CONVENTIONAL ALTERNATIVE CONVENTIONAL ALTERNATIVE

With its Zerand web-fed platen die- cutting solutions, BW Papersystems WEB-FED PLATEN DIE- offers a true alternative for maximum flexibility regarding production and line configuration. Being part of CUTTING SOLUTIONS BW Papersystems and the Barry- Wehmiller Group since September FOR FOLDING CARTON 2017, the flexible Zerand production system enables die-cutting in-line with the press for production in PRODUCTION one operation, or offline where one press can feed more than one WITH ITS BRAND ZERAND, BW PAPERSYSTEMS, A MANUFACTURER OF HIGH-SPEED WEB-FED PLATEN platen die-cutter with rolls of pre- DIE-CUTTING MACHINERY, OFFERS A REAL ALTERNATIVE TO CONVENTIONAL SHEET-FED FOLDING printed material. The Zerand web- CARTON PRODUCTION. THEIR WEB-FED PLATEN DIE-CUTTING SOLUTIONS CAN INCREASE fed platen die-cutting solutions can PRODUCTIVITY AND OFFER LINE CONFIGURATIONS SUITABLE FOR EVERY CONCEPT OF OPERATING run multiple short and medium runs ENVIRONMENT. and handle a wide range of carton types with fast job change times. “When we talk to converters about web-fed production, they are often surprised to learn how far the technology has progressed,” explained Luigi Pessarelli, VP of Flexible Zerand solutions: die-cutting in-line with the press for production in one operation, or offline Sales North America White Paper with one press feeding more than one platen die-cutter with rolls of pre-printed material. at BW Papersystems. “Many of their carton types can be produced far preferred web printing technology in carton blanks cost comes from the more efficiently than they are today the folding carton industry, previously board, any saving due to web fed using sheet-fed production.” dominated by Offset or Gravure production is more than welcome. Both the in-line and the offline printing,” stated Luigi Pessarelli. Reduced board usage also contributes solution have their customer individual A Zerand platen cutter installed to our environmental policy.” advantages and offer different in-line with a press has a capacity of In addition, web-fed platen die- efficiencies. While the in-line 25,000 sheets per hour with widths cutting does not suffer the high With web-fed, many folding carton types can be produced configuration reduces logistics and up to 1400mm. The entire line, tooling cost associated with rotary far more efficiently than they handling efforts as well as WIP of including a mechanised palletising die-cutting. In fact, tooling costs are are today using sheet-fed production. printed rolls, the offline solution can system, can operate with three very similar to those of a sheet-fed reduce the cost of automation. Opposed to four operators. Because the die-cutter. Some other benefits of web to having a complex and expensive carton blanks are produced in one production include the ability to apply or years, folding carton robotic palletiser, folding-carton printers operation, floor space, waste, WIP and grease or moisture barrier coatings producers have been facing can connect the output of a stacker to logistics are substantially reduced. in-line, to reverse print with no loss of F an aggressive price point the folder gluers by means of conveyors. In any configuration, be it in-line production efficiency and to apply a set by the industries they serve. In Beyond that, the offline solution or offline, these web-fed platen wide range of spot and full coverage response, they are continuously allows the press to run at higher speed die-cutting solutions require no varnishes without a loss of production searching for real solutions to the in a roll-to-roll configuration and feed gripper margin and offer better efficiency. Not all Zerand customers challenges they face – reduction of more than one platen die-cutter with carton nesting flexibility. The board demand wide-width solutions. Using material, logistics and staff costs. rolls of pre-printed material. usage per carton is always lower narrower machines below 600mm, Conventional production processes In the in-line configuration, a and sometimes substantially so. A some can achieve job changes where reels are converted into sheets platen cutting system works well Zerand customer who has both sheet- including the press in 15 minutes which are then printed on a sheet- with any type of web press, including fed and web-fed capability in the and still enjoy single pass, low waste fed press are part of the problem. Flexo, Offset, Gravure or Digital. “The same plant, reported, “The decision production with reduced labour costs. With its Zerand web-fed platen die-cutting solutions, BW Papersystems offers a true They can cause expensive board speed and quality advances made by to produce a job in sheet form or In order to optimise folding- alternative for maximum flexibility regarding waste, are personnel-intensive and leading Flexo press manufacturers web form is based mainly on the carton production, Zerand not only production and line configuration. demand high logistics effort. has seen Flexo print becoming a board waste. As up to 50 percent of have an eye on the system, as Luigi

36 FOLDING CARTON INDUSTRY » MARCH/APRIL 2021 www.thepackagingportal.com 37 CONVENTIONAL ALTERNATIVE

Pessarelli commented, “In many parts. BW Papersystems as a large meetings we initially are not talking “The range of cartons group with an international service about a machine. Instead we are support team and regional spare parts talking about a production system produced by our warehouses offers worldwide support and what it can offer that particular customers is ever for Zerand web-fed platen die-cutters. site.” Customers are invited to growing.” “The range of cartons produced by provide details of their most common our customers is ever growing,” said carton designs with the layout they Luigi Pessarelli. Common applications LUIGI PESSARELLI, VP OF SALES NORTH currently use. These are studied AMERICA WHITE PAPER AT include cartons for fast food, beverage, and a report is prepared including BW PAPERSYSTEMS. mailers, pizza, cereal, tissues, details such as production rate and toothpaste, detergent and many more. board usage per carton. “This often environment the machine must be Many folding carton producers are stimulates interest and leads to further both simple to operate and heavily seeking to develop fibre-based discussions where other savings in constructed. As the machinery is so alternatives to plastic packaging. One the area of labour cost, floor space robust, critical machine sections can example is the KeelClip™ paper and WIP are quantified,” explained be rebuilt and upgraded with the fastener replacing rings, tops and Pessarelli. Only at this point when the latest controls and safety technology, shrink wrap packaging. Pessarelli process benefits are established, can thus, guaranteeing the protection proudly declared, “This innovative the machine details be discussed. of the customers investment over high-volume product, developed by Zerand customers run their an extended period of time. our customer Graphic Packaging machines at high speed, 24 hours per When things do go wrong, customers International, really benefits from the day, 7 days per week. To excel in the require urgent support and spare Zerand technology.” n

38 FOLDING CARTON INDUSTRY » MARCH/APRIL 2021