German label production facility expands with Mark Andy presses

A preference for the 13” web width was a deciding factor in Etikon’s choice of a Mark Andy 2200 flexo line according to owner Alex Maree, who began life as a label broker in his native Holland. Today, Etikon’s modern production facility at Rodersdorf in Germany may at first sight appear a high risk venture, but is in fact the result of careful planning and skilful use of local resources. Maree initially spotted the opportunity in 1998 and laid plans for one of Europe’s most unusual label converting plants.

With the aid of grants from the Local Government, Maree set about restoring the tumbledown buildings and installing the infra structure that a modern label production plant requires. He budgeted €3m for the renovation, but it eventually cost twice that amount, and today constitutes a beautifully restored piece of local heritage, employing 65 local people in an area where unemployment runs at 27 per cent.

Beginning with old Webtrons, Maree chose Mark Andy as his new machine partner, and in 2001 installed his first 2200 press, a six-color 13” press with full UV curing. The 13” web width allows him to buy substrate cheaper from the mills, and the 2200’s quick change cassette system and registration capability at high speed were added bonuses. At the same time, Etikon invested in a Mark Andy DCR 100 unit to run blank labels at high speed.

In 2002, Maree restructured Etikon and installed a second Mark Andy 2200, this time a 13” two-color press, and a second DCR 100 unit. With business improving, Maree fitted Vectra and KTI turret rewinds to his Mark Andy lines, and installed waste extraction to allow faster running speeds. The benefit is a two to three per cent saving on substrate costs running speeds up by 30-100 per cent. The company also saves money on waste collection and removal by having its own compacter onsite. 

Needing extra capacity, Maree added a third Mark Andy 2200 in 2005, this time a 17” two-color press with full UV.  By then the need for further expansion was obvious, and the company embarked on a €2.5m investment program, including an additional factory.

The new facility adds 1000 square meters of space over two floors and provides additional storage capacity.  Long term, Maree is looking to install four or five new machines, including a Mark Andy LP3000, and grow the workforce to around 100 to handle the 30 million square meters of material per year, which he sees as the optimum size of company.

Remarking that Etikon is already the third largest employer in the region, with a reputation for financial stability, Maree has also opened additional sales facilities back in Holland to serve the markets in the Benelux countries.  Offering an eight-day turnaround on work more typically quoted at three weeks is one of Etikon’s great strengths, and is key to the company reaching its target of doubling in size by 2010.

Photo: Alex Maree (left) shakes hands with Mark Andy AG’s Ernst Meyer on the installation of his company’s latest 2200 press