Koenig & Bauer News Feed https://www.koenig-bauer.com/ en Koenig & Bauer AG Tue, 29 Sep 2020 23:30:15 +0200 Tue, 29 Sep 2020 23:30:15 +0200 news-1810 Tue, 29 Sep 2020 16:11:21 +0200 Zumbiel Packaging Addresses Soaring Demand With New Koenig & Bauer Rapida 145 Seven-Color Press http://iberica.koenig-bauer.com/en/news/detail/article/zumbiel-packaging-addresses-soaring-demand-with-new-koenig-bauer-rapida-145-seven-color-press/
  • New sheetfed press is equipped with unique automated features
  • Plans call for expansion in marketplace and 40% increase in reduced makeready time
  • Determined that large format was ‘way to go’ for its specific carton sizes and market demands
  • If you ask any of Zumbiel Packaging’s many well-known name-brand customers in the food and beverage industry, they’ll tell you that the Cincinnati-based firm has always been essential to producing their impressive high-graphic packaging. But as the pandemic grew this past spring, Zumbiel’s legion of 350 skilled associates became even more essential as front-line workers putting in extra hours to increase the firm’s production and match the soaring demand. Even its pressroom got a boost as Zumbiel’s management team had the foresight to invest in a new highly-automated large format press from Koenig & Bauer, which will be delivered this fall to maintain and expand its production.

    “Historically, as our customers have grown, so have we,” says Tom Zumbiel Jr., its marketing director, and fourth-generation of the 177-year-old family-owned business. “But now the market has boosted consumer demand for our products. Our customer base has seen the need for additional food and beverage packaging for a vast majority who are eating at home. As one of the largest independent converter of paperboard packaging in the U.S., we pride ourselves on offering more choices, better innovations and customized solutions, outstanding service, and colorful branded cartons that set us apart from the competition. Our goal is to proactively design innovative packaging solutions to help our customers sell more, reduce costs and protect their brands.”

    The new Koenig & Bauer Rapida 145 57-inch seven-color press will be delivered to Zumbiel Packaging’s new 500,000-square-foot facility in Hebron, Kentucky

    The new Rapida 145 57-inch seven-color press will be delivered to Zumbiel’s new 500,000-square-foot facility in Corporex Co.’s Gateway Industrial Park in Hebron, Kentucky. There it will begin production along with Zumbiel’s flexographic and digital production capabilities.

    Superior Koenig & Bauer technology and unique features enhance new press

    Precision, speed, and efficiency drove the choice for a new Koenig & Bauer Rapida press at Zumbiel. The large format size was important to increase process efficiency in existing carton production by reducing makeready by 40% while supporting growth into new markets and providing additional capacity. Its extensive unique automation includes DriveTronic SRW (simultaneous roller wash), which washes up PMS colors while the press is in operation; CleanTronic Synchro to automatically wash blankets and impression cylinders for the fastest operation; and in-line color control, all at a lightning fast speed of 18,000 sph.

    Extensive ROI study

    Serving the most selective consumer-facing brands in the country is a challenge that Zumbiel has met successfully since it was established in 1843 and today it remains the largest independent converter of paperboard packaging in the U.S. Generation upon generation has carefully selected the right equipment to produce products for its customers. Zumbiel’s team undertook a thorough and extensive analysis of various manufacturers to determine which press investment would supply the best ROI, highest print quality, and would align with its corporate philosophy of being 100% customer-centric.

    “We forge deep partnerships with our customers to provide the safest, most secure, yet eye-catching cartons for their products,” says Zumbiel. “Not only are we protecting their product within the carton but we are helping to sell the product on the store shelf amid a very competitive environment. This is an on-going process as consumer taste and trends change quickly. We continue to invest in our future and our new Koenig & Bauer Rapida press is our latest acquisition to embrace our long term vision.”

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    news-1809 Tue, 29 Sep 2020 07:13:56 +0200 Koenig & Bauer gears up for the future http://iberica.koenig-bauer.com/en/news/detail/article/koenig-bauer-gears-up-for-the-future/
  • Continued focus on packaging as a growth market
  • Clear commitment to the current portfolio strategy
  • Research and development budgets remain unaffected
  • To reinforce the company’s position as the leading supplier of press and post-press solutions for packaging, industrial and security printing applications, and to boost the earning power of the Koenig & Bauer Group, the management board has been working intensively on developing and expanding the “Performance 2024” efficiency programme over the past months. There are also plans to realise annual cost saving effects which will then amount to more than €100 million and continue increasing until 2024, while maintaining and, in fact, accelerating all innovation, process and product developments. The non-recurring costs in the mid two-digit million Euro range this makes necessary will be recorded in the group results for the business year 2020 as expenditure realised as a provision

    The board members responsible for the "Performance 2024" efficiency programme explain to employees the measures that will enable the company to continue to develop even in a tense global economic situation. (from left to right: Michael Ulverich, COO, Claus Bolza-Schünemann, CEO, Dr. Andreas Pleßke, Segment Board Member) (1)

    The principal market segments addressed by Koenig & Bauer, such as the structurally expanding areas of packaging and industrial printing, remain fundamentally intact. This is clearly demonstrated by the good levels of capacity utilisation currently reported by printers of packaging for food products, beverages, and pharmaceuticals, as well as the booming online trade. Even so, customers are postponing new investments due to all the uncertainty brought by the Covid-19 pandemic.

    The primary objective of the four-year, multi-pronged programme is to strengthen the company’s competitiveness for the long term. A range of measures aims to ensure further development of the product range in accordance with market needs, to continue with the digitalisation of processes, and, at the same time, achieve reductions in manufacturing costs. Koenig & Bauer continues to focus on end-to-end system solutions and optimisation of the total cost of ownership (TCO) for the customer. The investments in digital print and direct post-printing on corrugated board are being pursued with vigour, as is the joint venture with the Durst Group;  so too are new developments for security printing in the pipeline. Koenig & Bauer stands by its current product portfolio and will continue to work on consistently expanding it. The further digitalisation of the services it offers is another area at which particular attention is being directed.

