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GPD Foodpackaging is installing two fully automated Bobst Masterfold 75 folder-gluers, which will be used to produce 750 million pizza boxes a year, among other things.
GPD Foodpackaging GmbH has been producing food packaging in its new smart factory in Rinteln in Lower Saxony, which is designed for maximum efficiency, since 1 January, including 750 million cartons of frozen pizza every year. The blanks are folded and glued using two Masterfold 75 folding carton gluing machines from Bobst.
The two fully-automated, each equipped with a Easyfeeder 4 prefeeder, a Cartonpack 4 packing system with an integrated Lantech shipping case erector and high-speed machines equipped with robotics are currently being put into operation. The Masterfold 75 achieves operating speeds of up to 600 m/min. It is the most automated high-performance line for the production of folding cartons on the market.
„The Masterfold 75 is the best folder gluer for the requirements of our new plant in Rinteln. It is well established on the market and is known for reliably delivering top performance for many packaging manufacturers around the world. In addition, the Masterfold 75, with its particular flexibility and very short set-up times, ideally supports fast production changeovers. We also see these as decisive advantages of this machine.“
Bärbel Wetenkamp, Chief Operating Officer at GPD Foodpackaging.
Breaking new ground in production technology
The systems reliably process a wide range of different packaging materials. That was for GPD Foodpackaging another important criterion. „When planning our new plant, we focussed on the goal of achieving significant savings compared to conventional packaging production - especially in terms of energy and paper consumption. Among other things, we are achieving this, by replacing virgin fibre cartonboard with recycled cartonboard“, explains Bärbel Wetenkamp. The two Masterfold 75 lines in Rinteln produce blanks from GD2 chromo duplex board with basis weights of between 200 and 500 g/m2 process.
GPD Foodpackaging is breaking new ground in this plant in terms of production technology in several respects. The company works with a web offset printing system with rotary inline die-cutting that is unique in Europe and specially designed for carton printing. This works with food-safe, EB-drying colours and offers high productivity with its above-average printing speed.
„Our customers like the fact that we rely on this high-end technology to process the blanks into the finished packaging.“
Bärbel Wetenkamp
The interaction between the Masterfold 75 and its peripheral devices ensures that the work can rely on maximum productivity in an uninterrupted folding carton gluing process. At the end of the lines, the packaging machines each gently fill up to 200,000 packs per hour into shipping cartons, offering GPD Foodpackaging various options. The company can save all the settings for the individual production orders in the MATIC control system of its folder-gluers and call them up at any time for repeat orders, which further reduces the set-up times for these orders.
Both Masterfold 75 lines are operated via a secure Internet connection. Connected to the remote maintenance service Helpline Plus from Bobst, to enable rapid fault diagnosis and rectification in the event of any technical difficulties. In addition, plant management can use the productivity apps from Bobst access the machine data at any time and use it for analyses or process optimisation.
Source: Bobst
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