Bobst Web-fed Solutions and Rotomec SpA

Transcription

1 Productivity gains in the light board packaging markets Bobst Web-fed Solutions and Rotomec SpA Welcome the participants of the GAA Pressroom Conference Session 4 A 1

2 BG1 Productivity gains in the light board packaging markets Who is Bobst Web-fed Solutions? (Former Bobst-Champlain) World leader for in-line printing and converting equipment for the manufacturing of folding boxes. LEMANIC LINES Single-source supplier Original equipment manufacturer 2 2

3 Slide 2 BG1 Bobst Group, 3/7/2008

4 Web-fed Gravure Markets Segments & Trends Transfer 1% Paper/board 13% Woodimitation 5% Giftwrap 3% Wallcovering 4% Labels 8% PVC 3% Alum 2% Fastest Growing Segments Other 1% Flexible Packaging 60% 3 3

5 Web-fed Gravure Markets Paper/Board Segments & Trends Converting 40% Rotary 60% Flatbed Tobacco 69% Converting 95% Rotary Liquid packaging 3% General folding carton 28% Converting 20% Rotary 80% Flatbed 4 4

6 Market News and Trends Brand Owners are more and more concerned about the environmental impact of packaging. Paper and Cartons have more a better image (recyclable) WRIGLEY is pursuing the production of ECLIPSE in Web-fed gravure Nestlé did switch his After Eight production from Sheet-fed UV offset to Webfed gravure Advanced discussions to convert Fast Food packaging to gravure Japan continues to invest in Gravure Web-fed lines Consumers in emerging market are more and more attracted by quality packed product. 5 5

7 Gravure adds value and guarantees quality Minimal colour variation from start to finish Excellent repeatability (between jobs and machines) Intense colours, for solids and process with no ghosting Metallic and fluorescent inks (cost saving alternative to hot foil stamping) Environment friendlier inks and process (no photo initiators such as ITX in UV inks), food grade and water-based inks Pre-coating to improve the board surface Truly differentiate yourself with gravure 6 6

8 Productivity gains in the light board packaging markets Suppliers of gravure printing in-line equipments must provide solution to meet the actual and future Customers specific requirements and growths By proposing: Cost-effective solutions In-line or off-line Processes (for value added products) Sustainable development 7 7

9 Web-fed Gravure vs. Sheet-fed Offset : fewer flow interruption between processes Folding Carton Inline printing & converting Paper / Board Winding Gravure Printing and Coating Die-cutting / sheeting Folding-Gluing Web-fed process Offline processes Hot-foil stamping Flatbed die-cutting Folding-Gluing Offline printing & converting Paper / Board Sheeting Offset Printing Flexo Coating Laminating Flatbed die-cutting Folding-Gluing Sheet-fed process Flatbed hot-foil stamping Rotary hot-foil stamping Flow interruption 8 8

10 Web-fed with in-line processes: from start to finish Stripping, blanking, stacking cutting, creasing, embossing quality control printing (up to 12 units) web cleaning unwind Gravure printing: most simple method for high quality printing Reel vs Sheet: more than 5% cost saving Finished cartons in one pass = Maximized value at lowest cost 9 9

11 Saving board waste increases directly your profitability Cost breakdown Example: Lemanic DELTA with in-line rotary die-cutter Cost per 1000 boxes = 100% Simulated Waste level = 5% Maximum Output 0.8 = 1,2 Mio p.a. HL20 Machine availability = hours p.a. Percentage of each production costs 60.4% 2-3 % less start up waste > 3 % less register waste > 1% less layout waste compare to Sheet-fed offset 1.7% 3.3% 3.4% 1.4% 0.2% 15.1% 0.5% 1.1% 7.2% 1.3% 4.8% Capital costs Packing and delivery Salaries Rental of rooms Storage of raw materials Electricity Board Maintenance Inks + varnish Flat Bed dies Waste Printing cylinders 1% waste represents a minimum of $ p.a