    Alongside increased efficiency, the Performance programme also aims to scale group activities, as the global economic situation, the still widely applicable travel restrictions, and worsening Covid-19 developments suggest there will only be moderate turnover growth in the next few years, and a short-term return to pre-crisis levels is not anticipated.

    Koenig & Bauer's portfolio strategy has proved a success and will be continued - eg with the Rapida 106 X - the new performance benchmark in industrial printing (2)

    The supervisory board was closely involved in the evaluation process and approved the programme after detailed deliberation and extensive discussions during the board meeting held on 28 September 2020.

    As supervisory board chairman Prof. Dr.-Ing. Raimund Klinkner explains: “Alongside the strategic ongoing development of the Koenig & Bauer Group, the supervisory board has taken a very close look at the plans that the management board tabled on the basis of its broad expertise and commitment to increasing the earning power and overall performance of the group, and we have contributed our own experience and know-how to the evaluation process. The Performance 2024 programme is laying the foundations for a profitable development of the company, which builds up on interesting future opportunities for new markets and technologies.”

    The effects of the short- and medium-term measures will bear fruit in the period from 2021 to 2024, whereas a continued negative impact on business results is expected in the third and fourth quarters of 2020 due to the Covid-19 pandemic, which is worsening internationally. In addition, the planned introduction of a new internal guideline in relation to turnover reporting in the Sheetfed segment in 2020 will result in a one-time balance sheet deferral amounting to approx. €40–60 million in turnover and €9–12 million in EBIT to 2021.

    Upon conclusion of the programme, turnover at the Koenig & Bauer Group is expected to reach around €1.3 billion. On the earnings side, the management board hopes that implementation of the approved cost and structural adaptations will help maintain a return on sales totalling at least 7% over the medium term, while reducing working capital requirements to an average level of 25% of annual turnover.

    The programme adopted provides for the following:

    • Supply chain reorganisation effected by changes group-wide structures, purchasing arrangements and production processes within the framework of one organisation, as well as innovative approaches to part and component optimization
    • Adjustments to cost and personnel structures, and improvements in productivity based on process streamlining and standardization
    • Increased effectiveness and efficiency in development and design by implementing measures targeting product, process and organisational optimisation, such as design-to-cost projects
    • Continuation and acceleration of the development of new products and solutions for the fields of sheetfed and webfed packaging printing by means of conventional and digital printing technologies, hollow container decoration, post-press and banknote production
    • Reduced administration costs by continued pooling of specific tasks as shared services, as well as changes to sales and service structures
    • Optimisation of the production and assembly factories, including internal pooling within the group, and the relocation and realignment of production and assembly facilities

    In the technology and customer centres, the product portfolio is being systematically enhanced to address new markets and create future prospects (3)

    In addition to the effects of the measures already being implemented, such as cutting back on overtime and subcontracted labour, a hiring freeze and short-time working, the group-wide measures approved today will affect between 700 and 900 jobs in the short and medium term. The changes will be discussed and negotiated with employee representatives and social partners over the coming months. Along with implementing the necessary measures in a socially acceptable manner, the objective is to achieve a return to the planned level of group growth in the medium term by taking innovative approaches.

    “Today, we have made far-reaching decisions for Koenig & Bauer, made necessary by negative global economic developments in tandem with ever-changing customer needs and demands. They are also associated with painful cuts for the workforce. These difficult and challenging steps were not easy to take, but they are imperative to safeguarding the long-term future of our 203-year-old company,” as President and CEO Claus Bolza-Schünemann explains.

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    news-1805 Tue, 22 Sep 2020 13:01:07 +0200 Kenmore Envelope’s New Koenig & Bauer Rapida 106 LED-UV Six-Color Press Delivers High-End Direct Mail http://iberica.koenig-bauer.com/en/news/detail/article/kenmore-envelopes-new-koenig-bauer-rapida-106-led-uv-six-color-press-delivers-high-end-direct-mail/
  • New Rapida 106 produces 195,000 sheets in one 12 hour shift netting 16,250 sph and a total of 489,500 sheets over three 12 hour shifts
  • Operating one of the fastest lithographic presses on the market at 20,000 sph
  • Expands customers’ needs by offering any special effect leading to increased customer response rates 
  • Investment in new press technology fits mission as the most progressive and premiere leader in high-end direct mail in the industry 
  • Direct mail is an incredible marketing tool especially in this extremely competitive environment, says Kenmore Envelope Company, and they have the statistics, personnel, and equipment to back it up. As the premier leader in high-end direct mail that specializes in high-quality printing and converting envelopes, Kenmore’s team creates envelopes of all sizes from a variety of paper substrates decorated with specialty coatings, windows and other unique design elements. To deliver these products on time and at the highest quality possible Kenmore depends on its new Koenig & Bauer Rapida 106 LED-UV six-color press, which it has been operating since early this year at its Richmond, VA facility.

    Left to right: Kristin Ogo, COO of Kenmore; Scott Evans, Kenmore’s President / CEO; praise the efficiency, productivity, and capacity of their new Koenig & Bauer Rapida 106 press at their facility in Richmond, VA

    “We produce beautiful and innovative envelopes to distinguish businesses from their competition, make an impact, capture attention and build brand awareness and loyalty,” says Kristin Ogo, Chief Operating Officer at Kenmore.  “With our new Rapida press, our clients are able to produce high-quality, quick turn, special effect envelopes under one roof and that’s something we’re very proud of. Kenmore is the premier leader in high end direct mail and services the best clients in their respective industries.”

    Impressive press technology

    To maintain this high level of service, Kenmore equipped the new Koeing & Bauer press with its most unique technology. “In today’s world, technology leads the way and our Rapida’s array is so impressive,” she says. “We’ve addressed the need for speed and quick turnaround with DriveTronic SRW (simultaneous roller wash), which washes up PMS colors while the press is in operation. This allows us to run a new job while we are washing up the previous job at the exact same time. The roll to sheet feeder allows us to be more competitive on paper and feed the press from rolls or sheets. The color control system reads every sheet and controls color every tenth sheet. This allows us to secure consistent color for our clients from the first sheet to the last during production.” 

