Carbon fibre as the silver lining Viscosity Standardization in Flexographic Printing:
The@vanced Technology for a New Age
Reducing flexos carbon footprint
New generation brings a wind of change 1
2
6
In the history of our company we have applied every type of viscosity sensor: rotational, falling ball, falling piston and acoustic wave. The similarity between these sensors is that they are all calibrated with a cup, in our case the DIN cup with a 4 mm outlet.
18
There is no question we are in the midst of a climate emergency. Across the globe, individuals, corporations, governments and organizations are working to offset the impact being done to our planet.
22
Machinery manufacturer KAMPF pioneers the digitalization and automation of converting with their innovative the@vanced solution. The goal is to interconnect machines and allow control of production by available data in real time and thus lead to the improvement of slitting programs, setup and maintenance times, energy efficiency and more.
26
Slitter rewinder manufacturer Euromac has a long and successful history to show for. Now they prepare for a generation change. We met with the next generation of managers in order to learn more about the future plans of the company.
32
Pronexos has an interesting history, with its activities originating from a different industry. However, since 2013 the company utilizes its long-standing experience with carbon fibre materials in new areas. Today Pronexos manufactures a wide range of carbon fibre rollers for the packaging and printing industry.
3
4
Happy New (Drupa) Year It is already 2020, which means drupa takes place in very few months. I think its safe to say that we all are very excited for what June brings. New and more sustainable technology, digital printing, alternative substrates, etc etc etc. There had been lots of talk about the negative impact plastic, and therefore plastic packaging has on the environment. However, plastic and packaging consumption is still on the rise, due to the unbeatable advantages it offers over alternative materials. We believe that the current environmental discussion is needed, but what isn't needed is all the hysteria and biased opinions. Despite all the negative reports, packaging is here to stay. Book your banner now We have sold some top banner positions in our ever more popular newsletter, so we recommend you to act fast and reserve your favourite position. Please note that we now have more than 22,000 subscribers. New editor
As some of you already know, we hired a new editor. Her name is Jackeline Salazar Rodriguez. She will be responsible for the Spanish language content as well as contribute to the english language platform. With more than 9 years of experience as trade journalist in the packaging industry she will be the perfect complement.
www.packagingnewsletter.com 5
Viscosity Standardization in Flexographic Printing: A new approach to controlling the largest variable in flexo and gravure printing In the history of our company we have applied every type of viscosity sensor: rotational, falling ball, falling piston and acoustic wave. The similarity between these sensors is that they are all calibrated with a cup, in our case the DIN cup with a 4 mm outlet. In itself this worked well and due to lack of a better alternative DIN cup 4 became the standard measurement in the flexo and gravure industry.
In December 2017, when looking for a better solution, I came in contact with the Rheonics SRV as an alternative to the sensors we had been using, which were too inaccurate and insufficiently repeatable. In January 2018 we started testing two of these sensors and in June 2018 we equipped all 8 printing stations of the CI press with Rheonics SRVs. Last year we conducted many
tests, gathering experience and new insights. We developed a formula to convert the unit centipoise, or mPaS, which is the unit delivered by the SRV, to DIN Cup 4 seconds because we were accustomed to working with these units. After a few months we decided to completely stop using the DIN Cup units, for reasons that will become clear in this article.
The current generation of printing machines are extremely accurate in terms of adjustment (in Îźm range) and have a very high degree of automation, such as a 100% inspection system, fully automatic impression setting of anilox rolls and plate cylinders, automatic register control and inline spectral colour measurement. However, the largest variable in the printing process,
www.packagingnewsletter.com 6
the viscosity of the ink, is still measured with a unit that is determined manually! In many cases even automatic viscosity controls are calibrated with a cup because operators are used to thinking in cup seconds. In practice, viscosity calibration is often not done because it is time consuming, or because the cups are dirty or not available. The viscosity is a very important parameter in the final quality of the printed matter. If the viscosity is not correct, the flow behaviour and ink layer thickness will vary, which will lead to problems in print quali-
ty. In addition, poorly adjusted ink viscosity can lead to excessive ink consumption.
difficult to control. Contamination of the cup and different densities of inks influence the run -out speed. All of these Accuracy add up to poor repeataEvery operator is used bility and accuracy of to working with some DIN cup measurements. sort of viscosity measIn practice, error maruring cup. These measgins can be as high as 5 urements have never -10% , which is a big been totally standardbandwidth of viscosity. ized and are only For example, for an ink "reliable" over a relahas a viscosity of 20 s, tively narrow measuring an error margin berange with a large martween 5-10% means a gin (5-10%) of error. bandwidth between 1 s Some of these errors and 2 s! are caused by the cup itself, others are a func- How does the accuracy tion of operator skill. and repeatability of the Measurements are not Rheonics SRV compare repeatable. Tempera- with DIN cup measureture, which has a strong ments? influence on viscosity, is Here is an excerpt from the Rheonics SRV specification sheet: The sensor’s operation is based on a vibrating element that is immersed in the fluid, and whose resonance is damped by the fluid’s viscosity. The Rheonics SRV differs from other vibrating sensors in that
www.packagingnewsletter.com 7
its resonator is completely balanced, making its accuracy immune to its mechanical environment. It is also extremely robust, meaning it can be cleaned, when necessary, by wiping it with a solvent-soaked rag.
