Good Planning is Half the Battle!
When it comes to quality, CPC Haferkamp in Oldenburg, in
northwest Germany, does not compromise. From the floor covering to
the presses as well as the room temperature and air quality, the
packaging and label specialist has optimized its production
conditions down to the smallest detail-thereby laying the basis for
Nobody is allowed to enter the pressroom without wearing clean
working clothes. On a huge floor area, half the size of a soccer
field, six Heidelberg Speedmaster CD 102 presses-three of which are
equipped with UV technology-produce in-mould and wet-glue labels.
The printing company works for leading businesses in the global
food and consumables industry. They appreciate the compelling
quality that CPC Haferkamp has continuously and meticulously been
enhancing since it started to specialize in packaging and labels.
That included the planning of its new building: "Even for the first
architectural layouts, we closely cooperated with Heidelberg. The
surface conditions were defined exactly, for example, so the
presses would operate without vibration. That is important for
processing paper, but imperative for foil. Here, even the smallest
lapses lead to visible imperfections," reports Axel Beneke,
Operating Manager of CPC Haferkamp.
Heidelberg experts were part of the team when the
infrastructure requirements were laid down. The printing company
made use of the know-how of specialists from the most diverse
fields, for instance to decide which power lines were needed or
where to plan channels for water pipes and compressed-air lines.
Material and workflow were just as important as the optimization of
the press positions and their connection to Prinect Image Control.
Configuration & Parameters
CPC Haferkamp has expanded its foil label business in a
targeted manner. It now makes up 40 percent of the overall
production. The labels are printed and coated using UV technology.
To avoid heat damage when processing foil, Haferkamp uses a
CoolCure UV device with two of its six Speedmasters CD 102. It
replaces oxygen by nitrogen during the printing process, thus
improving the drying behavior while minimizing the heating of the
Electrostatic charge is also a challenge. To save time and
money, the label specialist uses 40.1 inch- wide (102 cm) foil
rolls with an average diameter of 3.28 feet (1m). The foil is
unwound in-line by a Heidelberg CutStar and cut to the required
format. "The shingling of the sheets creates an enormous adhesive
force," explains Beneke. Together with Heidelberg, CPC Haferkamp
has solved the problem: A newly developed additional apparatus
prevents the build up of electrostatic charge during the shingling
of the sheets. That makes the processing much easier and highly
flexible: The sheeter can simply be pushed aside to print paper
Indoor Humidity & Drying Process
Once the sheets reach the delivery, it is important for them
all to maintain the same moisture level. A detailed analysis of the
air circulation in the pressroom is needed to isolate problem zones
and correct the situation. CPC Haferkamp therefore continuously
measures and adjusts the temperature and indoor humidity to balance
variations and maintain its high quality standard. The raw material
is stored in the pressroom, so it can adjust to the room
temperature and air quality and be processed at its best.
Production Reliability & Top Performance
CPC Haferkamp operates around the clock in four shifts, from
Sunday night to Saturday evening. On Sundays, the machines are
maintained. To ensure constant adherence to delivery dates and top
quality, the company carefully records the availability of every
new machine during its first year and uses the record as a basis
for optimization measures. Moreover, all machines are included in
the service package Systemservice36plus by Heidelberg Germany. "We
have established an excellent early-warning system based on the
remote service. Heidelberg's reaction times are extremely short.
Normally, the parts are delivered the next day," commends Beneke.
That explains the company's high machine availability.
Without the close partnership with Heidelberg, the production
conditions could not have been optimized so efficiently. To sum
things up, Beneke says: "I can only advise all other printshops to
plan their production factors precisely before expanding or
building a press room and to make use of the experience and
competence of Heidelberg."
Over 4,500 extremely well-trained and highly motivated staff
provide the full range of production-related and consulting
services you need to optimize your production and business