Only waste? - Model Holding AG

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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
Page 1 and 2: No. 65 | 2nd Quarter 07 BOX 2 3 4 6
Page 3 and 4: Throwaway society The throwaway soc
Page 5 and 6: without boundaries Waste management
Page 7 and 8: Cardboard pre-cuts produced an ecol
Page 9: sia soft The packaging is intended
Page 13 and 14: SCHENK RECYCLING The business of re
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Only waste? - Model Holding AG

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