately, even ecological solutions have
to be cost-effective, otherwise they cannot be
implemented without strict state control. Increased
substitution of closed nozzle systems
for rollers can reduce adhesive application
weights, which also saves energy and space
when the machine is not in use.
Your products are used in packaging,
printing and graphics, woodworking, car
manufacturing and the textile and hygiene
industries. What do you have to watch out
for in particular with each specific appli -
cation of adhesives?
Materials, the properties of the adhesive, and
the process speeds differ from industry to industry
and application to application. Thanks to
the extensive practical experience of our application
technicians, we can adapt standard solutions
to individual situations.
How do you see the future development in
your market?
Innovation is the key to Robatech’s ambitions
to become a market leader and new products
are the key to active growth in new niches. On
the other hand, we are also steadily gaining
market share in our traditional markets such as
packaging. The Swiss market in particular is
very aware of «total cost of ownership (TCO)»,
i.e. overall cost effectiveness. Thanks to highquality
reliable products, we have a reputation
for operational safety and low maintenance
costs. We believe that in the medium term
these factors will also play a more significant
role in low-wage countries.
11

Recycling process
As a consequence of the Model
Group’s decision to hive off its plastics
recycling business, Martin Model’s
Inno Holding AG and the Texta Group
in Eschlikon together founded Inno -
Recycling AG and InnoPlastics AG to
acquire the plastics recycling operations
of Poly Recycling AG.
InnoRecycling collects
and separates waste
and forwards the fractions
to the appropriate
recycling companies.
Thurpapier receives
recoverable
paper and cardboard
and InnoPlastics, an
affiliated company,
the soiled polyethylene.
This company
processes the plastic
to granulates, which are used to manufacture
new products. Plastics recycling is a young industry
with huge potential, and as the price of
oil needed to make plastics continues to rise,
recycling makes increasing economic and ecological
sense. Not surprisingly, the two companies
have developed splendidly.
Martin Model himself runs InnoPlastics with
enormous personal commitment and pioneering
spirit. We wanted to learn from him how
the plastics recycling market functions and to
what extent there are similarities with the recoverable
paper processing operations of Thurpapier,
a Model Group company. As one might
guess from his name, Martin Model is well
acquainted with both procedures.
Are there any obvious similarities between
the Model Group and InnoPlastics?
Both companies offer solutions that make ecological
sense: products made from waste materials,
which conserves resources. InnoPlastics
produces plastic granulates and the Model
Group papers that are subsequently processed
into corrugated board. Supplies of raw materials
are guaranteed, as these are
produced from local waste ma-
➊
terials and not imported
from or transported
➏
through areas of political
conflict. This groundbreaking
local closed
loop led major customers
such as Denner
to outsource its ➎
entire waste disposal
to InnoRecycling.
➍
Do the collection and recycling processes
at Thurpapier function like those at
InnoPlastics?
Both InnoPlastics and Thurpapier close the
recycling loop, thus offering their clients an
ingenious solution that will become more
important in the future.
The sources of recovered plastics and cardboard
waste are often the same – for example,
distribution centres.
However, there are considerable differences in
processing, although the technical challenges
are similar, whether it be fluctuations in raw
material quality, high wastage on account of
the contaminated raw materials, or the enormous
costs in the field of waste water.
Typically, both companies are also subject to
hefty market volatility, in recent years most
particularly in the huge increases in the costs
of raw materials and rising prices.
Thanks to its higher collection quota and welldeveloped
market for recoverable materials,
Thurpapier has a greater range of raw materials
to choose from. The collection quotas for plastics
are still too small, although the potential is
huge. The possibilities of employing recovered
plastics are far from exhausted. Recycled
plastics can, for instance, also be used as an
alternative fuel.
Both recyclers offer their customers important
advantages, logistical as well as ecological:
supplies on the outward journey, waste disposal
on the return – their raw material can always
be transported on the return journey, the
so-called empty run. This reduces transport
costs.
Is the market situation for recycling processes
in Switzerland similar to that abroad?
Switzerland promotes waste incineration.
Other countries favor recycling. However, high
➋
➌
How the plastic recycling process
works
➊ Deliveries
➋ Cut up
➌ Wash
➍ Separate
➎ Granulate
➏ Use
INNOPLASTICS
commodity prices have helped to improve the
market situation. At present, waste incineration
plants obtain sufficient refuse from abroad, and
collecting recoverable materials pays because
of high commodity prices.