The manufacturer's specification shows that it has a broad measuring range and very high accuracy, but what does that mean in practice? We tested its accuracy by adding 20 g of solvent to 25 kg of ink. The sensor registered a viscosity change of 0.1 mPaS, which is the equivalent of a cup measurement difference of .02 seconds! This is a previously unknown accuracy of the measurement of viscosity in this industry. And because the SRV incorporates an accurate temperature measurement into the sensing element, it is possible to accurately compensate for the effects of temperature,
as we will describe in Solvent based inks exthe next section hibit non-Newtonian behaviour. Under the We have found that influence of shearing working with the cup is force their viscosity not only outdated, but changes. Ink is also actually counterprothixotropic, a stationductive. After a few ary ink having an apmonths we stopped preciably different visconverting to cup seccosity than an ink that onds altogether, finally is in motion. The viselevating viscosity cosity of a stationary measurement, the last ink can differ from that crucial variable in of a moving ink by as printing, to the same much as 20%! And in technological level as addition, ink viscosity the rest of the process. is strongly temperature We finally arrived in dependent. On printing the 21st century. Non-Newtonian behaviour, thixotropy, and temperature compensated viscosity Due to the accuracy and repeatability of the Rheonics SRV sensor, we have gained a lot of insight into the behaviour of inks -- sometimes more than we expected. Ink is a rheologically complex medium, and the SRV gives us some insight into that complexity that is not observable with the DIN cup.
www.packagingnewsletter.com 8
presses on which the temperature of the inks is not conditioned, ink temperature – and therefore viscosity - can vary greatly due to changes in the ambient temperature, but also due to the heat generation in the press itself. One of the first things that we have explored with the Rheonics SRV is the temperature dependency of ink viscosity. We built a test set-up consisting of a closed flow loop in which the ink is continuously pumped in a circuit, at a speed comparable to
that of the ink circuit in our press, and slowly heated up. Every second the temperature and viscosity are measured, giving more than a thousand measurement points in a typical test run. The graph in Fig. 1 shows the temperature dependence of the viscosity of a number of different inks (modified nitrocellulose ink yellow, magenta, silver and a polyurethane white) over a temperature range of 20 °C. Over this range, the viscosity can differ by up to 60%.
One of the most important uses of viscosity measurement is to determine when and by how much ink must be diluted in order to compensate for loss of solvent during the printing process. Solvent evaporation increases the pigment loading of the ink, resulting in poor print quality and excess ink consumption. This loss of solvent also increases the viscosity of the ink. However, since viscosity is also a strong function of temperature, it is necessary to distinguish between the effects of temperature and evaporation in order to determine the amount and timing of solvent addition. Without temperature compensation, an ink at a low temperature would give a high viscosity reading, suggesting that dilution is necessary. However, diluting the ink would give a lower color density, since the higher viscosi-
www.packagingnewsletter.com 9
ty was due to lower using our special algotemperature, not to rithm, enabling us to fihigher pigment loading. nally achieve tighter control over pigment Using graphs such as loading and its effect on those in Fig. 1, we deprinting quality. veloped an algorithm that allows us to com- Installation: pensate for the effect of The sensor is mounted temperature on the visin a connector with an cosity, resulting in a inlet and outlet opening “temperature compenand installed in the supsated viscosity” that is ply line between the ink a true measure of the pump and the doctor pigment loading. Therechamber. Influences fore, it can be used disuch as machine vibrarectly to control solvent tions or pressure pulsaaddition to make up for tions from the diaevaporation, because it phragm pump have no removes temperature effect on sensor operaas a variable affecting tion or measurement the measurement. accuracy. Using our compensation The sensor is maintealgorithm, we reduce nance-free – each the error deviation to 1 cleaning cycle of the % over the entire temlines and doctor champerature range. In the ber ensure that the automatic viscosity consensor is clean again, trol the temperature since it is automatically compensation can be washed in solvent. As selected for each type shown in Fig. 2, only a of ink. We have detervery thin haze of color mined this curve for almay remain on the senmost every ink we use, sor, which has no influand have determined ence on its accuracy or the temperature comrepeatability. And bepensation parameters
cause of the sensor’s robust construction, any necessary cleaning can be done with a solventsoaked rag, with no danger of damaging the sensor or changing its calibration. All sensors are separately connected via industrial grade cables to their electronics units, and these communicate with an industrial grade pc. The computer controls a valve island, which in turn controls the pneumaticallyactuated valves for dosing solvent. The system includes a touchscreen,
www.packagingnewsletter.com 10
next to the operator control panel, which operates the intuitive user interface of the Rheonics viscosity control software, Inksight. In the creation of the user interface it was obvious that it had to be clear, intuitive, effective and quick to operate. The interface displays a dashboard, on which the operator can monitor the viscosity of all
stations. Touchsensitive controls enable the operator to switch individual stations on or off, enable automatic control, and to set the viscosity limits. A separate station hub switches to a display that monitors the viscosity over time and allows adjustment of specific sensor and valves.
