By investing in two VISIONCUT 106 LER flatbed die cutters, a VISIONFOIL 104 embossing foil printing machine and an EXPERTFOLD 110 A2 folder gluer from Bobst, Schäfer Druck & Verpackung has set an example in the market. And has also completed the technical generation change.
Timo Schäfer, Managing Director of Schäfer Druck & Verpackungs GmbH & Co. KG, emphasises that „the food industry in particular relies on Long-term partnerships and continuity sets. By organising the succession in our company and our extensive investments in the latest technology from Bobst, we have given our customers the signal that we will continue to stand by them in the future.“
As fast as the fire brigade
If required, the packaging manufacturer based in Werther, Westphalia, can handle the orders from its customers even within 24 hours off. For example, when food manufacturers want to take part in discount retail promotions at short notice or customers need packaging, shelf cartons or sales displays made of solid board for test markets at short notice.
But the Three-shift full-service provider is committed to providing what its customers need. The print runs of the folding cartons, some of which come into direct contact with food, range from 1,000 to around one million units.
Production geared towards stability
Why does the company rely on machine technology from Bobst? „Our technology must support our flexibility and speed“, explains Timo Schäfer. The decision in favour of the VISIONCUT 106 LER was preceded by discussions with colleagues who use this flatbed die cutter and a test at the Bobst Meerbusch Competence Centre preceded. This confirmed the required criteria for the machines. „The sheets run very quietly and smoothly through the machines. We reliably produce consistently high quality with the VISIONCUT 106 LER,“ analyses the boss.
Their double cam gripper drives accelerate and decelerate the sheets extremely evenly. The platens are also equipped with cam drives, and the Bernoulli sheet braking devices also support the smooth and even sheet flow. This allows the packaging manufacturer to High running speed of its two die-cutters up to 8,000 sheets per hour for the majority of orders.
Added to this is the Perfect print and punch register, which the machines owe in part to their dynamic optical side register systems. These align the individual sheets using either their edges, the print images or special register marks. In addition to Solid cardboard With the VISIONCUT 106 LER, Schäfer Druck & Verpackung also processes Thinner materials with basis weights up to 170 g/m2. They run just as smoothly through the punches.
Exceptionally reliable
In favour of VISIONFOIL 104 were their Flexibility, reliability and embossing quality. Among other things, it embosses packaging for a globally recognised chocolate brand in Werther with gold lettering and filigree ornaments. In addition to gold foils, other foils are also used. The machine is also heavily used with Relief embossing demands. „Here and there, we achieve top quality even with difficult, very demanding embossing,“ says Udo Schäfer.
The VISIONFOIL 104 boasts various features that combine to guarantee its high embossing quality. For example, a double-cam gripper bar drive ensures extremely even sheet transport. The heated upper platen ensures the highest quality in foil application, while the clamping frame with honeycomb platen guarantees a high level of quality. Precise positioning of the embossing tools ensures.
Added to this is the Economical film consumptionThe OACS system (Optimal Advance Computing System) always calculates the optimum film feed and utilises the film rolls in the best possible way. The separately driven rolls of the patented external film unwinding system in turn give the company practically unlimited possibilities in embossed foil printing to cover new customer requirements.
Schäfer Druck & Verpackung also needs flexibility in Folding carton gluing. The particularly versatile EXPERTFOLD 110 A2 universal folder-gluer from BOBST was the ideal choice.
„We used to have our packaging glued and folded externally. Today we can Produce more flexibly and utilise the full potential of the EXPERTFOLD 110 A2 for our customers,“ explains Timo Schäfer.
At speeds of up to 450 metres per minute, the machine produces a number of different box types from a wide range of different materials. For example, it can produce up to 28,000 four and six-point boxes per hour. Its sophisticated, tried-and-tested technology, from inserter to delivery, guarantees exceptionally reliable operation.
Fast order changes
The work has also become more interesting for the employees at the punching presses because they now also work with the VISIONFOIL 104. „The fact that in both processes the Entry practically from a standing start We didn't expect it to work out like this,“ says Udo Schäfer, praising the commitment of the machine operators and the support of the BOBST instructors.
The User-friendly technology made it easier to get started with both processes. A total of seven employees operate the two die-cutters and the embossing foil printing machine. They can conveniently set the platen pressure on the die-cutters using the CUBE controls and automatically lock and unlock the cutting dies and counter plates at the touch of a button thanks to the quick-change concept.
In addition, the Punching quickly from blanking to full sheet delivery without special tools and back again. Its full-sheet delivery places the sheets with maximum precision, especially for embossing and creasing work.
With the VISIONFOIL 104, the Special ergonomics The CUBE control system for external film unwinding provides the operator with convenient access and therefore the shortest possible set-up times. All machine functions can be conveniently set via the CUBE control system. No further settings are required during production. All areas of the EXPERTFOLD 110 A2 are also easily accessible for the quickest job changes. Up to 5,000 jobs can be stored in its CUBE control system and called up again at the touch of a button.
„With our new Bobst machines, we produce the quality that our customers expect from us faster and more reliably. At the same time, we have simplified the process for our employees,“ summarises Udo Schäfer summarises the advantages of the technology.
A look at new services
With Bobst's Helpline Plus service, Schäfer Druck & Verpackung ensures that downtimes in the event of technical difficulties are minimised via remote maintenance. In addition, the company has set up the Bobst mobile portal app Permanent access to performance data of the two die-cutters and the folder-gluer.
With the exception of the VISIONFOIL 104, the new machines are already connected to Bobst's Connected Services. This opens up the possibility for Schäfer Druck & Verpackung to Machine data for process optimisation evaluate.
[infotext icon]Schäfer Druck & Verpackungs GmbH & Co. KG, based in Werther, was founded in 1987 by the current senior partner Udo Schäfer with the takeover of a small company that produced commercial print products for a renowned confectionery manufacturer. The trained letterpress printer soon expanded the portfolio to include cardboard packaging and invested in the necessary technical equipment for printing and finishing from around the turn of the millennium. Today, the full-service provider with more than 35 employees produces for branded goods manufacturers, primarily in the food industry, with a focus on frozen food[/infotext].
