Trouble-Free New Rapida Press Runs At Carton Plant

Product development from the initial concept to the finished carton is the core business of Van Genechten Packaging (VGP) in Turnhout (Belgium).

Product development from the initial concept to the finished carton is the core business of Van Genechten Packaging (VGP) in Turnhout (Belgium).

The press room in Pulheim houses a new six-colour KBA Rapida 142 press configured with two coaters, two dryers and an extended delivery.

For maximum efficiency when handling cartonboard in three full shifts per day, the press stands on a plinth that increases the height of the in-feed and delivery piles to almost two metres (6' 6").

An automatic non-stop roller facility at the feeder allows pile pallets to be changed without stopping the press, whilst at the delivery there is a height-adjustable roller facility linked to the pile logistics system.

Jorg Effertz, VGP's master printer and project manager for the commissioning of the new Rapida technology, said: "The press runs trouble-free in all three shifts and meets its output targets during every production run.

This is vital because we have up to eight job changes a day." The new B1 press (a Rapida 105 universal with six printing units, coating and drying capabilities and an extended delivery) has a range of features that will enable the company to offer its customers an even wider choice of top-quality products, added VGP.

The company became Van Genechten Packaging in 1968 when it progressed to being an international player in the folding carton market.

Two years later VGP expanded its portfolio to include playing cards.

Since then it has added production plants in France, Germany, the Netherlands, Poland and Russia to the original one in Belgium, giving a grand total of 10.

Under chairman Philippe de Somer the various companies in the Van Genechten Packaging Group have evolved in to what is claimed to be the most advanced folding carton manufacturer in Europe.

A key element in the group's strategy of focusing on the high end of the market was its investment in KBA sheetfed presses.

The most eye-catching of those is a 14-unit Rapida 105 universal B1 (40-inch) press at the group's headquarters in Turnhout, which will be used to print playing cards featuring a range of special effects.

Since moving in to the playing card market in 1970 VGP has kept that side of its business separate from its packaging activities.

Around 230 million playing cards are printed every year, with licensed products accounting for a large proportion.

VGP frequently creates new card designs for special events, one such being the latest James Bond film, 'Casino Royale'.

The group's German operation is VG Nicolaus in Kempten (Allgau), with a branch in Pulheim.

The playing-card division employs 3,000 people, whilst the packaging division has a payroll of 2,000 employees.

VGP's packaging division focuses on product innovation and more sophisticated finishing options, said KBA.

As a result, it has been the recipient of eleven Pro Carton-ECMA awards.

Last year there were two awards, one for the most innovative design, or new carton application and the other for frozen-food packaging.

At the Luxpack 06 trade fair in Monaco VGP also won an award for a new folding carton shape.

'Serial luxury' is the name VGP has given to a concept it devised for producing high-grade packaging more efficiently.

The move is said to have attracted widespread interest amongst clients, particularly those in the perfumes, cosmetics, champagne, premium wines or spirits, and chocolates and confectionery sectors.

The range of folding cartons and packaging is supported by the group's development units in France, the Benelux states and Germany.

VGP said that it promotes customer loyalty by using modern media, such as the internet, upgrading its CAD/CAM workflow system and actively engaging customers in the creation of new products.

The company believes that its policy not only leads to greater variety and new forms of packaging but it also expands the range of applications for existing materials.

The development department's database contains 3,000 packaging models.

Coating plays an increasing role in enabling customers to differentiate their products in an intensely competitive field, said the company.

Even discount retail chains, such as Lidl or Aldi are exploiting the impact of coated packaging to a greater extent.

The member companies in the VGP group have, therefore, invested in new equipment to enhance value-added capabilities.

According to De Somer, consumables account for 50 per cent to 60 per cent of the group's total manufacturing costs, so those consumables must be processed in such a way as to maximise quality and impact.

He explained: "In-line finishing must enable us to provide an even broader variety of packaging and that means, for example, that we must also be able to laminate.

If we are to rise above the competition, we must streamline workflows and enhance our cost efficiency wherever possible." But packaging is not the only product VGP develops.

It has also been known to design the machinery on which the packaging is processed and to have that equipment built by associated companies.

Three examples are packaging for spark plugs, Duracell batteries and McDonalds' Big Macs.

Whatever the product developed, the company makes a point of using materials made from renewable resources, it added.

VGP's production plants boast a total of 45 sheetfed presses, of which 31 printing units were built by KBA.

Dieter Heinzelmann, the managing director of VG Nicolaus, noted the high degree of organisation that such a plethora of presses requires amongst the member companies.

He said: "The operation is as centralised as necessary and as decentralised as possible.

Another positive aspect is the short chain of command arising from the fact that the company is owned by the de Somer family.

In Pulheim we produce drinks packaging and non-food packaging, whilst the Kempten plant specialises in frozen-food packaging with a polyethylene coating.

Our customers come from all over Europe, with the accession states proving to be a fast-growing market.

We address a demand for high-volume packaging produced to the highest quality specifications." The company believes that the packaging sector is experiencing a steady shift towards shorter print runs.

VGP has responded by switching to computer-to-plate systems at all its production plants.

It also runs an in-plant toolmaking department to preserve its independence by ensuring the continuous availability and timely supply of cutting dies.

CAD workstations are used for product development, with conversion in to the corresponding data files in the in-house repro department.

The die-cutting and carton-gluing lines are equipped to handle the maximum output off the presses.

Since, for customers' convenience, finished packaging is stored for up to six months, VGP has built a warehouse capacity of 5,000 bays and automated the logistics workflow for semi-finished and finished goods.

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