Furthermore, the software notifies the operator when the viscosity changes are too large and helps by making the right correction to solve the problem. Automatic control, CS -Control. During printing there is continuous evaporation of solvents; evaporation increases with increasing printing speed and rising ink temperature. The SRV sensors measure the actual value of the viscosity and ink temperature once a second, enabling the software to calculate the temperature compensated viscosity. This, in turn, enables the controller to determine whether the temperature compensated viscosity falls within the desired tolerance. The controller will add a quantity of solvent that depends on the size of the deviation from the setpoint. During printing, it is possible to maintain a deviation
www.packagingnewsletter.com 11
only 0.5 % from the set point. Special dosing valves are used that can add the very small amounts of solvent that are necessary to achieve such fine control. The plots below are of the same colour with different scales, with vertical magenta lines indicating automatic solvent dosing.
The SRV-based control system is extremely accurate because it can compensate rapidly and often for the evaporation that is occurring constantly during the printing process. To achieve such very small deviations from the setpoint, the system will sometimes dose as little as 10 g of solvent every thirty seconds.
If an ink with too high a viscosity is added to the ink bucket, the control responds immediately by measuring the response at each solvent dose, with the subsequent dosing of solvent being adjusted accordingly. In the end, the set point is reached very gradually with very little overshoot . Besides the extreme accurate control, it’s possible to keep the viscosity stable when the level in the ink bucket is very low, just enough to pump the ink through the system. Quality assurance, improvement and standardization An experienced operator knows what viscosity must be maintained for which types of ink in the particular process being used. This depends on the kind of ink – the Pantone color as well as special challenges, such as those presented by metallic and white inks, which have
www.packagingnewsletter.com 12
a somewhat different behaviour with temperature than “normal� inks. And the desired viscosity also depends on the type of substrate on which the printing is done. To better understand the problem and its solution, we performed a series of experiments on the effects of ink dilution on print quality and measured ink viscosity. With these results we now which viscosities have to be maintained for the type of substrate (paper, polyester, polyethylene, polypropylene).
In a first experiment 10 kg ink was 10% diluted, press running at 200 meters/min, the polyester film was marked and the press was stopped. The ink was diluted with a further 3% of solvent, the ink was circulated until the viscosity stabilized and the process was repeated a total of 15 times. The film was removed, and all 15 segments were measured with a spectrophotometer, and photographs of the film segments were made for subjective visual evaluation.
The following composite figure shows the visual appearance of the printing quality at a series of dilutions. At the lowest dilution (highest viscosity), too much ink is deposited and does not flow properly. Pinholes develop, and overall quality is poor. Although the colour between the pinoles is quite dense, the measured density is low, due to the high reflectivity of the pinholes. As dilution increases, viscosity decreases and the flow improves, but pigment loading decreases and the colour becomes lighter. Each sample was measured with the spectrophotometer and compared with the digital PMS reference. The following chart and table show the dE2000 and color density as functions of dilution and viscosity. Viscosity difference values are referred to sample 6,
www.packagingnewsletter.com 13
which is the target den- bandwidth was Âą 0.5 sity. cup seconds (about Âą 2.2 mPaS) with the visThis experiment shows cosity being checked that with the Rheonics every 5-10 minutes. system, very accurate The amount of solvent viscosity control can be that was then dosed achieved, with a viscoswas between 0.2 and ity bandwidth of 0.5%. 0.5 kg (depending on By dosing of very small the ink coverage, type quantities of solvent of solvent, anilox volabout every 30 secume, machine speed onds, the system enaand temperature. bles very small variations in dE values to be We now have changed achieved. the process of printing a Pantone colour, beAt the time these excause we not only know periments were done, which viscosities have the customary viscosity to be maintained for the
type of substrate, but can hold tight tolerances on this viscosity. Certain substrates require a higher viscosity due to the fact that the ink "sinks" too far and so the structure becomes visible, resulting in a decrease in colour strength, while other substrates need a lower viscosity due to their smooth surface and good ink acceptance. With the experience gained with the Rheonics sensor, we know exactly which viscosity should be maintained for the type of substrate (polyethylene, polypropylene, polyamide, polyester, paper, and biodegradable), and have actually determined a standardization for ourselves. With the very first print, the colour density of the pantone colour is measured and then the operator checks whether the ink has the correct viscosity for the relevant substrate. (The
www.packagingnewsletter.com 14
ink is usually not brought to the correct value in advance because the substrate may vary slightly in terms of surface quality, so we have some room to play with the viscosity for optimum results). In the older method, if a colour had too high colour density, we reduced it with varnish and/or with a different anilox roll. If in doubt, the viscosity was checked with a cup, which usually necessitated re-calibration of the relevant sensor. Because we now have a more reliable measure for the initial temperature compensated viscosity of the ink, its viscosity can immediately be adjusted automatically by diluting an ink to the correct value . Because the correct viscosity values are maintained, this leads to better ink transfer from anilox roll to printing plate and finally to the substrate. Contamina-
tion of the anilox roll can also be noticed earlier because we know which colour strength should be reached with a certain viscosity. Too high viscosity leads to poor transfer resulting in visual characteristics like opacity and “ghosting�. Due to a more accurate viscosity, the cell of the anilox roll is better emptied and the ink usually flows better, giving in a smoother ink layer and increased colour strength. With increasing speed, the ink transfer decreases, but because the ink has the correct viscosity and performs optimally, these variations are smaller compared to our earlier method using cup calibrated sensors.