12 What GFC needs to address : Spread of volumes or family of jobs which generates too small run lengths Per runs > Sheets and Total ca 3 500Tons p.a. Off-line or In-line Converting Board Quality Light Board <18pts (<350g/m 2 ) Fear of Gravure Variable costs and flexibility (JIT) - Big Size Boxes (cereals, soap, small bottle carrier) - Re-use of existing offline-tooling in case of in-line sheeter - Education, lobbying, presentation of newest gravure technologies 11 11

13 Web-fed Gravure push down breakeven point Flexibility Productivity LEMANIC DELTA High volume press with Rotary Die-cutter Medium size press with Rotary Die-cutter Medium size press with Sheeter LEMANIC RIVIERA sheets sheets sheets IIIB equivalent sheets Production per run 12 12

14 Web path orientation American vs. European reduces overall waste American web path advantages Shorter web path => minimum start-up and running waste No need of turning bars or a reversing web path before the converting equipment => optimum register stability and minimum waste Compact height => better accessibility, operated from floor level Printed side UP American Web path European Web Path Printed side DOWN 13 13

15 Key points for Web-fed gravure to be successful in GFC Packaging carton industries should accelerate its rate of introduction of new printing and converting technologies Go in-line as much as possible Concentration of volumes to favor economy of scale Tool suppliers to continue effort to reduce costs and time to market to comply with shorter runs Board supplier to broaden their choice of carton quality suitable for gravure printing GAA to continue to promote gravure also for carton 14 14

16 The future outlook for shrink films Rotomec SpA Gravure Printing Solutions Trends and solutions in the label market 15

17 Global Label Sleeve Market per Types Major Growth 14.4% 1.5% 2.1% Shrink sleeves: 1,5 bn sqm Shrink sleeves: ~ tons 46.3% 35.8% Total 2006: 30 bn sqm Pressure sensitive Glue applied Shrink IML Others Source: AWA 16 16

18 Shrink Sleeves by Printing Process Shrink Sleeves by Printing Process 9% 4% Gravure Flexo Digital 26% 7% 16% 65% The main reason for Gravure vs. Flexo solution resides In the highest control of the drying process 17 17

19 Global Shrink Sleeve Market per Country Region 2003 (tons) 2006 (tons) 2011 (tons) Growth % Western Europe ,50% Eastern Europe ,30% North America ,00% Latin America ,50% Asia (Japan not incl.) ,00% Japan ,30% Rest of the World ,00% Total ,40% Source: Pira International 18 18

20 Global Shrink Sleeve Market per polymer Polymer 2003 (tons) 2006 (tons) 2011 (tons) Growth % PVC ,70% PET ,90% OPS * ,70% Others ,70% Total ,40% * OPS is very sensitive to temperature (handling, storage & production) Source: Pira International 19 19

21 Key Points for Gravure Printing on Shrink Films Material sensitiveness Shrink films are sensitive to temperature, warehouse and production halls should be at controlled temperature Dryers Very low range of air temperature for drying with high accuracy thermal regulation. For this reason, it needs a very high efficiency dryer. Web Handling Shrink film needs a very accurate control and a the low web tension Very high sensitivity of the idle rollers to avoid friction Appropriate finishing surface of the idle rollers to keep the web stable along the printing units Electronic line shaft ELS is a must 20 20

22 Key Points for Gravure Printing on Shrink Films Print Quality High performance inking system (two dynamic inking bars) High efficiency ESA system Register Control Performance Including : self adapting elongation control algorithms to cope with a variety of materials Total Automatic Pre-registration Function, High Dynamic Interface and preventive algorithms to minimize waste. Rotomec is world leader thanks to its integrated Bobst Registron system 21 21

23 To be successful in shrink label gravure printing Adapt printing technology to your market target Narrow web is not always the solution Film producers to work on more stable and cost effective material Tooling cost and turnaround time must decrease 22 22

24 WEB-FED SOLUTIONS THANK YOU FOR YOUR ATTENTION 23 23