From Jürgen Möller and Frank Woltering - Due to automation, new technologies and improved process control the price of rotogravure cylinders has come down in the past years.
But still the contribution of printing tools to the overall costs of a print job is highly relevant.
When talking about ideas and concepts to make rotogravure print jobs more profitable, especially on short-runs, cylinders suddenly become a key aspect.

Since the very beginning 4packaging is manufacturing rotogravure cylinders in a fully automated production line.
During our presentation we will share some insides and describe the relation between physical cylinder properties such as type or dimension and their impact on the potential of automation.
We want to initiate a discussion about a narrow web cylinder concept that allows printers and cylinder suppliers to maximize automation, bring down cost and make better business!

Extent: 116 pages , Size: 19.09 mB, Language: german

From Colin Ord - What is the position of Mars with so many Brands within Snack/ Pet and Food • What are their quality objectives • They recognise that overall in the market quantities are dropping it makes it more important to have good process controls and procedures • How can Mars still maintain quality... [Show more] throughout the supply chain. printing, prepress and ink etc. • How can we standardise to maintain quality, control cost and reduce lead-times • Forward control through good communication and by working together Today Mars gives you that challenge, Nils satis Nisi optimum (nothing but the best is good enough

Extent: 30 pages , Size: 16.78 mB, Language: german

From Dirk Schibull - Basically has the packaging gravure printing a very complex and demanding requirement profile. Specific ink systems and substrates require in the context of compliance with all relevant packaging features a comprehensive know-how. On this basis and in light of the general market trend with the tren... [Show more]d of steadily increasing pressure quality standards at the same time reducing lot sizes is a key success factor lies in the cross-vendor standardization of processes. The standardization of concepts should include all the essential printing process parameters and variables: • Design system and reproduction • printing form configuration • Color Management • Color System • printing process The potential of a successful standardization are to increase the basic security system, the possibility of increased efficiency, and not least in increasing customer satisfaction

Extent: 34 pages , Size: 1.90 mB, Language: german

From Adolf Ahrens - Over the last years the order sizes of the food packaging sector became smaller and smaller. Even if food consumption in Central Europe stayed nearly constantly more and more private and regional labels or premium, bio and wellness brands are taking over the shelves, especially in the chilled sector... [Show more] of processed meats and cheeses. The result is a split of total quantities within the segments which causes a drastic reduction of lot sizes. To gear up for this situation is a hard challenge – especially for gravure printing. The prepress as well as the printing production including their technical equipment were conceived for high circulations. With a consequent standardisation of the processes of their in house repro department and cylinder production and an intelligent adaptation of planning, their machine technology and the whole peripheral equipment Wipak managed to adapt to this trend even with wide format printing machines

Extent: 37 pages , Size: 843.82 kB, Language: german

From Thomas Reckert - Short runs production with rotogravure machine technology requires different demand on the machine supplier. Different machine concepts will be presented witch one available on the market today. Short runs can be produced with narrow web as well with conventional width web gravure presses. Part of... [Show more] this presentation will be a comparison of production cost between narrow web and width web. Additional advantages will be present how to produce short runs more economical like short web path, fast Job change over as well the integration of auxiliary equipment should be help to reduce waste. On hand of Rotomec product range we like to present different machine concepts for different Product range

Extent: 29 pages , Size: 787.22 kB, Language: german

From Volker Haske - Branded companies and retailers alike expect an ever-increasing print quality for their film packaging. Simultaneously, decreasing order sizes and continuous cost pressure challenge manufacturers and converters to find or combine respectively printing technologies, which are suitable and effective f... [Show more]or them. The paper is a field report from the point of view of a flexoprinter, who has successfully implemented rotogravure as a complementary printing process. The paper will point out the reasons for this decision and also illustrate the process as to how to select from the available machine concepts and technologies respectively (e.g. sleeve system). In doing so, both, rotogravure and flexographic printing will be compared to each other from the point of view of a printer

Extent: 22 pages , Size: 664.82 kB, Language: german

From Christophe Pondaven - - Presentation of DCM Group and the activities of the four companies - Presentation of gravure printing in the DCM group - DCM gravure printing and narrow web offer - DCM gravure printing time equipment and advantage - DCM gravure printing research and development - DCM coating and laminating - DCM ... [Show more]rolling and cutting machine for the processing of processed film