In the last six months we have improved colour quality and are able to maintain much smaller deviations of dE2000 values, especially during long runs .
A result of tighter viscosity control is that the print inspection system sees far fewer errors in colour strength deviations. Our operators have complete confidence in the accurate and repeatable values of the sensors and control system. This trust has led to our press achieving excellent print quality for jobs small and large. In addition, we have performed neither maintenance nor calibration of the sensors and beyond our initial temperature compensated viscosity parameter measurements for each ink, no further standardization of the viscosity values needs to be done. We now know what viscosities should be maintained for specific substrates. After printing each new order, we store the viscosity set values and use these for repeat orders of the same job.
www.packagingnewsletter.com 15
So why not convert to give the false imprescup seconds? sion that the sensors themselves are not reAlthough formulas exist peatable! It is only to convert viscosity valwhen we compared acues from mPaS to DIN tual printing results uscup seconds, we have ing the new sensor sysfound that abandoning tem to what we were cup-seconds has severaccustomed to that we al advantages. saw the real value in Above all, it has thinking in the new, unchanged the way we familiar units. It enathink about viscosity. As bled us to “think small”, long as we thought in to be able to see small terms of cup seconds, variations in viscosity keeping a tight control that were otherwise inon viscosity seemed like visible. Furthermore, it an impossible task. Our let us get our viscosity expectations were lim- under tighter control, ited by our previous ex- which had direct posiperiences, so we set the tive impact on the qualbar lower than was nec- ity of our final product, essary to achieve the which is, after all, our kind of print quality we main goal. knew was attainable. As printing speeds inFurthermore, thinking crease, and profit marget tighter, in terms of cup seconds gins made us want to grab a “getting it right the first cup and check the accu- time” becomes much racy of these new sen- more important. An ersors, with which we ror in initial viscosity were unfamiliar at the setting can result in time. But checking the producing several thouaccuracy of the sensors sand meters of waste in with a much-less- no time at all. With the repeatable method can Rheonics SRV system,
we have been able to streamline our printing process while improving color quality and reducing waste. In the next article in this series In this article we have focused on the basic challenge of viscosity monitoring and control, showing the benefit of tight control for print quality and ink economy. In the next article, we will look more closely at the control system that make it possible for the press operator to achieve and maintain this quality with a minimum of intervention. The system, Rheonics Printing Solution (RPS), consists of a control box containing a process computer and valve control that directly controls solvent dilution based on measured viscosity. The RPS can accommodate up to 10 printing stations, with SRV sensors doing the monitoring. The RPS hardware is supported
www.packagingnewsletter.com 16
by a sophisticated software system that estimates the required dilution based on measured viscosity and is controlled by a simple and intuitive user interface to set and adjust the desired viscosity. We will also consider the challenge of viscosity control of special inks, such as UV inks whose viscosity is very temperature sensitive, and whose viscosity is best controlled through thermal controls.
www.packagingnewsletter.com 17
Reducing the Carbon Footprint of Flexo Printing Plates
There is no question we are in the midst of a climate emergency. Across the globe, individuals, corporations, governments and organizations are working to offset the impact being done to our planet. At Asahi Photoproducts, we have been working to create a safer, cleaner flexographic printing process for almost half a century. The outcome? CleanPrint. It helps bring flexographic printing into balance with the environment while delivering exceptional quality and productivity.
CleanPrint flexographic plates from Asahi Photoproducts have been specifically engineered
by Asahi’s chemical gineers to transfer remaining ink to printed substrate,
enall the re-
ducing makeready time and press cleaning stops as compared to other platemaking systems while delivering exceptional quality. Asahi CleanPrint flexographic plates are also ideal for fixed color palette printing, a method that is increasingly being adopted to save time and money while still delivering the quality brands expect. This
www.packagingnewsletter.com 18
is made possible by the precise register fine dot structure of Asahi CleanPrint plates. In Balance with the Environment CleanPrint plates emit fewer VOCs in prepress as they don´t use solvents in the washout process. Studies show that water washable CleanPrint plates have the smallest cradle-tograve carbon footprint when compared to solvent or thermal solutions. Less makeready waste and waste due to plate cleaning press stops brings the process even more in balance with the environment. And more efficient
throughput means less energy consumption. But we are not stopping here. Be sure to put us on your drupa 2020 calendar to learn how we are bringing to market a new capability that reduces platemaking waste water by 80%!
