Packaging printer achieves high environmental efficiency and saves costs with technology from Heidelberg

The ceremony for the “100 Betriebe für Ressourceneffizienz” (100 Companies for Resource Efficiency) took place in October of this year under the auspices of Minister President Winfried Kretschmann. Among the companies were packaging manufacturer August Faller GmbH & Co. KG. based in Waldkirch and Heidelberger Druckmaschinen AG (Heidelberg), which together developed an environmentally friendly offset printing application for folding cartons.

• August Faller and Heidelberg chosen to be part of the “100 Companies for Resource Efficiency” initiative • Anicolor technology permits annual savings of 37 metric tons of CO2 and 80,000 kilowatt hours as well as around EUR 155,000 through less paper waste

August Faller GmbH & Co. KG produces folding cartons for the pharmaceutical and healthcare industries at its location in Waldkirch. The Speedmaster XL 75 Anicolor permits cost-effective and environmentally friendly production, even with short runs.

The “Allianz für Ressourceneffizienz” (Alliance for Resource Efficiency) was established in 2014 in Baden-Württemberg by the Federal Ministry of the Environment and the leading trade associa-tions as well as the state Chambers of Industry and Commerce. A key initiative of this alliance is “100 Companies for Resource Efficiency”. Its purpose is to showcase how resource efficiency can be successfully implemented and the kinds of economic and ecological successes that can be achieved, using 100 companies as examples.

August Faller GmbH & Co. KG manufactures folding cartons for the pharmaceutical and healthcare industries and was one of the first packaging print shops to recognize the potential of the Anicolor technology in 50 x 70 format from Heidelberg. The company was looking for a cost-effective process to address the increasing trend towards short runs, while also taking into consideration the constantly changing spot colors specifically required for folding cartons. The Anicolor unit is a zoneless inking unit that needs just two rollers rather than the up to 17 rollers required in conventional offset printing. Faller worked closely with the specialists from Heidelberg to pilot the adaptation of the Speedmaster XL 75 Anicolor for the production of

Heidelberg NewsBRIEF • January 2017

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NewsBRIEFHeidelberg Graphic Systems Southern Africa (Pty) LtdTel: +27 (0)86 142 4756www.heidelberg.com/za/enJanuary 2017

Heidelberger Druckmaschinen AG was chosen with Faller as one of the “100 Companies for Resource Efficiency” in Baden-Württemberg.

folding cartons. Up to then, the press was mainly used for commercial printing in 35 x 50 cm format.

Paper waste, costs, and impact on the environment all reducedThe pilot phase ran from the start of 2014 until the middle of 2015, with impressive results: the Speedmaster XL 75 Anicolor enabled paper waste to be reduced by 71.5 percent compared with conventional offset printing, which is equivalent to a saving of 163 metric tons of cardboard and around EUR 155,000 per year. The environment also benefited, with savings of around 37 metric tons of CO2 and around 80,000 kilowatt hours per year.

All of these technical adaptations have now been incorporated into the Speedmaster XL 75 Anicolor, and 40 percent of all Anicolor presses supplied are now being used in packaging print shops. An enhancement of the Anicolor press, Anicolor 2, was presented at drupa 2016 with an even wider range of applications and new uses, particularly in packaging printing (see press release dated 18 February 2016). Examples are 7-color printing with Multicolor technology and UV printing for achieving an even glossier result. The Speedmaster XL 75 Anicolor 2 with the new design has been in production since November of this year, and is supplied with all the other drupa innovations.

pure-bw.de/de/100betriebe/winners

www.august-faller.com

At a stand shared by Heidelberg, POLAR and Müller Martini, POLAR’s machines are integrated into the live production of a brochure. Visitors are shown how to ensure an efficient and high-quality production.

Digicut ECOThe innovative Digicut ECO laser cutter opens up numerous possibilities to creatively finish small quantities. The laser not only enables the most intricate contours to be cut, but also perforated, creased and engraved - all in a single pass and on a wide variety of materials. Besides paper and card stock, you can also process wood, acrylic glass, glass, cotton, leather and natural rubber. There are practically no limits when it comes to the contour. The GS sign awarded to Digicut means that the machine meets the highest safety standard.

BC 330 three-side trimmer The robust POLAR three-side trimmer is suitable for networking and perfect for automatically trimming perfect-bound products. Its superior cutting precision and the wide range of formats offered by the BC 330 are most impressive. Products from size DIN A6 to size DIN A4 can be processed without any need to convert the machine. The BC 330 trimmer is operated using an ergonomically positioned 18.5” touch-screen display. A clearly arranged menu navigation makes operation easy for everyone and allows the cutting program to be set up in less than one minute. Multiple setting options ensure that every product can be produced in the best possible way.

Cutting machine D 56 ECO POLAR D 56 is a sturdy, programmable cutting machine with hydraulic drive unit and perfect for handling limited cutting volumes. The optimum solution for digital printing. A 5.5“ monochrome display with additional low-profile keyboard makes the ECO model very easy to operate. Repeat sequences can be saved in one of 198 available memory positions and even be adapted at any time. The cutting programs are either generated manually or in a menu-driven and intuitive way via block programming.

At the Hunkeler Innovation Days held from 20 to 23 February 2017 POLAR will be presenting once again its efficient cutting and finishing solutions. In addition to Digicut ECO, the BC 330 three-side trimmer (book cut-ter) and the D 56 ECO cutting machine will be on show.