    Kenmore’s envelopes stand out in the mail due to their cutting edge special effects and thus increase their client’s ROI for their campaigns. The Rapida is flexible enough to efficiently print many new eye-catching effects with motion coat, glitter, liquid foil, heavy grit, Soft Touch, and spot UV. 

    To answer the demand for quick turnaround, the Rapida has a docking station at each print unit for LED drying and the coating unit was designed to utlize either LED or traditional UV coatings. “Speed wins in our industry and the time to market continues to shrink,” says Ogo. “Being able to print, cut, and fold all in one day is amazing. Previously we’d have to wait for sheets to dry for 24 to 48 hours on our non-Koenig & Bauer presses before cutting and folding. Now we can move right to the finishing steps and deliver faster.”

    Outstanding productivity

    Kenmore’s press operators are also amazed with the Rapida’s ease of use and productivity due to the servo motors and touch screen interface. Its operators received expert training in Germany, which is allowing quick changeovers even at 20,000 sph.  “Recently we’ve been able to produce an outstanding 195,000 sheets in one 12 hour shift netting 16,250 sph,” says Scott Evans, Kenmore’s President / CEO.

     “As we continue to grow, our goal is always to have the capacity to work as we always have --- at the highest service level, quality and speed to market,” says Evans. “Koenig and Bauer is a true partner and collaborates with our organization at a level above any press manufacturer in the market today.”

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    news-1803 Tue, 15 Sep 2020 12:23:57 +0200 Bonifatius looking forward to a Rapida 106 X http://iberica.koenig-bauer.com/en/news/detail/article/bonifatius-looking-forward-to-a-rapida-106-x/
  • Eight-colour perfector press with coater and reel-to-sheet feeder
  • 20,000 sph in perfecting mode is a clear competitive advantage
  • Substrate flexibility from lightweight papers to board production
  • Spotlight on digital processes
  • The printing and publishing house Bonifatius in Paderborn/Germany recently ordered a new Rapida 106 X. Its installation is scheduled for early 2021. By investing in this highly automated eight-colour perfector press for 4-over-4 production with additional inline coating, the company has doubled down on its commitment to the medium of print, even in these currently troubled times. Moreover, it is one of the first printing houses in Germany to opt for the new Rapida generation, which was only recently unveiled at the virtual trade fair “Koenig & Bauer Live”.

    Bonifatius will be taking delivery of an eight-colour Rapida 106 X with perfecting unit for 4-over-4 production, inline coating unit and reel-to-sheet feeder in spring 2021 (1)

    Bonifatius makes regular investments in new production equipment. In the past years, a new hall was added to the production complex which today houses a very highly automated 16-page web press. In the meantime, it has also been joined by new post-press machinery. The trend towards ever shorter runs calls for constant optimisation of the way production is structured. The new eight-colour press gives the company the option of printing covers with a high-quality finish in a single pass. Reaching speeds of up to 20,000 sheets per hour, and this in perfecting mode as well, the press is also able to deliver the content for short-run products more economically than its webfed counterpart. This means less waste, faster makeready and greater flexibility in the handling the large number of product variants. The RS 106 reel-to-sheet feeder system allows the same types of paper to be printed on both the sheetfed and webfed presses.

    Replacement investment with added punch

    There were many reasons for the purchase of the Rapida 106 X: After six years of production, the time had come to consider replacing the Rapida 106 that had been used to date. After weighing up different offers and testing the latest technology, the specialists from Bonifatius were impressed by the Rapida 106 X that they went to see at Krüger Druck und Verlag in Merzig. The commanding level of automation and the high production speeds of the new Rapida generation in perfecting mode represent a clear competitive advantage when compared to the other possible alternatives. Moreover, the production chain at Bonifatius is already configured for the use of the Rapida technology. The operating concept for the new series has undergone significant modernisation, yet many elements nevertheless remain familiar to the printers. That will make the transition even easier.

    Looking forward to the new Rapida 106 X (l-r): Tobias Siepelmeyer, managing director of Bonifatius, plant manager Wolfgang Hettlage and Ralf Engels, senior key account manager from sales partner Steuber – together at the Rapida 106 press currently in use (2)

    Managing director Tobias Siepelmeyer and his team particularly value the extremely fast makeready on the Rapida 106 X, not to mention its high production speeds, the fast-reacting inking units, the sidelay-free infeed with DriveTronic SIS, the fully redesigned delivery, the inline colour control system which requires only 3 mm high colour bars, and the fact that the plates no longer have to be bent before mounting. Further praise is given to the quality of service assistance from the company Steuber, which provides local support for users of sheetfed offset presses from Koenig & Bauer in the North Rhine-Westphalia region. The media house has enjoyed a collegial relationship with Steuber over many decades.

    Other outstanding features of the Rapida 106 X are remote-controlled plate stretching using the console (paper stretch compensation), the VariDryBlue IR/hot-air drying systems, simultaneous plate changing using DriveTronic SPC, and the CleanTronic Synchro washing systems that enable parallel washing processes.

    In addition to commercial printing, there are also plans to use the new Rapida 106 X for packaging production. This is why it has been configured with both lightweight and board-handling accessories. The presses currently in use are already printing regular packaging jobs today – including food packaging on substrates up to 600 g/m2. The Rapida 106 X, however, will also ensure that there are sufficient units available for spot colours and coatings.

    Tobias Siepelmeyer in the paper stores. The reels can later be used on both the sheetfed and webfed presses (3)

    Digital and environment-oriented

    The year 2020 has directed a spotlight on digital processes at Bonifatius. In the print section, the new MIS PrintPlus has replaced an analogue production planning system and allows for direct networking with the printing presses. The Rapida 106 X itself incorporates a number of digital solutions ranging from autonomous printing and the LogoTronic Cockpit with displays of performance indicators to a maintenance manager and additional smart services. The company uses smart software to prepare the content for cross-media output and publishes attractive digital content on the Internet in addition to its printed editions.