Reducing Flexo’s Carbon Footprint CleanPrint helps flexographic printers with regulatory compliance and creates a safer, cleaner work environment for employees. Not only does it reduce flexography’s carbon footprint, it also results in a total process cost reduction.
Today, there is no standard means of calculating carbon footprint, although ISO has work in progress under PAS 2050:2008, Specification for the Assessment of the Life Cycle Greenhouse Gas Emissions of Goods and Services. The goal of that program is to ensure a scientifically substantiated, transparent and international coordinated assessment framework for both corporations and their products, from manufacturing to use to disposal. Lacking that international standard, Asahi Photoproducts has chosen to use one of the three existing software calculation packages
www.packagingnewsletter.com 19
available today: the Japan Environmental Management Association for Industry (JEMAI) methodology. Originally developed under a Japanese government pilot project, which was completed in March 2012, the Carbon Footprint of Products (CFP) was transferred to JEMAI in April of that year and continues to evolve in
conformance with ISO 140XX standards and without government involvement. The program enables companies to visualize carbon hotspots in a product’s life cycle and also works to promote communication between companies and consumers with a view to accelerating the achievement of a lowcarbon society. In
2017, the program was integrated with EcoLeaf. Using these calculations, we have compared the life cycle of Asahi Photoproducts’ AWP water washable plates, as they exist in the market today, with solvent and thermal systems. As shown in the graphic below, AWP plates have the small-
www.packagingnewsletter.com 20
est product carbon foot- nent of the highly conprint of the three plate- centrated extracts also making solutions. contributes to required cooling of the incineraWhat’s Next? tion plant, adding to the With the introduction of life cycle carbon footreduction and a new recycling unit print that will be standard in bringing the flexographall new Asahi Photo- ic platemaking process products platemaking even more in balance systems at drupa 2020, with the environment. this comparison will be Existing Asahi Photoplatemaking even more favorable in products light of the 80% sav- solutions will be able to ings in water use be retrofitted with the (reducing water usage recycling unit. from 10 liters to 2 liters CleanPrint plates offer a per m²) and the ability win/win solution to flexto incinerate both dry ographic platemaking and highly concentrated today, and even more extracts in order to so as we progress into minimize any contamithe future. Flexo printnation of water sysers/converters win by tems. The liquid compo-
increasing capacity and reducing costs. Brand owners win by reliably acquiring extremely high-quality labels and packaging that set them apart on the shelf without incurring excessive costs. Everyone wins by making the flexographic printing process more in balance with the environment.
www.packagingnewsletter.com 21
The@vanced Technology for a New Age
Machinery manufacturer KAMPF pioneers the digitalization and automation of converting with their innovative the@vanced solution. The goal is to interconnect machines and allow control of production by available data in real time and thus lead to the improvement of slitting programs, setup and maintenance times, energy efficiency and more. We met with Markus Vollmer, Sales Director to discuss this topic in detail.
In order to improve, you need to know your numbers first. How many customers are currently implementing overall equipment efficiency (OEE)? From my point of view not more than half of our customers are utilizing it but we are looking positive towards the future; I think not anybody is doing it until now because this is not their main focus yet.
They rather put their attention on played capacities instead of the entire process - which is actually crucial for the result. For whom of your customers do you see the potential to use your new the@vanced solution?
for those, who already work with it, prevented maintenance is a great extension – the preliminary step of intelligent and self-learning systems. In my opinion it is not possible to dispense with the machine operator in the next 10 years but it will be a significant relief especially for complex situations.
Nearly everybody! It is especially interesting for companies that want Your to start with OEE. But form
integrative platthe the@vanced
www.packagingnewsletter.com 22
consists of 3 pillars, can mentioned steps in deyou explain the con- tail: nected procedures in Smart production is detail? about being efficient. Our motto is: Maybe Customers have the was yesterday – we are chance to compare and converting 4.0! With analyze orders, perforthe the@vanced our fu- mance and shifts. They ture-proof vision finally are able to receive conbecame reality: The in- stant production infortegrative platform is mation and machine structured in our 3 pil- status in real time. lars of efficiency: Smart Moreover they can exproduction, smart change information with maintenance and smart other systems and prooperation. It is linking cesses. Additional addmachinery, production ons are digital roll proand enterprises. Addi- tocols where one can tionally we are hereby see and analyze macreating and connecting chine data like speed, knowledge and convert tension, contact pres4.0 networks together sure and much more. It with our strong part- provides answer to ners: Extrusion experts, questions like: What is data analysts, software the current status of my developers, drive- and shop floor? Why does sensor specialists and efficiency drop while printing experts. We are humidity rises? Very exfocused on connectivity, iting! interoperability and exSmart maintenance is panding our possibiliabout staying efficient: ties. To increase effiYou can receive spare ciency in real time! part information, In the following I would among others, which like to explain the 3 part needs to be cleaned or exchanged in
future and label and identify certain machine parts. As well easy understandable maintenance videos about necessary settings are available. It is naturally possible to download all data fast and convenient via, among others, QR-codes. All necessary instrument documentation is always available as well as digital protocols from every stage of the process for every produced finished product. Smart operation then boosts your efficiency. It opens up new potential through big data. You can use default views or create individual charts and much more, meaning, it provides the entire relevant statistics: Which activities am I currently implementing, what are my up- and downtimes. So the systems tells you when do you lose time and where do you actually spend your time. In the age of big
www.packagingnewsletter.com 23
data one can conclude that we do not have historical- but real-time data. Within my analyses I can combine factors however I want. This is an efficient point when it comes to view the whole process and is crucial to raise efficiency. Moreover it provides process consulting by checking influencing factors which come from the process, like material characteristics and ambient temperature. It offers solutions how these factors can be improved: How should I react and how runs the machine in its optimum. These are relevant topics, naturally next to topic academy, further training and retrofitting, which are also integrated. It states exactly the possible maximum velocity of my machine to reach the required quality. That’s fantastic! Machines are then able to regulate themselves optimally.