Trends in the recycling business
Rising raw material prices and scarce resources
in conjunction with environmental
policy are bound to translate into increases in
collection quotas and demand for recycling.
There are signs of a growing investment boom
which will make its mark in the market.
Precisely because plastics recycling is a young
industry, reliability – not only in delivery times,
but also in quality – is a significant factor in
guaranteeing the firms’ survival. The same
optimized technology, deep experience and
processing know-how have triggered greater
demand for InnoPlastics’ granulates from
abroad as well. Today, InnoPlastics exports
around 40% of its production volume to neighboring
countries. Italy is one of the most
important markets.
The plastics recycling market remains exciting
since there are as yet no «off-the-peg» machines
and today you still have to lend a
hand and tinker with every single processing
machine.
13

SCHENK RECYCLING
The business of recycling –
value in waste
Karl Schenk founded his company in
Albstadt Laufen (State of Baden Württemberg)
some 50 years ago. It started
off by recycling recovered paper using
a single mechanical baling press. By
1980, the firm had grown so big that it
had to move into new premises. Still a
family business, Schenk Recycling is
now headed by Ute Schenk. The company
specializes in collecting, transporting
and sorting materials.
Schenk Recycling accepts various recyclable
materials, including paper, film, loose polystyrene,
wood and certain related products
such as belts, canisters and edge protection
made of paper. The materials are collected in
different ways in containers of varying sizes.
A number of large companies collect recoverable
material in containers and press containers
located on their premises. Schenk sends its
own trucks to pick these up as soon as they
are full. Smaller containers have been set up in
a number of different places (in particular
schools and other public buildings) and are
picked up on a regular timetable. Some of the
waste material is delivered directly to the gates
of Schenk Recycling. Regardless of how the
goods are delivered, on arrival in Balingen they
are checked by the receiving office. Pre-sorted
materials are placed directly on the conveyor
belt and pressed into bales in the channel baling
press; most of the waste materials, however,
need to be sorted. This is done in two
sorting plants, in which the employees sort the
14
material by hand in accordance with specific
criteria. Then these materials are also pressed
or loaded as loose material into containers. The
bales are stored separately by quality and material
and sold. Only sorted material is valuable.
People who think that recycling is an easy business
are very much mistaken. A study of the
stringent statutory specifications for the industry
is enough to open people's eyes. Although
the regulations deal primarily with waste products,
the entire process is subject to strict legal
provisions. Schenk works exclusively with nonhazardous
materials, as hazardous materials
are subject to even stricter regulations. Besides
the obvious material-related provisions,
there are also a number of statutory regulations
governing in-house operations. In many
cases, skills and licenses apply to people and
not the firm, so that these frequently have to
be renewed when the personnel changes.
The recycling process turns the «waste
product» into a valuable commodity
This is Ute Schenk’s starting point. She has
had herself certified as a waste disposal specialist
and has adapted the company’s
processes accordingly. The trend towards using
recycling materials is growing. The market
for recoverable paper has grown 40-fold in the
past 50 years. Although environmental awareness
suffered a brief setback, it is on the rise
again. Demand for recycled materials is huge,
with the result that prices in the industry are
very volatile. Schenk’s size gives it a crucial
market advantage. The company is now a constant
in the recycling landscape. It is in a posi-
tion to react flexibly and quickly to its customers’
needs, be they paper factories, waste
material merchants, recyclers, or service
providers. The prices are based on the price
level calculated by the business information
service EUWID Recycling and Waste Management.
Trends
As a consequence of the sustained high consumption
of recoverable paper by the European
paper and cardboard industry, there are
signs of growing competition for supplies of
the secondary raw material, recoverable paper.
The marginal increase in quantities of recoverable
paper in some European states is unlikely
to substantially alter this situation.
(Source: Recy Aktuell, No. 3)

Exact, fast and clean
Exact, fast and clean – the way to
process corrugated board
Thanks to just-in-time deliveries and putting
production directly on rail or road instead of
warehousing it, the size of orders is falling
steadily. In particular the food industry, one of
the largest consumers of corrugated board
packaging, demands a large number of different,
often very small, top-grade printed, highprecision
processed forms of packaging.
To ensure that people, machines and material
work together better and so enhance productivity,
Model also invests in in-house logistics,
including solutions to collect and recycle diecutting
waste as economically and ecologically
as possible.
A case in point is the Weinfelden site, which
this year installed a new corrugated board disposal
system incorporating state-of-the-art
technology. Recoverable corrugated board was
previously shredded by hand, now it is tossed
directly onto a conveyor belt by a machine. It is
then pressed into bales and forwarded directly
into the in-house recycling loop (Thurpapier)
(see also the InnoPlastics interview on Page 13
of this issue of Model Box).