    Even so, the specialists at Bonifatius are firm believers in the printed product. “It still earns its place in the communication mix,” says Tobias Siepelmeyer, whose conviction is founded not least on experience with his own book and magazine publishing house. Text books and leisure magazines are segments which are continuing to grow. Some 50 per cent of the publisher's products are sold through bookshops, including shops owned by the company itself. Another trend that Bonifatius has recently identified is seeing advertisers beginning to turn their backs on social media. The increasing prices for online ads is one of the reasons for this.

    Bonifatius worked on a major project to expand its production space in 2017/18. The newly built hall can be seen in the background (4)

    Bonifatius is fully committed to ecological print production. Digital job data increase the efficiency of both makeready and production. Materials consumption, energy input and transport processes can be optimised. That saves natural resources and helps the company to achieve the environmental targets it has set itself. Bonifatius has eliminated industrial alcohol from its production process, and the publishing house, print centre, bookshops and media offices all use green electricity. The environmental management system is certified in accordance with FSC, PEFC and EMAS standards, as well as ISO 9001 and 14001. Bonifatius offers its customers climate-neutral printing (Climate Partner) and is entitled to use the “Blue Angel” ecolabel. A detailed environmental statement provides information on the company’s ecology goals and reports on the results achieved to date.

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    news-1800 Mon, 14 Sep 2020 10:02:53 +0200 Koenig & Bauer Displays Deep Commitment and Leadership to Large Format Press Segment http://iberica.koenig-bauer.com/en/news/detail/article/koenig-bauer-displays-deep-commitment-and-leadership-to-large-format-press-segment/
  • Substantial growth in large-format sheetfed offset press orders 
  • Broad diversity of configurations yields customized solutions
  • Strong commitment to automatization, service, research and development 
  • Only manufacturer to offer neutral consulting with an extensive press portfolio from half-size to large format
  • With more than 200 years of experience and a stellar reputation as the leading innovator among its customers, Koenig & Bauer has maintained its foremost position as a stable innovative partner and continues to be the leader in large format press production. Its successful customers rely on Koenig & Bauer to effectively and profitably produce a wide range of applications from folding cartons and top sheets for the most well-known brands in the world. 

    “We have earned our distinguished reputation as the market leader of manufacturing large-format press models,” says Eric Frank, Koenig & Bauer senior vice president of marketing and product management. “Our large format press models display proven performance and extraordinary print quality. After seeing at least 50% or higher efficiency, productivity, and output on their large format press models, our customers agree with our assertion through their own KPI’s and analytics.”

    Koenig & Bauer large format press models display proven performance and extraordinary print quality

    Large format’s many benefits

    Due to the on-going advancements in new technology on its large format models, Koenig & Bauer has repeatedly sold more large-format models than any other press manufacturer. In part, this is due to its stable of models: the large-format press line runs the gamut from the Rapida 145 57-inch with its production speeds of up to 18,000 to the 64-inch Rapida 164 printing at 17,000 sph.

    Large format customers point to the competitive advantages they receive including 50% or more square inch capacity, reduced make-ready time per box, and the highest production speeds, with the most industrialized customers producing in excess of 90 million sheets per year on a large format press. Everything about a Koenig & Bauer large format press--its high nonstop productivity, less paper waste, shorter makeready times, and simultaneous processes that allows for ultra-fast job changeovers, this in combination with the exceptional print quality, and the highest level of engineering and craftsmanship-- is designed to allow the press to produce the work of two smaller format presses with the investment into one press.

    Due to the broad diversity of configuration options, accessories and automation solutions, the large-format Rapida’s are an efficient means of production for both established and niche markets. They can be equipped with a reel-to-sheet feeder, a double-pile delivery, diverse drying units such as UV and LED, additional printing units after coating and perfecting facilities, as required for the individual application. For packaging printing, they can also be placed on raised foundations and integrated into a fully automatic pile logistics system. Presses with up to 16 printing and finishing units are already in daily use.

    Strong demand

    Koenig & Bauer large format customers have transformed their businesses by investing in solutions that provide high quality, faster turnaround, and increased automated technology. There has been a continuing strong demand for this size press all over the world.

    Litho-laminated corrugated packaging manufacturer Accurate Box chose a new large format Koenig & Bauer Rapida 164 seven-color press to help its elite customers “stand out”, not “blend in” on store shelves. Working with major nationally-recognized brands such as Kellogg's and Pepsico and their specific color schemes, logos, and graphics, it is imperative for Accurate to match those shades and images box-to-box and run-to-run using its new Rapida 164 press configured with new computerized quality systems and enhancements.

    A large format Rapida 164 64-inch eight-color is supporting the explosive demand and growth at Huston Patterson, a privately owned package printing business, that serves such well-known firms as Disney, Pampers, Sony and Coca-Cola. “It is our go-to press,” says Tonya Kowa-Morelli, HP’s president.

    Earlier this year, Oliver Inc. chose its ninth Koenig & Bauer press: a Rapida 145 57-inch seven color serving the food, health and beauty, and pharma package printing niches. This new workhorse press will provide 20% more production and capacity and provide enhanced creative solutions, speed to market, and high-end finishing capabilities. 

    To boost its printing capacity by 40%, Superior Litho in Los Angeles chose a Rapida 145 seven-color coater press, its third large-format press from Koenig & Bauer. Equipped with UV dryers, inline color control and PDF-Check, Superior Litho supplies packaging for the food, electronics and cosmetics industries, as well as for special products. 

    Foster Printing will be adding its fourth large format press from Koenig & Bauer, a new Rapida 164 six-color 64-inch press. Foster proudly installed the unique Koenig & Bauer Rapida 205 81-inch press, the largest ever produced, in 2012 and continues to utilize that extra large format press. “It was and continues to be a workhorse machine for us and supply immense productivity,” says Kris Blackburn, Foster’s vice president of sales.

    Strong commitment

    “While our large format models have many benefits for our customers, we’re proud to act as neutral consultants in which we bring a full press portfolio from half-size to large format,” says Frank.