Hunkeler Innovation Days: POLAR’s efficient and creative cutting solutions

POLAR BC 330 three-side trimmer

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Series production of digital press gets off to successful start in the growing label market

Series production of the Gallus Labelfire 340 digital label press – a joint development by Heidelberg and Gallus – is getting off to a successful start at the Wiesloch-Walldorf site.

• Considerable customer interest in joint development by Heidelberg and Gallus • Well-known U.S. label print shops order further presses • Heidelberg site in Wiesloch-Walldorf becomes production center for digital presses

The label market is one of the printing industry’s biggest growth segments. The dynamic growth in demand for digitally printed labels in particular continues unabated. Following the global market launch of the Gallus Labelfire 340 digital label press – a joint development by Heidelberger Druckmaschinen AG (Heidelberg) and Gallus based on leading inkjet technology from Fujifilm –, series production is now getting off to a successful start at the Wiesloch-Walldorf site. Initial customers of the new series presses include several companies from the United States.

Heidelberg produces the digital inkjet print engine of the Labelfire in Wiesloch-Walldorf. The company’s entire digital printing portfolio will also be manufactured here in the future. The base unit of the new press is made by Swiss subsidiary Gallus at its German production site in Langgöns. The system is designed to meet growing demand for the cost-effective production of short, medium, and versioned label runs.

“The requirements related to quality, flexibility, and speed are getting even more demanding in label production,” says Stephan Plenz, member of the Management Board responsible for Heidelberg Equipment. “With the Gallus Labelfire, we’re leading our customers into the digital future with the growing label market. The considerable interest confirms we’ve adopted the right approach,” he adds.

Well-known U.S. label print shops order further presses Following numerous orders from Europe and Australia, Heidelberg and Gallus are now also enjoying success in the key American market. Info Label from Clifton Park in New York is getting the first Gallus Labelfire 340 supplied to a label print shop in the United States. The company’s President, Mark Dufort, took a look at the first demonstration press at the Digital Label Forum in Heidelberg and then at Gallus in St. Gallen. “By investing in the Gallus Labelfire 340, we’re offering our customers outstanding quality combined with shorter delivery times at lower costs,” he explains.

Another U.S. customer – Hub Labels from Hagerstown in Mary-land – has also signed up for the new Gallus Labelfire 340 digital label press. Its first glimpse of the machine was at Labelexpo Europe 2015 in Brussels and the scheduled delivery date is fast approaching. Thomas Dahbura, President of Hub Labels, has the following to say about the press: “This is the first digital press I’ve seen that can do exactly what I expect it to. It integrates all steps from the reel to the finished label in a single production pass – whether digital or flexographic printing, cold-foil printing or die cutting. I was impressed by how much effort Gallus and Heidelberg put into ensuring this system was a success. Although we’ve already seen other presses with an excellent resolution of 600 x 600 dpi, this one is simply unbeatable with its resolution of 1200 x 1200 dpi.”

Digital printing drives change in the growth segment The new Gallus Labelfire 340 digital printing system has been designed for the self-adhesive labels market. The global print volume for these labels is growing by about 4 percent a year. Although nearly 5 percent of this volume is printed digitally, this figure is rising rapidly with up to double-digit growth rates. Indeed, digital printing is driving change in this highly promising market segment. It is anticipated that, in the medium term, just under half of the presses sold in this sector will be digital. By launching this new technology, Heidelberg and Gallus are actively shaping change in the business models used in this segment and offering users a versatile and cost-effective solution.

The entire digital printing portfolio, together with the offset systems from Heidelberg, can be integrated into a print shop’s overall workflow using the new Prinect Digital Frontend (DFE). Web-to-print applications and multi-channel publishing business models are also supported. In this way, Heidelberg is making the smart print shop a reality, enabling users to largely automate their offset and digital printing processes and control these in a standardized, transparent way. The medium-term goalis for digital business to account for around 10 percent of Heidelberg Group sales.

The Heidelberg Wiesloch-Walldorf site is becoming a production center for digital presses.

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Open to new things. Open Days and Info Days in the Print Media Center in 2017.

Open to new things.

HEIDELBERG OPEN DAYS

The future in action: all the machines in the Print Media Center Commercial will be running and the entire team will be on-site for you at the Heidelberg Open Days. Each day will run from 9 a.m. to 4 p.m.:

23 March 2017Print Media Center Commercial

27 April 2017Print Media Center Commercial

29 June 2017Print Media Center Commercial

To register, click on the below link:Contact form

Open Days in the Print Media Center in 2017.

HEIDELBERG INFO DAYS

Our solutions for your success:

Presentations, product demos and talks by experts on modern concepts, smart technologies and the key topics for packaging and commercial printers:

5 April 2017Info Day Commercial

10 May 2017Info Day Packaging

28 September 2017Info Day Label Production

To register, click on the below link:Contact form

New technologies and innovative solutions for the Smart Print Shop:

Heidelberg will be presenting a full-service, fully integrated print shop in action in two showrooms for commercial and packaging printing. Be there with us to experience the smart print production of tomorrow.

Heidelberg NewsBRIEF • January 2017

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Heidelberg NewsBRIEF • January 2017

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