Albéa installs Flexowash system for clean production

Albéa has installed a FlexoWash PW45 plate cleaner at its tube manufacturing factory in Colchester, UK. 

The decision to support the plant’s three Arpeco presses with automated plate cleaning was based on the company’s previous experience with a similar unit at its factory in Poland, and its quest to attain EN ISO 14001 accreditation when production is moved to a new facility in 2012. 

‘It might have been one of the smallest, but it’s one of the best investments we’ve made since I’ve been with the company,’ commented production supervisor, Julian Suttle. 

‘We were experiencing plate damage from manual washing and a degree of inconsistency in performance on-press.  In particular, the hard brushing affected tonal areas, and ink residue left unremoved caused an orange-peel effect on the plates.’  He found that plates could be reused only three times before damage occurred; now, with the new system, plates can be reused four times or more, saving at least 25 percent on annual repeat plate costs. 

The health and safety executive was also instrumental in the company reducing the usage of PM solvent at the Colchester site, which the FlexoWash unit – along with other measures – has achieved to an extent of between 80 and 90 percent. Fellow production supervisor, Derek Toms, said: ‘Not only are the plates more effectively cleaned, and longer lasting, but the FlexoWash unit, which is located on the production floor, has made for better workflow and an improved working environment for the crews, who can set the machine going and then be deployed on other jobs.’ 

Where disposal of the PM solvent created a problem, the cleaning agent used in the FlexoWash is collected and recycled.  Formulated to last one week, Albéa has found that the solution actually lasts twice as long, thus halving costs, during which time it will clean 1680 plates (140 sets) to keep pace with the company’s 24/7 working pattern.  The FlexoWash unit is maintenance free, according to Toms, requiring only a filter change when replacing the solution. He added: ‘It’s a machine that draws a positive attitude from the crews, with an effect that is enjoyed by our customers.’ 

Albéa is looking to diversify sales of its products into the food and pharmaceutical markets, which have long been the domain of the aluminum tube. With growing demand for more colors and vignettes, special finishes such as metallics and the use of metallic foils, general manager Allan Lock confirmed that recent investments will raise the Colchester plant’s capacity from 580 million tubes this year to 630 million in 2012 – all from a staff of around 190, only 20 percent of the number of people employed a few years back. ‘The move to our new site will offer room for growth and improved productivity and comes as a welcome boost to morale after a number of tough trading years,’ said Lock.

The need for a FlexoWash anilox roll cleaner is currently under discussion. Tests have demonstrated the performance improvement of fully cleaned aniloxes, which would tick another box in the EN ISO 14001 program.  Derek Toms concluded: ‘To see used rollers come out looking like new gives our staff and our productivity a real boost, and all for a relatively low investment.’