Lübbeck-based cardboard packaging manufacturer PackConcept installed the first Kolbus RD 115S rotary die-cutter in July 2020 as part of a field test agreement. With this investment, the fast-growing company, which was founded in 2012, aims to meet the increasing demand for printed corrugated cardboard die-cut packaging.
Until now, die-cut packaging, such as that found in outer packaging, only accounted for around a quarter of PackConcept's total order volume, while classic folding cartons in accordance with FEFCO standard 0201/0202 made up the lion's share of production. However, Managing Director Henning Spilker would like to increase the proportion of die-cut packaging due to higher added value and rising demand. "We will strongly bundle our sales activities here. The aim is to reach a significantly broader range of customers and bulk buyers in the industry."
Henning Spilker has invested in a new Kolbus RD 115S rotary die-cutter in order to be able to offer the required capacity right from the start. It is the first such machine ever on the European marketalthough the machine concept has been tried and tested for a long time.
In 2011, Kolbus took over the US manufacturer Hycorr, which for decades had produced rotary die-cutters for corrugated board exclusively for the markets in North, Central and South America. Under the Kolbus umbrella the machines were thoroughly overhauled and modernised. In addition to the introduction of the globally used metric system, this also included the changeover to decentralised servo drive technology for all production-relevant axes and a state-of-the-art electronic machine control system with a high degree of automation.
Many other detailed optimisations have led to an improvement in user-friendliness. And, of course, the machines now comply with all international safety standards, such as the CE standard. The RD 115S has a passage width of 2,921 millimetres. This means that even Up to four uses per corrugated board sheet possible, which the machine, together with its Processing speed of up to 12,000 sheets per hour also makes it an attractive solution for large-volume orders of 100,000 units and more.
Rotary die-cutter with up to eight printing units
The core expertise of the RD 115S lies not only in punching, but also in the printing process: It can be expanded modularly to up to eight flexographic printing unitsprinting units can also be used from above for double-sided printing. The pilot machine at PackConcept initially has three flexographic printing units, which are used to print flat motifs on the outside of the cardboard.
"The precise guidance and slip-free transport of the sheets in the machine ensures very good register accuracy from printing to die-cutting, resulting in very high-quality products. The level of workmanship, the quality of the components used and the expertise of the Kolbus specialists represent the best engineering made in Germany!" Henning Spilker
An assessment that Wilfried Kröger, Managing Director of Kolbus"Here at PackConcept, we have the unique opportunity to test and optimise our new rotary die-cutter under regular production conditions. We can also use the installation for customer demonstrations."
Henning Spilker's choice of the RD 115S is not the first time he has shown the right instinct. It all began when he founded the company in January 2012. After twelve years as a management consultant, the industrial engineering graduate decided to set up his own company and After analysing the growth opportunities, the company decided to focus on corrugated cardboard outer and shipping packaging. "Cardboard packaging has a future," the now 53-year-old company owner realised, and he was proved right. PackConcept initially started on 750 square metres and with used machines in an industrial estate in Lübbecke. Just weeks later, a further 500 square metres had to be rented and a further 15 months later, the company moved to a 1,700 square metre space with a corresponding expansion of the machinery.
I need boxes!
From this point until 2019, PackConcept doubled its turnover and relocated again: In May 2020, the company moved into a new 2,500 square metre building in Lübbecke. This is where Henning Spilker with its now 14 employees, achieved a turnover of 1.7 million euros this year. 30 per cent of revenue is generated via the web shop. http://www.ichbrauchkartons.de while 70 per cent comes from orders for industry and trade in a wide range of sectors - retail, the furniture industry, printing and media, as well as metal, glass and plastics processing.
Initial contact between PackConcept and Kolbus dates back to 2018, when Kolbus was looking for partners to establish its new machine portfolio for corrugated board processing on the market. Henning Spilker recognised the potential of a collaboration with the long-established mechanical engineering company from Rahden: "Kolbus is a valuable, strong partner with great expertise." This had already been demonstrated during the installation of the Autobox AB for the production of non-die-cut folding cartons as part of the recent move to the new building.
Profitable partnership
"The support was unparalleled. Minor problems were solved immediately on site or via remote maintenance," says Spilker. Autobox AB is already the third Boxmaker at PackConcept. The machine has with a working width of 2.60 metres and equipped with an autofeeder, multi-cut and flexo printing unit the production possibilities considerably. Henning Spilker confirms: "We would be delighted to be involved in the piloting of new Kolbus machines again in the future. I am eagerly awaiting the direction in which the development will go. Perhaps it will even be a fully automated 'inliner' ...?"
Author: Andreas Tietz
