Koch Pac-Systeme: Special machine construction with a sustainable corporate strategy

„We are proud of every packaging that we develop in collaboration with our customers or that is produced on our systems and then successfully establishes itself on the market.“ This is how Koch Pac-Systeme GmbH, which was founded back in 1969 as Koch Maschinenbau, positions itself.

After Dieter Koch and his team served a variety of fields of activity at the beginning of the company's development 1973 the first moulding, filling and sealing machine developed and built. In the following 1970s and 1980s, the company specialised in special machines for the production of packaging, which were used in a wide range of industries. The classic plastic blister packs of the time were mainly used for writing instruments or batteries.

Early focus on sustainable solutions

As early as the end of the 1980s, however, the company was also committed to sustainable packaging solutions in addition to classic blister packaging. In 1988, for example, the first plastic-free packaging for kitchen knives was created for a well-known Swiss manufacturer. The public debate and the legal obligation to collect household packaging from the beginning of the 1990s led to an initial rethink among the population on the subject of waste. Many people remember the Green Dot.

The company founder and managing director at the time, Dieter Koch, then developed the First single-material packaging made entirely from cardboard: the so-called OnlyPack packagingng. Several customer projects were realised, for example for lip care products or batteries. Equipped with a viewing window for optimum product presentation, they were present in drugstores for a while. However, the market as a whole was not yet ready for such solutions at the end of the 1990s.

When the discussion about plastics picked up speed again a few years ago, Koch Pac-Systeme was also challenged as a machine manufacturer. The relaunch of NurPack took place in 2019 with CyclePac. In the past, NurPack packaging was criticised for not offering any protection against soiling. CyclePac has now solved this problem with an improved solution on the flaps and, if required, the packaging can be covered with a recyclable film on the viewing window be closed.

This means that classic plastic blister packaging can be completely replaced, depending on requirements.

Advantage Network Uhlmann Group

The increasing internationalisation of the customer base led to the opening of the first foreign locations in the USA in the 1990s, followed later by France and Singapore. Today, the company employs around 450 people worldwide and also has sites in Scandinavia, China, India and Brazil. Since 2006, the machine manufacturer Member of the Uhlmann Group, which has positioned itself as a specialist in the development and provision of packaging solutions.

The wide-ranging portfolio of the five companies Uhlmann Pac-Systeme, Koch Pac-Systeme, Cremer Speciaalmaschines, Wonder Packing Machinery and Axito includes high-tech packaging machines and digital solutions as well as corresponding services for the pharmaceutical, medical, consumer goods, food and agricultural markets. In terms of service options, the Global presence (in more than 14 countries) is an important benefit for the development of the „Koch“ brand.

Sustainability is a strategic issue for the Group that has been implemented and practised for many years. There are teams throughout the Group that are dedicated to this topic and consistently pursue a holistic approach.

Pillars of the sustainability strategy

Participation in the Ecovadis Award, for example, is derived from the company's general basic position of thinking sustainably and acting holistically. The quality of the CSR management system is assessed there in order to create transparency and identify starting points for improvement. The main aim is to ensure that profits are not made at the expense of others or the environment. Successes in this area can be seen in the award of the Ecovadis Award 2021 in silver.

In addition, the company's commitment to the United Nation Global Compact is a contribution to the fair shaping of globalisation. The company's activities are based on core values in the areas of human rights, labour standards and environmental protection. Koch relies on its employees and their active participation. A process that is further developed and expanded every year.

In addition to the sustainability-oriented product portfolio, seemingly insignificant aspects also play an important role: for years, the company has relied on the following for many partners and service providers Regionality and orders goods and services in the region. Employees receive mineral water from a local supplier, and company events are organised with partners directly from Pfalzgrafenweiler. The company's own e-charging points for cars currently provide employees with energy free of charge.

And in order to protect the environment, in addition to a waste concept, it is particularly important to develop innovative infrastructure projects, as well as appropriate Energy audits. At the Pfalzgrafenweiler site, electricity is generated by the local combined heat and power plant - 100 per cent eco-friendly. This responsibility characterises the holistic approach.

Special packaging solutions

As the requirements of the industry are very complex, Koch has brought further solutions onto the market. There is now a whole range of sustainable packaging solutions: The aim is not always to replace the plastic completely, but to minimise the Sustainable optimisation of the advantages of plastic packaging. This means that improvements are made by saving and optimising materials, or recycled or recyclable films are used, e.g. rPET, i.e. 100% recycled PET.

„When it comes to the resource-saving further development of packaging, we see it as our duty to make a contribution with technically mature solutions.“ Karl Kappler, CTO  Koch Pac-Systems GmbH

In addition to the now renowned CyclePac solution, there are other approaches such as the newly developed, also patented so-called CycleBox. This can be produced using the one-piece, completely flat cut on existing Koch packaging machines and offers the advantage of feeding via the top-loading system. In contrast to CyclePac packaging, this packaging consists of one part and not several parts that still need to be sealed together.

In addition, films have been and continue to be permanently tested for their possible applications on cooking machines and a wide variety of materials have been analysed, particularly with regard to their Environmental compatibility evaluated. The aim is to be able to provide customers with even more personalised advice and to take environmental aspects into greater consideration when making a selection: this means that the most suitable material and the most efficient machine solution can be offered for every task.

However, plastic packaging is still required to optimally protect certain products. The sustainability concept is supported by Cook developed machines for years, as new developments are constantly being introduced here too.

Requirements for a special machine manufacturer

As the focus is on realising customer wishes, the necessities and challenges formulated there drive developments forward. Only if trends are recognised at an early stage and corresponding concepts are developed can they be made available to customers. proactive are presented. It is particularly important for the globally active mechanical engineering company to recognise how customers and markets on different continents produce and perceive different trends.

In special machine construction Customised solutions offered. This fundamentally distinguishes Koch Pac systems from series machine manufacturers, who often work with modular systems, and requires a customised approach. The investment for the customer is higher, but usually pays off after a short period of time if the customer has higher performance, higher availability, more complex lines in use as turnkey projects or can produce more sustainable packaging. According to the company, customer calculations regarding the total cost of ownership (TCO) clearly demonstrate this.

The mere fact that customers are returning to the company for subsequent packaging developments and ordering new special lines demonstrates their trust in the customised solutions. In their assessments, customers also emphasise the company's expertise in terms of active consulting, comprehensive implementation in production and the responsive and efficient service hotline.

Where is Koch Pac-Systeme heading?

„For us, acting sustainably is not a negative obligation, but a logical continuation of the measures that we have anchored in our sustainability mission statement. As a packaging machine manufacturer, we have always been used to being viewed critically. At the same time, however, we know that packaging must continue to exist and that it is indispensable in many cases. For us, the Decide on constant and resource-saving further developmentd - always with people and the environment in mind. Fachpack 2021 will set new standards,“ emphasises Karl Kappler.

Because the latest highlight, the CycleForm, will be on show for the first time at the trade fair in Nuremberg. With this packaging solution, the blister is no longer thermoformed from plastic, but is instead Moulded from paper. This packaging has already aroused great interest among brand owners and global players in the consumer goods industry and could revolutionise the packaging landscape in the consumer goods market.