Extent: 55 pages , Size: 1.32 mB, Language: german

From Harry Sieljes - Efficient Short Run Production in Gravure is easier said than done. It is, anyhow, far more then just installing modern narrow web gravure printing equipment. Critical aspects are the pressroom organization that must be changed from a linear meters bulk generator to a set-up- and waste-control focus... [Show more]sed organization. The ink department and more-over the systems that enable to re-process press returns and as well the number of ink systems should be part of the short run philosophy, as is the attitude of the pressoperators (performing and maximizing change-overs instead of watching the machines printing) and the way working methods are implemented (such as pit-stop philosophy and parallelity instead of sequential working). Raw material waste in % is a major factor to be controlled, not only from the perspective of machine design- but also including ERP aspects. From an external point of view there are many limitations as suppliers from direct materials and tools do not, in real life, consider short run gravure as (potentially) major business. Finally, other print-technologies should be considered as well in the short run business, my initial scepticism regarding web offset for hybrid packaging purposes has been altered to web offset as a technology that starts to carry surmountable problem areas (critical issues are inks, web tension and machine hour-costs)

Extent: 19 pages , Size: 53.05 kB, Language: german

From Dr. Matthias Henker - Although the gravure printing process is well know as a very precise process with good reproducibility and it is mechanically relative simple a wide range of problems can occur in the daily production. Scumming, doctor blade stripes, comets, missing dots are just a few. In the presentation typical p... [Show more]roblems are shown and their reasons and some ink related solutions are discussed

Extent: 28 pages , Size: 988.48 kB, Language: german

From Dr. Werner Prell - Our competence is printing in Roto and Flexo. ? The existing roto presses are not fit for small lots or order quantities. ? World class standards are the demand to pharma packaging products. They can never be achieved in Flexo print. ? Development (market demands) -> the lot quantities are decrea... [Show more]sing. (We gathered experience with small batches in the pharma industry ranging from 500m2 to 5000 m2 Flexo prints for years in our production sites in Germany and Belgium). ? Demands to Constantia Hueck Folien: - High efficiency for small order quantities - Production costs meeting market prices - Optimized waste rates - Short setup times and short ways within a self contained production – In-Line printing (Roto) and laminating / heatseal coating. ? The Challenge: - Sleeve technology in Roto (production on site) - Sleeve technology in Flexo familiar – no experience in Roto - Handling und storing sleeves - Defining printing widths - Back up for Fa. Constantia Patz with the product groups blister foil and coldform (contact lens-, security- and high-temperature blister foils) - Use of existing Roto cylinder bases - Storage systems and cost-benefit analysis ? Decision parameters Pro/Con: - Introduce sleeve systems (max. printing width) - Storage systems – cylinder bases/sleeves - Produce cylinders in-house or externally - Handling by operators etc

Extent: 23 pages , Size: 3.72 mB, Language: german

From Lothar Roth - Color Management will be focused this time not from a technical aspect at all. Anyway, for a better understanding a comparison has to be done on color management for packaging printing versus standard 4C printing. Without any doubt, color management has raised the level of quality and consistency an... [Show more]d given a predictable and stable process for printing. But: Was kind and amount of effort has to be given as input to get a good and reliable color matching during press run? What kinds of cost are coming up? Where do we have cost savings at the press run if a color management is properly implemented? Does this effort give a payback? Are there other ways to handle this issue? A lot of questions that will be illustrated during the presentation

Extent: 31 pages , Size: 332.44 kB, Language: german

From Frank Beuleke - Everybody knows that the world is colorful. But how colorful excactly? In a digital world you’ll be more and more confronted with color values. So how can I reduce the error sources as much as possible, or how can I even find them? To define a color digitally is no problem. Butt he digital commun... [Show more]ication today cantains still possible error sources. What kind of error sources can be found? How does a color measurement device work and where are its borders? Which error sources should I know and how should I avoid them? This presentation should give you a basic info on the different measurement possibilities and the minimum requirements for a secure and reproducable color communication

Extent: 25 pages , Size: 933.36 kB, Language: german

From Jürgen Möller and Frank Woltering - Due to automation, new technologies and improved process control the price of rotogravure cylinders has come down in the past years. But still the contribution of printing tools to the overall costs of a print job is highly relevant. When talking about ideas and concepts to make rotogravure print jo... [Show more]bs more profitable, especially on short-runs, cylinders suddenly become a key aspect. Since the very beginning 4packaging is manufacturing rotogravure cylinders in a fully automated production line. During our presentation we will share some insides and describe the relation between physical cylinder properties such as type or dimension and their impact on the potential of automation. We want to initiate a discussion about a narrow web cylinder concept that allows printers and cylinder suppliers to maximize automation, bring down cost and make better business

Extent: 116 pages , Size: 19.09 mB, Language: german