To sum it up: The@vanced is the specific solution for film- and converting business with an open digital infrastructure. It enables new approaches: Turn signals into data, data into information and information into concrete measures: Observe, analyze, interpret, predict and respond. Recognize our value drivers, create digital and added value and increase your uptime and lower the costs. It provides data based services for all decision makers and your machine is keeping you up to date: Simple, clear and easy to understand. Our platform is the place where people, machinery, components, process knowledge and IT world fuse into pure information and relevant data is automatically collected and transformed into expressive information. Companies can monitor, ana-
lyze, interpret and decide explicitly to stay on top of things. It is a rather simple system, but smart and secure. You get real time information, mobile and web based. Special sensor packages are also available and we do continuous development of new features. This is the the@vanced - all are our key assets to industry 4.0!
So within the topic industry 4.0 you are definitely a pioneer. Do you plan to exchange this knowledge with other distributors to create an overall status? Our solution has absolutely the potential to realize this! With pleasure we invite other market players to focus this topic as the key is to share knowledge we all need to learn from each other. The the@vanced builds the groundwork and an adequate platform for
www.packagingnewsletter.com 24
this - we want to make years was not that tan- available our industry smarter. gible for the people. crease. Everyone was talking Is it possible to upgrade about it, but what I elder machines? need to do to raise my First of all: New KAMPF OEE 1% is calculable lines are the@vanced and determinable only enabled and existing recently. machines can surely be How many the@vanced upgraded. There is a -equipped machines technology standard have you delivered until that is upgradable, a now? level of 2-3years, depending on status of We have just started hardware. So machines with the series produccan be retrofitted up to tion. The last 2 years a certain extent. we did the pilot production with several lead In certain countries digcustomers in a rather italization is working small quantity. Now we slower, does this inhibit have more than 20 apthe spread of 4.0? plications in the field Both my personal expe- and it is universally rience of live and expertise in economy taught me something that is relatively simple: Anything that is proved and provides a benefit will prevail quickly! But it is always important that somebody takes the first step - if the benefit is somewhat huge it will prevail even faster. The importance of industry 4.0 in past
and will in-
www.packagingnewsletter.com 25
New generation brings a wind of change
Slitter rewinder manufacturer Euromac has a long and successful history to show for. Now they prepare for a generation change. We met with the next generation of managers in order to learn more about the future plans of the company. Can you tell us about now managed by my yourself and your uncle and father. In the background? future, it will be me and my cousin, but he is I studied political scicurrently quite young. ence and job manageMy cousin is interested ment at university and in technical and sales then moved on to my departments, and wants position here. I started to go into the full proas an apprentice/ cess from production to trainee for 3 years, assembly. helping my father, as I learnt about the dy- I’ve heard you were namics of the company. a driving force beI have been with the hind the new facility. company for 6 years. Yes, it was my project. I I’m third generation. My have been involved with grandad and his brother every process from founded the company working with builders to 50 years ago, and it is
the bureaucracy behind the project. It has been hard because it is my first project depending not only on Euromac, so managing the bureaucracy and getting things signed off has been very tough. There are so many regulations around things like energy efficiency and what materials can be used, making it challenging to get things approved. We started planning in December 2016, about 3 years ago, and it will be ready in November. It took up until Septem-
www.packagingnewsletter.com 26
ber 2018 to have per- We aim to provide betmission. ter service and implement a new software to Was moving to andesign faster. We impleother country ever an mented a new electronoption? ic design software 6-7 No, we believe it will be months ago and have too hard. We have roots started to use it in the here and the headquar- right way. We also aim ter will always be in Ita- to implement general ly. Maybe in the future software to make evewe will open a second rything connect better factory in North Ameri- to each other as well as ca to be closer to cus- a new website to help tomers, it is something clients more with usthat’s important for the age. We may even think American Market. I about implementing inthink that will be our ternet software where next move, we are like- clients can look up ly to be in the USA in items – spare parts, user manuals, automatic the next 7-10 years. updates. From a maWhat other changes chine point of view, sedo you think will be curity is a current hot implemented? topic that is requiring new resources.