The recycling of this material, whether corrugated
board or paper, creates a lot of dust. Until
recently, this was sucked out through an exhaust
ventilation system. Now it is collected in
a piping system, pressed into briquettes and
removed. This protects not only the employees’
respiratory tracts, but also reduces wear
and tear of the control system and mechanics
of the converters. Less dust also has a positive
effect on the printing quality of the packaging
involved.
The adapted dust extraction plant and the new
waste disposal system have resulted not only
in «cleaner» jobs, but also a «smooth» conversion.
The removal of the shredder and the ventilator
has also noticeably reduced dust and
noise emissions. Of course, this is also a response
to the company’s successful BRC/IoP
hygiene certification in summer 2005.
Corrugated board continued to be manufactured
and processed throughout the remodeling
phase. This required an enormous logistical
effort. It was necessary to suspend production
for five days to install the last components and
complete the project. The transition from the
old to the new in-house recycling system
demonstrates how good communication can
smooth the process of remodeling.
MODEL AG
15

PREVIEW
16
International School Kreuzlingen Konstanz
The International School at Kreuzlingen, Konstanz (ISKK) opened its doors in August 2004.
The ISKK is open to children and young people in the 3 to 11 age group from all over the world. The
splendid learning environment of the Villa Doldenhof, a family atmosphere with a day-school structure,
an English-language environment in which children easily develop fluency, an environment
that permits and encourages independent learning, a respectful attitude towards one another and
the theme-oriented preparation of the subject matter, internationalism and much more besides are
just a few of the attributes that apply to the school.
The school is based on the principle of the «Haus des Lernens». One of the things we mean by this
is the opportunity for everybody to take responsibility to the full extent of his possibilities. Depending
on the age group, children undertake more profound, more far-reaching projects. The day-school
system encourages the child to take responsibility in the personal sense, as well as for his school
work. Solutions to conflicts, whether personal or school-related, are worked out jointly with the
children. This is an active contribution to the children’s development.
The ISKK is open to children who do not yet have a command of English. The qualifications
awarded are recognized nationally and internationally, so that children can transfer from the stateschool
system to the ISKK and vice versa without difficulty.
The ISKK International School at Kreuzlingen, Konstanz is run by a charitable foundation. The
operating company is SBW «Haus des Lernens», a private school in Romanshorn.
Most of the ISKK’s funding comes from school fees and business. Children whose parents lack the
necessary financial resources should also be given a chance to enrol. To this end, places are
sponsored by companies.
The Model company promotes and supports projects that foster a sense of responsibility in children
and young people. This is why it has decided to make a financial contribution to the ISKK.
Both towns – Konstanz and Kreuzlingen – supported the project because it would appeal to further
international circles and contribute to the attractions of the location.
Many thanks to our interview partners:
Federal Office for the Environment FOEN, Dr. Hans-Peter Fahrni, www.umwelt-schweiz.ch
KVA Thurgau, Dieter Nägeli, www.kvatg.ch
Lyreco AG, Erwin Fries, www.lyreco.ch
Rhône-Clichés, Médialliance Groupe, Frédéric Valz-Blin, www.medialliance.org
Robatech AG, Loan Kutter and Ruedi Brun, www.robatech.ch
STIHL & Co., Peter Weibel, Antoine D'Aversa and Stefan Benz, www.stihl-co.ch
InnoPlastics, Martin Model, www.innoplastics.ch
Schenk Recycling, Ute Schenk
Asian Development Bank, Rita Festin, www.adb.org/phco
ISKK, Stefan Preisig, www.iskk.ch
Model Box
The Model Group customer magazine
Volume 18, published quarterly
© Model Management AG, 2007
www.modelgroup.com
Circulation
3900 copies German, 1800 copies French, 400 copies English
Editors
Luis Flores, Editor-in-Chief, luis.flores@modelgroup.com
Karin Bächer, karin.baecher@modelgroup.com
Ruth Wiesmann, Editorial Assistant, ruth.wiesmann@modelgroup.com
Model Management AG, T +41 (0) 71 626 76 21
Layout
dfp Kommunikation AG, Weinfelden
Printing
heer druck ag, Sulgen
The cover of the current issue was printed on Thurpapier Testliner III 130 g/m 2 , the contents on Sihl Eika RecyStar 100 g/m 2