    “But due to the technology, service, and support of our large format models, customers easily choose one of those models due to their ability to be a profit leader with this format size. Only Koenig & Bauer can customize each press to each customer’s application allowing them to offer a unique printed product for extreme market differentiation. It is important to Koenig & Bauer to be the only press provider that can start and grow with a customer in all format sizes to ensure their long-term success.”

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    news-1799 Thu, 10 Sep 2020 09:05:35 +0200 Koenig & Bauer presents the Rapida 76 for high-end print production in B2 format http://iberica.koenig-bauer.com/en/news/detail/article/koenig-bauer-presents-the-rapida-76-for-high-end-print-production-in-b2-format/
  • Comprehensive automation to shorten make-ready times
  • Versatile configuration and finishing options
  • Application-orientated measuring and control systems
  • Access to a diversity of digital services
  • A new generation of the Rapida 76 from Koenig & Bauer has just been released onto the market. The B2 press (standard sheet format 530 x 750 mm; special format 605 x 750 mm) impresses with its extraordinary level of automation, a minimal footprint and peak printing speeds of up to 18,000 sheets per hour. Boasting a fully revamped and particularly aesthetic appearance, it also stands out visually from its predecessors, and presents itself in the new, award-winning Koenig & Bauer design.

    New and proven automation functions characterise the Rapida 76 as an extremely efficient, high-performance sheetfed offset press. Key features are the DriveTronic dedicated drive components, which eliminate complicated gear systems and provide for both simple handling and parallel processes during job changeovers and make-ready. The full preset capabilities of all press components are a further valuable benefit. In addition to the ErgoTronic console with wallscreen, the Rapida 76 possesses further decentralised touchscreens for maximum ease of operation. For users who are at home in the B2 format class, the Rapida 76 is an ideal means of production.

    The new Rapida 76 is an immediate eye-catcher in the new Koenig & Bauer design (1)

    Broad diversity of configurations

    To cater for as many different applications as possible, up to 11 printing and finishing units can be combined to configure a Rapida 76 which is tailored precisely to individual production needs. That could mean a ten-colour press with an automatically convertible perfecting unit for 5-over-5 production – possibly together with an additional coating tower to allow the printing of covers, for example – or packaging presses with double-coating facilities for the production of pharmaceutical packaging and the like. Further variants incorporate raised foundations to accommodate higher piles with board substrates, or various delivery extensions for coating applications. Ink duct dividers can also be chosen to enable rainbow printing. Thanks to a comprehensive range of measuring systems and optional facilities for inline sheet inspection, the Rapida 76 is ideally prepared for a diversity of special applications, including even the production of security documents.

    The half-format press is no less flexible when it comes to compatibility with different ink and coating systems. It handles both conventional and UV inks and coatings with equal ease. Beside IR/hot-air drying systems, various UV, HR-UV and LED-UV systems are also available.

    With a printing output of up to 18,000 sheets per hour, the Rapida 76 is built for speed (2)

    Specialities “Made by Koenig & Bauer”

    As if that were not enough, the Rapida 76 offers further special features which benefit users in their daily work but are still far from commonplace in this format class:

    as on all Rapida presses, inking units which are not required for a particular job can be disengaged from the press drive. This reduces roller wear and cuts make-ready times. When production is to be resumed, the units concerned are re-engaged at the press of a button.

    The times in which plates had to be bent before loading onto the press are similarly over. On the Rapida 76, unbent plates can also be mounted, irrespective of whether an automated or simultaneous plate changing system is in use.

    Simultaneous SPC plate changing with unbent plates (4)

    The ColorTronic ink ducts, with the bleed-free ink metering which is typical of all Rapidas, guarantee high repeat accuracy. This is achieved with individual ink keys and a special mechanical design which ensures that they are always set to the duct roller with an identical force. With this system, ink duct foils are rendered superfluous. Thanks to the EasyClean duct plate coating, extremely fast ink changes are possible nonetheless.

    With simultaneous plate changing, all the plates on the Rapida 76 can be changed in just 45 seconds. In combination with CleanTronic Synchro, the blankets and impression cylinders – and optionally also the ink rollers – can be washed parallel to plate changing. This shortens make-ready times dramatically and leaves much more time for actual production. The same applies to automated coating forme changes.

    One camera system for up to three functions: colour control, sheet inspection and PDF comparisons (3)

    Wide range of measuring and control systems

    Application-orientated measuring and control systems contribute to faster make-ready, reduced waste, and a consistently high and stable print quality. The Rapida 76 can be configured with systems for register measurement and control, colour control and sheet inspection. All inline systems operate with a common camera, which reduces maintenance requirements and simplifies handling.

    In a full-featured setup, ErgoTronic ICR controls the register by way of a single sheet placed on the console, while QualiTronic ColorControl provides for convenient colour adjustment. The camera system installed after the last printing or coating unit or after the last unit before perfecting automatically determines the optical densities and controls the ink keys without further intervention. As an option, the system can be expanded to implement colour control according to grey balance (QualiTronic InstrumentFlight). QualiTronic PDFCheck carries out inspection of the printed sheets and comparison with the customer’s PDF as the basis for uncompromising quality.

    Semi-automated technology also permits fast coating forme changes on the Rapida 76 (5)

    Digital services at the press of a button

    A multitude of digital services surrounding the Rapida 76 helps to reduce unplanned downtimes, facilitates convenient and barrier-free maintenance of the press, and permits anonymous comparisons of important performance parameters with other presses in identical configurations. The options range from PressCall for optimisation of communication with remote maintenance engineers and VisualPressSupport to enable a better description of the reason for a remote maintenance call using photos (with extensive commenting functions), texts, videos and audio, via Performance Reports and Press Inspection Reports, through to the first instances of predictive services based on methods of artificial intelligence.

    In this context, the Customer Community is a central point of contact bringing all service offers together under one roof. Users and the manufacturer have access to an identical information database, meaning that they are all on the same page when working together.