How big will the new facility be? What kind of production/service offerings will it have? It will have 2 floors and 18,000 square feet of production space. Overall the new office will be almost 22,000 square feet. An important feature of the new building is height as machinery is becoming taller. We currently have two special machines in production and the office needs to be finished by November for these new machines. We not only have more space, but room for different machines and different products. How much available?
land
is
www.packagingnewsletter.com 27
We still have about We have had expres60,000 square feet of sions of interest for building pot. training for customer operators, so this could Do you think about be our next move in 1setting up a technol2 years. We have conogy centre to hold sidered setting up a open houses? tech centre to offer classes for young people. This would be a
way of introducing them to the industry, and they could come to a mechanical company and be taught practical and theoretical knowledge. We currently collaborate with schools telling students what a mechani-
www.packagingnewsletter.com 28
cal engineering company is nowadays . We have a lot of direct contact with schools as these students are our future. It’s difficult to get people so we want to encourage students to visit with their parents.
What are your plans for next year? Timeline? It’s not always so easy to improve as we have a good company and there aren’t evident holes. We plan to open facilities in the USA and increase calibrators, making it more efficient. We will also look at lean production and see where we can improve, by going step by step with attention to detail. We are in a good position and can have a good future. There has been a change to software but what about machines, especially with Industry 4.0?
Customers currently have to link programs to machinery to fully automate and digitize. Our machines with integrated software and data share have always been applicable to 4.0, just a matter of linking it to the customer area. A company has requested we make fully automated machines, even inserting their core chips to track everything, but most of the time clients are setting up the 4.0 system. What about full automation of the entire converting department? Yes, we have robots and a lot of companies are also going for automated handling. We work with several partners that can offer this type of system, and it is sometimes we also offer as a total package. It allows us to take responsibility of the full system, including our slitter and the packaging line. It’s a great op-
portunity to make customer happy. How was 2018 in terms of sales and machinery? It was very good, we are happy. 2017 was better, but still very happy with our results. We have to finish the new building soon because business is moving so fast. We built 40 machines last year and they now have a 40% bigger dimension than when I started due to electronic parts. Lots has changed– trend towards automated machines, laser positioning – so we really need space. Are there any other plans for partners for delivery system, or any other cooperations or acquisitions? Laser or laminating? Not laminating, that is not our plan. What we see is a lot of clients asking for multi task machines, eg laser scoring. This is already
www.packagingnewsletter.com 29
something we have been doing for many years, but most of time clients say they have a laser system from another client and we like to keep ourselves detached from companies for more flexibility. We have done laser scoring and we have done embossing. We buy embossing units or ask clients to buy embossing units. Many years ago we did one system but usually this is for a very particular application. Printing systems should be for one product, otherwise the stop for
changeover is not worth it as you are not making money when not printing. Our flexibility means we can take projects as a one-off if clients request something specific or weird. We are extremely strong in special projects. If other companies say no, it’s not possible, that’s where we come in. We have tried many times to standardize slitters, but every time we have clients asking to customize and then we start again. It takes additional time to remake
a slitter. From that perspective, maybe we can bring slitters on the market that are standard, then some customized. Some slitters (CPP, OPP) going to Pakistan, India, China are all fairly much the same. What are your plans for the K show? We have to start thinking – we really want to bring machines dedicated to the film industry, but nothing extraordinary. We will demonstrate a lot of projects we have been doing and also hope to be able to offer clients a little less delivery time. We hope to reduce time by 1 month by October. We will then think over the next few weeks or months for something spectacular for the show. In 5-10 years, what will Euromac look like? It will be bigger, with more integrated systems. Maybe faster.
www.packagingnewsletter.com 30
Customers need speed and productivity. We might offer a different impact in terms of quality of cut and being more precise. We would like to offer better inspection to assess quality of cutting straight away. Also, a lot more automation and more turnkey solutions. We may send direct spare parts from our system. Essentially, we will be focusing on Integration, connection and speed. We would also like to partner with engineers to find new way to cut materials, maybe even work with students to find the best option. We have considered a scholarship or money incentives to attract student. We would like to work with people who are young and open minded, maybe in 2020,
Laser is bad for materials, plastics in particular are very sensitive and laser could destroy the border. Maybe, for easy opening. A lot of applications can now be done by round knives. It’s a lot safer as razorblades break and last less. We need new applications and technologies to cut thin materials and make cutting more efficient. When will you takeover as CEO? I don’t know. I need time and my father is still very active in the company and now I am his executive assistant. I am learning as much I can from him, but will not be taking over immediately.
Will knives still be a thing or will they be replaced by laser?
www.packagingnewsletter.com 31
Carbon fibre as the silver lining Pronexos has an interesting history, with its activities originating from a different industry. However, since 2013 the company utilizes its longstanding experience with carbon fibre materials in new areas. Today Pronexos manufactures a wide range of carbon fibre rollers for the packaging and printing industry.
