From offset printing to die-cutting and folding and gluing, Koenig & Bauer aims to minimize disruptions in the cardboard packaging production chain. On October 8, the German manufacturer hosted a demonstration day at its Radebeul facility for European packaging professionals.
Called "Large Format End-to-End," this event showcased a production line combining the Rapida 145 sheetfed offset press, the Ipress 145 Pro die-cutting press, and the Omega Allpro 110 folder-gluer.
The centerpiece of this line is, of course, the Rapida 145, which achieves a production rate of 18,000 sheets per hour. Koenig & Bauer showcased several automation features designed to reduce the number of tasks performed by press operators.
The AutoRun system allows multiple print jobs to be processed automatically in sequence, while AutoGuide guides the operator by displaying the production steps on the control panel.
Quality control relies in particular on the QualiTronic PrintCheck, PDFCheck, and PDF HighRes systems, which inspect the sheets and compare them to the reference PDF file. The InstrumentFlight system, meanwhile, uses the gray balance for color adjustment.
After printing, the sheets pass through the Ipress 145 Pro cutting table, then through the Omega Allpro 110 folder-gluer, which can reach speeds of up to 300 meters per minute.
Koenig & Bauer also showcased its VariJer 106 digital press, designed for the production of folding cartons in small and medium runs.
The manufacturer advocates a structure in which large-volume runs continue to be handled by large-format offset presses, while low-volume orders, product variations, and seasonal campaigns are directed toward digital printing.
Robots That Can Be Programmed Without Code
Guests also had the opportunity to learn more about the automation of production operations. Koenig & Bauer presented three industrial robotics applications that use programming interfaces that do not require coding.
They were able to test these controls, which are designed to simplify the use of robots. The German manufacturer hopes this will reduce the need for certain manual tasks, particularly in light of the challenges in recruiting qualified personnel. However, the applications presented still require further development before they can be deployed on an industrial scale.
Security features embedded in the print
Koenig & Bauer also showcased its work on brand protection through its "protected at print" program, developed by its Vision & Protection division.
This technology applies processes derived from security printing and banknote production to packaging. Invisible authentication features are incorporated directly during the printing and finishing of the cases, without altering their graphic design.
A smartphone app called Ava then allows users to verify the authenticity of products. This process also provides brands with traceability information throughout the supply chain.
Finally, Koenig & Bauer presented its work with Hybrid Software on digital packaging production workflows, as well as its myKyana digital environment. These developments complement mechanical automation by enabling data flow between the various stages of manufacturing.
