Spending to save

One of the main drivers in today's print market is the need to reduce costs in the production process. With environmental issues on waste also to be taken into account, converters are under pressure from all sides to streamline their processes and maximize efficiency, yet still follow an investment policy that yields a profit.

With printing presses becoming ever more sophisticated in what they can deliver at high speed, at the price of higher investment levels, shrewd converters are looking around for ancillary equipment that can boost productivity, lower production costs, and retain profit margins. Working on the principle that unnecessary substrate waste is expensive, and press downtime for roll changes even more so, not to mention the variation in print quality that it brings, one option is a move towards continuous running.

One company that has made a special study in this field is USA based Martin Automatic, which works closely with leading web press manufacturers to develop bespoke and standard web handling systems that will improve production efficiency across the board from narrow web label presses to wide web machines for flexible packaging and folding cartonboard production.

An example of Martin's collaborative work is an installation at Spanish label converter Germark, where the US manufacturer's automated MBS unwind and LRD rewind units have been installed on a new Omet press, and most retro-fitted to an existing MPS line.

Germark’s production facility includes presses from Gallus, Nilpeter, and Kopack, as well the Omet and MPS lines, all of whom are close co-operative partners with Martin Automatic.

With Germark's focus on premium labels for international brand leaders like Nestle, Kronenbourg, L'Oreal, and Unilever, consistent quality was essential. The fitting of a Martin Automatic MBS butt splicer and LRD rewinder on its Omet press line pointed the way forward for the company, and the latest addition of MBSF and LRD units on one of the MPS lines has not only reduced costs, but also improved overall quality.

The need for automated roll changing became clear as Germark moved from narrow web letterpress through screen to wider web flexo processes, the Omet and MPS lines being 410mm models. These wider, faster presses have large appetites for substrate, but to justify the case for investment in automated roll changing, Germark needed to consider the Return on Investment.

Industrial director Philippe Nowak explains: “We were pleased with the improvement in performance that the Martin equipment made to our older Omet line, so knew there was a solid base on which to prove the case for further investment.” When MPS was chosen as the preferred supplier in 2003 it was on the grounds of servodrive technology and the benefits it brought. A second MPS flexo/screen press was added in 2005, bringing colour combinations on the two presses to nine and 10, respectively.

The investment plan for the latest Martin equipment also included the installation of a Matho waste extraction system, and moving the MPS line to accommodate the new production layout. According to Philippe Nowak, this gives a potential ROI figure of 2.5 years overall, but with the Matho and press move costs deducted, a return of around 1.5 years for the Martin units seems likely.

In fact, according to Martin Automatic, a recent installation in the USA, where two of its butt splicers have been supplied, shows a payback period of 13 months, and significantly an increased throughput of 11 per cent. Spokesman for Martin Craig Thomson states: “It does not seem to matter whether you take our predictions for ROI or those done by the customer, they are always on the low side, and the reality comes as a pleasant surprise”.

At Germark, Philippe Nowak is already noticing a net production speed increase in the region of 15 per cent, which means more splices, less waste, and an even shorter payback period. This falls in line with the Spanish company's drive to reduce waste and make its production flow more logical as part of its 'Japanese style' 5S Programme for improved productivity.

Following the maxims orderliness, order, cleanliness, visual control, and repeatability, the aim is to close up the production processes to reduce error and increase the responsibility of the production teams.

“Our aim,” says Philippe Nowak, “is to add quality that will allow us to retain high value business.”

This policy seems to be working. From humble beginnings in 1958, Germark has grown to employ 130 staff in its 5,500m² factory at Cornella de Llobregat, near Barcelona, and it generates an annual turnover in excess of €15M. The company has sales offices in Bilbao, Madrid, Malaga, and Valencia, from where it also supplies and services its range of label application and coding systems.

Independent acknowledgement of its performance came in 1998 in the shape of ISO 9002 Certified Quality Assurance, and again in 2001 with ISO 14000 Certified Environmental Management System, the same year in which the company entered the Guinness Book of Records by producing the world's largest label at 100 x 29cm.

Looking ahead, Germark sees a growth in demand for filmic substrate products such as shrink sleeves, and an increase in specialization to meet the continued downward pressure on prices. As Philippe Nowak concludes: “We can no longer afford to be all things to all people - our investment policy is focused on the higher value end of the market, where efficiency is everything.”