    In addition to blanket washing, the Rapida 76 possesses a conveniently accessible impression cylinder washing system (6)

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    news-1793 Tue, 08 Sep 2020 13:30:00 +0200 New Koenig & Bauer Rapida 105 PRO Ten-Color Perfector Press Enhances Ultra-Rich Design Capabilities at TPC Printing & Packaging http://iberica.koenig-bauer.com/en/news/detail/article/new-koenig-bauer-rapida-105-pro-ten-color-perfector-press-enhances-ultra-rich-design-capabilities-at-tpc-printing-packaging/
  • New Rapida posts significant 50% increase in output with less machine hours
  • Increased speeds of 30% and reduced make-ready time of 50% due to improved automation  
  • Additional 60% capacity delivered into TPC’s pressroom
  • The perfector and cold foil units add enormous design capabilities for TPC’s world-class consumer retailers and well-known brand names
  • When world-class consumer retailers and well-known brand names require an especially unique luxury package, they turn to TPC Printing and Packaging, a highly-decorated boutique printer with an outstanding reputation for producing a wide range of high-end custom folding cartons and promotional packaging. At its Chattanooga, TN facility, the privately-owned firm operates a stable of automated Koenig & Bauer presses including two Rapida 105 eight-color plus coater presses and its new Koenig & Bauer Rapida 105 PRO 10-color 41-inch perfector press, a specialized versatile model that offers either 10 straight or eight-over-two perfecting, multiple inline curing units, combination LED-UV processes, full automation and color control, and the ability to handle multiple specialty substrates. Since its installation in early 2020, TPC has been generating increased double-digit speed, efficiency, capacity, and faster turnaround for its customers. 

    The new 10-color Koenig & Bauer Rapida 105 PRO perfector press is enhancing ultra-rich design capabilities and reaching new levels of quality and output at TPC Printing & Packaging

    “In the past eight months we have seen enhanced capabilities due to the new press,” says Joseph A. Schmissrauter III, president of TPC Packaging. “We’ve increased speeds and reduced make-ready time using improved automation on this press. The automation and enhanced speed have also helped production efficiency. We have already experienced a significant increase in output with less machine hours. We are showing our customers a lot of unique and innovative in-line cold foil using the inline Eagle cold foil system for eight-over-foil configuration.”

    Limitless designs    

    Schmissrauter and his team specifically designed the press as a perfector since about 60% of its work mix requires inside printing. Its in-line back printing uses the 8/2 configuration in which the press has a perfector between units 2-3 to allow for printing two colors on the backside and eight colors plus coating on the front side--all inline. The new press with perfecting has already seriously reduced the number of impressions through the pressroom, he says. The perfector and cold foil units have added enormous design capabilities for TPC’s luxury packaging customers. In fact, says Schmissrauter, when used in combination with its Scodix E-106 large format variable digital decoration device, the design options are almost limitless. “We are now the only folding carton company in the world to offer in-line cold foil, off line hot foil and off-line variable digital Scodix foil under one roof,” he says.   

    Environmental and sustainable packaging solutions are a growing demand from TPC’s customers. To provide options for these customers, TPC outfitted the new Rapida with a cold foil unit on units 1-2 to allow for in-line cold foil and eight color overprints + coating in-line. The in-line cold foil capability from Eagle has allowed TPC to avoid more expensive and environmentally challenging fully laminated metalized polyester (MPE), explains Schmissrauter. “We can now offer in-line foil transfer and only apply foil where it is needed.”

     TPC decided to partner again with Koenig & Bauer on the new 10-color press purchase because management believes that it is the best printing press in the world for package printing and is manufactured at the highest level of engineering and craftsmanship. “Our expectations were more than met when we installed the 2017 eight-color Rapida,” says Schmissrauter. “The new 10-color installation was complicated by the pandemic but TPC and Koenig & Bauer were able to successfully work through this challenge under some very rigorous conditions. The new Rapida 105 PRO press has exceeded our expectations. We are ready to go to a higher level of quality and output with this new additional press.”

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    news-1791 Tue, 01 Sep 2020 14:13:17 +0200 “All the signs point to growth!” http://iberica.koenig-bauer.com/en/news/detail/article/all-the-signs-point-to-growth/
  • Output expected to increase by 30 per cent
  • Consistently high print quality thanks to QualiTronic PDFCheck
  • Production space continues to grow
  • High degree of social responsibility
  • The raised Rapida 106 packaging press with double-pile delivery in full production. It is operated by Andreas Metz (at the delivery) and his son Alexander (1)

    “All the signs point to growth” – there is no question about that in the mind of Henrik Jung, technical director at packaging producer Heinrich Buhl in Neunkirchen/Siegerland. In fact, the company has developed constantly ever since its founding in the Buhl family home in 1961. “For the past five years, we have seen almost two-figure turnover growth,” Jung says. The workforce has also increased from 40 to 60 over the same period.

    Henrik Jung, technical director at Heinrich Buhl, and Ralf Engels, senior key account manager for print & packaging at Steuber, expect output to increase by 30 per cent compared to the predecessor press (2)

    One important contribution to future positive developments at the company is the installation of a Rapida 106 from Koenig & Bauer, which was commissioned in the spring of this year. Looking back over decades of trustful partnership and cooperation, Heinrich Buhl again chose the printing system house Steuber in Mönchengladbach as the supplier for its new equipment. The two companies have thus added yet another chapter to their joint success story.

    The print instruction was met with enthusiasm by all future operators of the Rapida 106 (3)

    The five-colour coater press stands in a brand new hall and has been raised by 675 mm to accommodate the higher piles typical in packaging printing. QualiTronic PDFCheck takes care of inline colour density control, sheet inspection and comparison of each printed sheet with the customer PDF. And that all with a single camera system. The double-pile delivery separates good and waste sheets to ensure that only flawless piles are passed on for further processing.

    For many jobs, this capability is also essential. Some brand owners reject even the tiniest flaws, e.g. deviations in a matt black solid. At the product filling stage – or, at the latest, when making up the trays – each individual folding carton is inspected by hand. The consistently high production quality definitely pays off here.