WHEN WAS THE NAME WAS THIS MADE BECAUSE OF THE DECIPRONEXOS BORN? SION TO PRODUCE FOR The name Pronexos THE PRINTING AND launched in autumn PACKAGING INDUSTRY? 2018. It is a relatively new name, but our en- We have chosen the gineers and technicians name Pronexos because rely on decades of ex- it is a strong and perience from our par- unique company name. ent company with high- The name has been crequality carbon fibre ated from the word products. We started “professional” and the word “nexus” working with CFRP latin connection. products way back in meaning the 1970’s, a time, This reflects our experwhen many companies tise in professionally did not even know that connecting and enhancthis material existed. ing quality materials
such as composites (CFRP) materials into value adding products. Our company had been supplying products and services for the printing and packaging industry before but then stopped for a while. After we restarted our activities in this business segment in 2013 there was strong knowledge still available in the company. Also, we still had some connections in the market that we could reactivate. Recently we moved full force into
www.packagingnewsletter.com 32
the industry as a supplier of quality carbon fibre rollers. We are fully convinced that the use of carbon fibre rollers will make a real difference to this industry.
increase our product portfolio. There is a new winding line which now enables us to accept orders up to a roller length of 6 meters thus far we could only do 4.5 metres. This improveWAS PACKAGING AND ment now opens up PRINTING THE ONLY BUSINESS YOU COULD MOVE INTO AT THAT POINT?
more significant market opportunities for us. We also purchased two CNC machines. Furthermore, we invested in an additional line to cope with the demands of our customers. We are working on getting eve-
No, there are some other business areas. In addition to the Carbon Fibre Rollers, Pronexos operates in the Aerospace and the Semiconductor Industry and supplies related Industrial Services. We use a range of different processes and equipment which enables us cope with various tasks and complexities. WHAT OTHER PLANS ARE THERE? DO YOU GET DIFFERENT PRODUCTS AND ACQUISITIONS? We currently installed a set of new machines at our manufacturing site in The Netherlands to
www.packagingnewsletter.com 33
rything in place to The critical speed is manufacture products mostly above 300 m/ that the market needs. min and the critical speed reaches 1500 m/ SO, IN GENERAL, min easily and more. WHAT ARE THE ADVANTAGES OF USING Secondly, carbon rollCARBON FIBRE? ers can realize significant energy savings Carbon fibre rollers due to their reduced provide three main adweight (68 % lighter % vantages: they are compared to a tradifaster, lighter and saftional steel roller). And er. third, the handling is Compared to a tradi- safer due to the retional steel roller a duced weight and the CFRP roller can in- change over is easier. crease the output of a In addition, deflection machine significantly. is an important ele97% faster productions ment in the printing inspeeds can be reached. dustry. Pronexos is
able to use specific fibres to make sure the deflection of the roller remains low. Like this, a wide range of stiffnesses for the exact purpose can be reached. It gives the customers more flexibility and increases the quality of the customers output. WHAT ABOUT THE LONGEVITY? FOR HOW MANY METRES CAN I USE OR RUN THE ROLLER BEFORE I HAVE TO REPLACE IT? Carbon fibre is more expensive than steel, but it lasts longer, in some cases 15 years and more. Coating is also an important factor when we talk about the long lifetime of a roller. There are carbon rollers out in the field which we manufactured in the 1990’s and they still run today. WHAT ARE YOUR PLANS FOR THE DRUPA? WILL YOU PRESENT SOMETHING
www.packagingnewsletter.com 34
NEW OR CAN YOU IM- STEEL'. WHAT ARE THE of the printing and PROVE THAT PRODUCT? ARGUMENTS? packing machinery belongs to carbon fibre We will attend the DRU- We don’t sell carbon roller solutions. PA next year in Düssel- rollers just because dorf and present our full they are carbon rollers. SO ,WHAT IS YOUR APset of capabilities to the We sell them, because PROACH TO CONVINCE market including the the CFRP materials and THE CUSTOMERS? latest developments the unique way we are We let the facts speak and latest machinery able to work with it profor themselves. They investments made. Our vide decisive competiare convincing enough. composite coating for tive advantages to our A good scientific insight instance is being opti- customers. In some about these facts and mized constantly and cases, steel may still be advantages is provided we can show some of the better option for a in the recent whitepaour latest developments customer and we tell per by Prof. Lutz Enby then. him so if this is really gisch and Dr. Simon the case. But for many WHEN YOU TRY TO Hamblyn from the Uniapplications a CFRP rollCONVINCE PEOPLE, versity of Leipzig, “A er is the better option. DOES EVERYBODY SAY review of carbon fibre Carbon rollers are lightYES OR WHY DO THEY rollers in the printing, er, faster and safer. For SAY' LEAVE ME ALONE, papermaking and allied this reason, we strongly I WILL STAY WITH industries” believe that the future
www.packagingnewsletter.com 35