Agile converting

Agile converting

With the German economy recovering quickly from recession, smaller, more agile converters like Papier Schaefer are reaping the rewards of investment in leading edge technology. Andy Thomas reports

Papier Schaefer, based in Weinheim, near Heidelberg in Germany, is a small, agile converter, which takes full advantage of opportunities to add value to its customers’ operations.

The company was founded as a commercial printing operation by the grandfather of the current owner, Juergen Schaefer. In 1976, Papier moved into pressure-sensitive label production with a Gallus A160 flexo press. Two years after Juergen’s father took over the business in 1984, the company moved into UV letterpress with a 6-color Gallus R160B.

Juergen joined the family business in 2000, and strengthened its flexo operations with a 6-color Gallus EM280 UV flexo combination press a year later. An ABG Omega 330 blank label converting machine was added to these machines. The company now employs 20 people, up from 14 in 2006.

Papier operates across a wide range of markets, including transport and logistics, food, household and chemicals –  but only where it can add significant value.

This was the motivation behind the purchase of two Graficon presses.

The first, intended primarily for booklet label production – a 7-color machine with cold foil, varnish, booklet making section and servo-controlled die stations – was installed in 2008. Pre-printed booklets are applied in register to a pre-printed web and over-laminated – gluing is available as an option –  all running at up to 500 booklets a minute. The press is equipped with a second web and turner bar for additional flexibility.

The booklets are printed and folded on Schaefer’s own offset press, ideal for short runs and rapid response to customer requirements. The top floor of the print shop where the booklet printing operation is located has a secure entry system.

The second Graficon press is equipped to convert double layer labels, typically for products like auto oil and chemicals. The top web path carries a pre-printed web, applied in register with the lower web after printing.

For promotional labels, the company can print on the adhesive, so a message is revealed when a panel is torn off.

The press is fitted out with a cold foil unit, a flexo unit can be inserted at any letterpress position – to coat silicone for special constructions, for example.

Pre-press

Papier has a comprehensive in-house pre-press operation. The company uses an EskoArtwork Sprint CTP unit to image digital letterpress plates – coated with a black ablation layer – digital flexo and digital offset plates. The plate processor is a Dantex AQF 500F water wash system.

Extraordinary print results are achieved with digital letterpress plates printed on the Graficon presses, including extremely fine text reversed out of four colors. Using stochastic screening techniques it is possible to achieve ‘fade to zero’ vignette effects without the hard line characteristic of analogue letterpress plates. Highlight detail is also retained to a high degree. ‘We are using the same LPI letterpress as we use for offset,’ said Juergen.

Responding to changing customer requirements is a key element of Papier’s business philosophy. It undertakes design projects for clients and recently invested in a 1600mm wide DG Roland VersaCamm inkjet-plotter. The machine will print metallics and opaque white, making it capable of a wide range of special effects. The digital press is used for a wide range of ‘customer service’ applications which complement wider business, including posters, point-of-sale materials, business cards and short runs of die-cut label sheets.

An Epson Pro 4880 inkjet handles color-accurate proofing and for ultra-fast turnaround work the company runs a Xerox DocuColor. ‘We act as consultants with our customers,’ said Juergen. ‘The customer comes here for acceptance of the job, and we can make corrections up to the last minute, giving greater flexibility.’

The company has an EMAS environmental excellence certificate and its energy saving initiatives include LED lights which have reduced energy consumption from 2,000 to 800 watts. Papier is proud of its ‘green’ credentials and Juergen is personally committed to running a sustainable operation. ‘The certification has been good for the company but has also saved us a lot of money.’ Other projects include looking at recyclable liners. ‘Raflatac has a scheme where they will buy plastic liners back.’.

With a strengthening German economy, Papier is well positioned for future growth. Juergen’s daughter is showing an interest in joining the business after completing her college degree and an apprenticeship at a nearby label converting company. Her skills in English will be particularly valuable. Brands such as Unilever now insist all business is done in English, no matter where the company operates.

Specialist rebuilds

Graficon has made a strong business out of refurbishing Gallus R160B and R200B letterpress machines. A press is effectively a new machine once it has been stripped down and rebuilt. The servo unwind incorporates web guide and ultrasonic sensor for transparent materials, web cleaner and corona treater. The press can be customized with various configurations of UV letterpress units with inter-station lamps, UV flexo with chambered doctor blades, rotary screen and laminating units. The letterpress units are equipped with AP adjustable zonal ink duct blades.

Papier’s presses are equipped with an IST-supplied UV curing system with chill rollers to handle thin, heat-sensitive films. The air-cooled varnish unit has an extended web path, allowing a high level of gloss to be achieved before UV curing.

The presses can be fitted with rotary or flat-bed die-cutting units and the servo driven rewind is equipped with automatic tension control. In the case of Schaefer, the presses have ABG turret rewinds. The presses are fitted as standard with Graficon TR03 automatic register control with auto-teach mode. The presses can also be fitted with multiple web paths and booklet label production systems, as seen on the Schaefer machines.

Pictured: Graficon press with booklet maker

This article was published in L&L issue 6, 2010 

Andy Thomas

  • Strategic director