    Die-cutting formes are valuable assets for every packaging producer. Over 1,200 formes are waiting to be used in the storerooms at Buhl (6)

    Maximum performance under real production conditions

    The company expects the Rapida 106 to boost output by 30 per cent compared to the predecessor press dating from 2011. The outstanding sheet travel capabilities of Rapida presses will play an important role here. Henrik Jung: “We are regularly able to run at speeds of 18,000 sheets per hour, depending on the product and substrate concerned.” Thanks to the EasyClean ink ducts, ink changes are also much faster, without requiring the use of ink duct foils. Flexibility in the drying systems supports the use of blister coatings and demonstrates Koenig & Bauer’s expertise in this field. When it came to the plate changers, however, the specialists at Buhl opted for a less highly automated variant, as its operators spend relatively little time on plate changing compared to their other tasks.

    Even so, make-ready times are now significantly shorter. This is accompanied by increased outputs and reduced waste rates. The new press, the only sheetfed offset press in the company’s print department, is furthermore a paragon of high production stability and reliability. Like the rest of the company, it is fully occupied in a three-shift system.

    With the installation of the Rapida 106 from Koenig & Bauer Sheetfed, Heinrich Buhl has come full circle. Presses built in Radebeul were already delivered to the company in 1987 and 1990.

    One camera system, three functions: QualiTronic PDFCheck takes care of inline colour density control, sheet inspection and comparison of the printed sheets with the customer PDF (5)

    Broad diversity of packaging

    Heinrich Buhl produces folding cartons, blister packs, skin packaging, product backing cards, counter display units and trays. Many of these products can be found in DIY and hardware stores. They are printed on both board and plastic films. The majority of the products are destined for the German market, though numerous customers are also supplied in France, Switzerland, Italy and the Czech Republic.

    Henrik Jung identifies flexibility and punctual deliveries as the most important characteristics of a packaging printer. There are often just 36 hours between receipt of an order and the delivery deadline. During this time, the packaging must be produced from scratch – nothing is held in stock in a warehouse. The perfect functioning of the underlying processes is illustrated by the long-standing partnerships which exist with many customers. Some of these business relationships have been going strong for more than 25 years.

    Heinrich Buhl specialises in packaging production in short and medium runs. The average run length is around 5,000 sheets, but there have also been orders for as many as 200,000 sheets.

    Impressive company headquarters: further investments and extensions are already planned for the coming year (7)

    Start of construction for a new office building

    There can be no doubt about the continued development of Heinrich Buhl: diggers and bulldozers will be back at the site in September. A new office building with modern social facilities is to be built. The plans also include a new car park and charger stations for e-bikes.

    Heinrich Buhl attaches great importance to motivated employees. Most remain loyal to the company over decades, and it is quite possible to meet several generations from one family in the packaging operation.

    Raising of the press foundations by 625 mm permits the handling of piles up to almost 2 metres in height (4)

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    news-1785 Wed, 19 Aug 2020 07:27:07 +0200 Over 100 Rapida printing units in operation at Parksons Packaging http://iberica.koenig-bauer.com/en/news/detail/article/over-100-rapida-printing-units-in-operation-at-parksons-packaging/
  • Rapida 76 boosts sheetfed offset press fleet
  • Rapida sheetfed offset technology valued for ist high productivity
  • Production focus: folding box production
  • Parksons Packaging is one of the biggest packaging solutions providers in India. Alongside its headquarters in Mumbai, the company, which is overseen by chairman Ramesh Kejriwal, operates five ultramodern production plants at locations all over the subcontinent. Only recently, a newly installed Rapida 76 was commissioned. This means there are now exactly 101 printing and finishing units from Koenig & Bauer in production for the Indian packaging giant.

    Impressive dimensions: The Parksons Packaging plant in Chakan, Pune (1)

    The first Rapida sheetfed offset presses started arriving at the company in 2005. At the time, Parksons Packaging was looking for presses to handle UV production. The Rapida 105 with its facility to switch dryer modules between multiple installation points was the industry yardstick in those days, not only at Parksons, but indeed for UV production throughout India. Later, Rapida 106 models joined the line-up – seven-colour and eight-colour presses and others in double-coating configurations. At the beginning of 2020, the company purchased its first Rapida 76 – in a six-colour version with coater and extended delivery.

    Faced with changing market demands, Parksons Packaging decided that it needed to install a half-format press alongside its medium-format Rapidas. The combination of high production speeds and a small footprint tipped the scales in favour of the Rapida 76. No less important were the short job changeover times – especially when using DriveTronic SPC – and an enlarged sheet format.

    At a ceremony to mark the commissioning of the Rapida 76, Dietmar Heyduck, Koenig & Bauer Sheetfed (2nd from right), honoured Ramesh Kejriwal, Parksons Packaging (centre), as an important partner. Also present: Aditya Surana from Koenig & Bauer sales partner Indo-Polygraph Machinery (left), Siddharth Kejriwal (2nd from left) and Subhasis Roy (right), both Parksons Packaging (2)

    Fast job changeovers and high production speed

    The capacity to disengage individual inking units, a feature unique to Rapida presses, also caught Ramesh Kejriwal’s attention: “We can already prepare the unused printing units for the next job while the press is still running the current production job. And as an extra bonus, that also reduces wear on the rollers.“

    Kejriwal is equally impressed by the high productivity of the other Rapida presses: “DriveTronic SPC allows job changeover times to be shortened by 30 to 40 per cent. And the number of jobs which we handle on the new presses has increased by 30 to 35 per cent.“

    On average, it can be said that each new Rapida is able to replace two older models. In addition to the high speeds, waste is also reduced. Parksons is very satisfied with the presses, the print quality and the installation and commissioning process. This is reflective of the fast and comprehensive service provided by Koenig & Bauer sales partner Indo-Polygraph Machinery. And so, with each new press, the company is building up a full package geared to the most important criterion for any type of production technology: Performance.

    It was two years ago that Ramesh Kejriwal, Parksons Packaging (centre), signed the delivery contracts for three seven-colour Rapida 106 coater presses, two of which feature DriveTronic SPC and QualiTronic ColorControl. Here in the photo (left to right): Aditya Surana from Indo-Polygraph Machinery, with Dietmar Heyduck, Bhupinder Sethi and Sascha Fischer, all Koenig & Bauer Sheetfed (3)

    Folding cartons in all dimensions

    All Parksons Packaging plants place their focus on folding carton production. The corresponding jobs can be assigned to a total of 22 offset production lines, 13 of them from Koenig & Bauer, and one digital line. Nevertheless, there are differences between the individual plants and their specialisations. Digital and screen printing are based in Daman, together with the production of pharmaceuticals packaging. Pantnagar is specialised in packaging with high-quality cold foil finishing. And Chakan produces beverage cartons. Additional production plants are located in Sricity and Guwahati.

    This nationwide base allows Parksons Packaging to supply a wide range of packaging products to customers in all corners of the country. Domestic production is complemented by a global export business. The product portfolio includes, among other things: Mono cartons, litho-laminated cartons, liner cartons, transport and retail packaging, shelf-ready displays, promotional and gift packaging, a broad spectrum of custom packaging, beverage cartons and blister packs. One of the company’s specialities is an ingenious slider pack design.

    In 2019, Parksons Packaging recorded a turnover of around €150m ($167m). Almost 18,000 different articles are produced, and approx. 100,000 tonnes of paper and board are processed every year. More than 1,700 employees work in plants with a production floor space totalling almost 100,000m2 (1,075,000sq.ft).

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    news-1778 Wed, 05 Aug 2020 11:52:21 +0200 Poland’s first Rapida RDC 106 rotary die-cutter now being used in production at Top-Pol http://iberica.koenig-bauer.com/en/news/detail/article/polands-first-rapida-rdc-106-rotary-die-cutter-now-being-used-in-production-at-top-pol/
  • Used for in-mould label production
  • Pioneer on the Polish market
  • Production output practically doubled
  • Top-Pol in Zbrosławice is the first print company in Poland to use a Rapida RDC 106 rotary die-cutter from Koenig & Bauer. The machine was purchased as part of a project to allow the printing of innovative IML labels in an offset process, and which received funding support from the EU. The rotary die-cutter aims to guarantee production stability and high cutting speeds, alongside significantly reduced makeready times.

    Top-Pol is a family-run company that has been active on the printing market since 1989, and has become a specialist for the production of labels using non-absorbent substrates – primarily plastics – since the end of the 1990s. Co-proprietor Marcel Topolski: “We were one of the pioneers in the use of UV offset technologies for substrates like this. IML labels soon became our flagship product and currently account for 70 to 80 per cent of our production volume. Another key area is the production of lids and covers made from PE, PS or PP for plastic packaging, for example for yoghurt pots.”

    Top-Pol exports 30 to 40 per cent of its production output. The end customers for the labels are primarily companies operating in the food and construction industries. “The systematic development we are pursuing means we are constantly modernising our production machinery, also with regard to finishing processes,” says Marcel Topolski.

    Marcel Topolski (left) has raised the bar for IML production in Poland with the Rapida RDC 106

    High production speeds, fast makeready

    The maximum mechanical output of the Rapida RDC 106 totals 15,000 sheets per hour. The press enables the die-cutting of substrates in thicknesses from 0.03 to 0.6 mm, and is equipped with numerous solutions that were introduced with the Rapida 106 sheetfed offset printing presses. These include, among others, DriveTronic technology with dedicated drives, the sidelay-free infeed DriveTronic SIS, and a camera system to monitor sheet travel at the feeder and delivery.

    One of the key functions of the machine is automatic adjustment of the die-cutting pressure. The pressure can be set separately for each side of the cylinder with a precision of 1 µm. This results in a high die-cutting quality over the entire length of a run. Fast, tool-free forme changes that use a “click & cut” process enable very short makeready times – as little as 5 minutes for repeat jobs. Smooth delivery of the sheets onto the pallet is realised by the dynamic sheet brake and an anti-static system with an extensive range of functions. This also allows further processing to continue immediately when the next step in the production chain starts. There is no need for time-consuming re-stacking ahead of automated further processing. The die-cutting units are equipped with a magnetic cylinder, to which the individual cutting formes are fixed. As a result, a range of processes can be realised in a single unit – from die-cutting to embossing or perforation, along with hole punching. The Rapida RDC 106 is available in a number of different configurations with one to four units.

    Enhanced production and productivity

    “Once again, we have assumed a pioneering role, this time by introducing the Rapida RDC 106 onto the Polish market,” says Marcel Topolski. “As we had already been successful using rotary label die-cutting in the past, the purchase was an ideal opportunity to continue to enhance our productivity and production. After all, our products are quite difficult to produce. The IML labels are made of plastic and also feature indentations to make it easier for the end customer to separate them later on. This makes it a perfect opportunity to broaden our knowledge, both for our own and for the manufacturer's benefit.”

    “Special mention must be made of the level of dedication shown not only by the sales team but also by the technical and service departments, both at our local Koenig & Bauer branch office and at the German headquarters. Integration of the press into the new technological process was completed efficiently and on-time during the first quarter of the year. Our operators have nothing but praise for it, especially in regard to the increased level of process stability and the doubling of production output compared to our previous solution.”

    “Our customers in the food industry, along with our customers in other sectors, expect labels of the highest quality. Accordingly, the solutions we use must also represent the highest standards and the best possible performance that the global market has to offer. The latest investment in the Rapida RDC 106 will more than satisfy these expectations, which are becoming more and more demanding due to changes to the market and to consumer tastes. These aspects are all the more important in the current global situation, which has, of course, also impacted our order volume,” Marcel Topolski concludes.

    Jan Korenc, managing director of Koenig & Bauer (CEE) adds: “This is a first-class solution which requires up to 40 per cent less makeready to complete an entire job. This is why we are confident that it will contribute to the continued growth of Top-Pol as one of the leading print companies in Poland, and play a role in the successful implementation of the new technology project for which the Rapida RDC 106 rotary die-cutter was purchased.”

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