Proteus Packaging Trades Old Iron for State-of-the Art Heidelberg VLF Press
08/27/2009
Company Is First in U.S. To Enter Production
with Speedmaster XL 145
with Speedmaster XL 145
Kennesaw, Ga. - The first U.S. company to purchase and
install a Heidelberg Speedmaster XL 145 VLF press reports that the
new press is now in full production and proving its mettle in every
way. Franklin, Wis.-based folding carton producer Proteus Packaging
chose the 6-color Speedmaster XL 145 press with inline aqueous
coater to replace a pair of aging 50" machines and enable the
company to maintain its competitive position in a challenging
marketplace.
"We made it clear from the get-go that we had high expectations for productivity and makeready," said Tim Wayman, executive vice president and chief operating officer. "Our old iron was slow to set up and too sluggish to keep up with today's market demands. Our original calculation was that the XL 145 would absorb in two shifts what our two older 50" machines were doing in two shifts apiece. Based on the XL 145's performance so far, that's still the plan," he said. "After only three months in production, we already are netting 10,500 sph and expect to achieve a consistent net run rate (including blanket wash-up and makeready) of 12,500 sph by the end of this year." With a top speed of 15,000 sheets per hour, the XL 145 is one of the fastest machines of its size on the market.
"Amazing, Really"
Proteus runs 10- to 30-point paperboard exclusively, so the performance of the XL 145's Preset Plus feeder was of paramount importance. "Our expectation was that we would be able to run these types of substrates without challenging the feeder or causing unnecessary stops and starts, despite deficiencies inherent in the material," Wayman said. "Even at high speeds, the feed table with central suction belt adjusts automatically to the format and printing stock, greatly minimizing our makeready times." Likewise, he said, "Prinect Inpress Control permits faster inking up and eliminates the need to stop the press for sheet pulls and color measurements, dramatically reducing our setup waste." Finally, given its size and the types of materials it consumes, "The press is also very quiet," Wayman added. "It's amazing, really."
Proteus' pressmen received extensive training on the new technology at Heidelberg's state-of-the-art Print Media Demonstration Center in Kennesaw. "We were very impressed by how efficiently and thoroughly Heidelberg's people handled training," Wayman said. "This not only provides a major advantage for our pressmen and the productivity of our shop overall, but also accounts for the speed with which we were able to move from the training phase into live production."
Service Cinches the Deal
Heidelberg's reputation for service also played a pivotal role in Proteus Packaging's purchase decision. "Heidelberg's service organization provides the best coverage in the industry," Wayman said. "There are simply more people available to help." As with all new presses from Heidelberg, the shop's XL 145 is protected by Systemservice 36plus, which is aimed at minimizing unplanned downtime and improving the overall productivity of the press. It also includes all repair services, parts and 24/7 support for three years, as well as regular preventive maintenance. In the early production stages, the company also has made frequent use of Heidelberg's Remote Diagnostics and eCall notification services, and has been extremely pleased with the quality and the speed of response from service organizations both here and in Germany.
For Proteus, the decision to go with Heidelberg came down to an alignment of superior technology, press performance and timing. The folding carton manufacturer relocated from downtown Milwaukee to a new facility two years ago with the intent to buy efficient new machines within a few years. "The timing was perfect," Wayman said. "As we began to discuss our upgrade plans, we were ready to listen to what Heidelberg had to offer in this category."
"At the time we purchased the press, we felt that high performance based on improved production speed and makeready would pay for this press," Wayman said. Now, with production ramping up, he adds, "That turns out to have been an accurate prediction. We truly are delighted."
"We made it clear from the get-go that we had high expectations for productivity and makeready," said Tim Wayman, executive vice president and chief operating officer. "Our old iron was slow to set up and too sluggish to keep up with today's market demands. Our original calculation was that the XL 145 would absorb in two shifts what our two older 50" machines were doing in two shifts apiece. Based on the XL 145's performance so far, that's still the plan," he said. "After only three months in production, we already are netting 10,500 sph and expect to achieve a consistent net run rate (including blanket wash-up and makeready) of 12,500 sph by the end of this year." With a top speed of 15,000 sheets per hour, the XL 145 is one of the fastest machines of its size on the market.
"Amazing, Really"
Proteus runs 10- to 30-point paperboard exclusively, so the performance of the XL 145's Preset Plus feeder was of paramount importance. "Our expectation was that we would be able to run these types of substrates without challenging the feeder or causing unnecessary stops and starts, despite deficiencies inherent in the material," Wayman said. "Even at high speeds, the feed table with central suction belt adjusts automatically to the format and printing stock, greatly minimizing our makeready times." Likewise, he said, "Prinect Inpress Control permits faster inking up and eliminates the need to stop the press for sheet pulls and color measurements, dramatically reducing our setup waste." Finally, given its size and the types of materials it consumes, "The press is also very quiet," Wayman added. "It's amazing, really."
Proteus' pressmen received extensive training on the new technology at Heidelberg's state-of-the-art Print Media Demonstration Center in Kennesaw. "We were very impressed by how efficiently and thoroughly Heidelberg's people handled training," Wayman said. "This not only provides a major advantage for our pressmen and the productivity of our shop overall, but also accounts for the speed with which we were able to move from the training phase into live production."
Service Cinches the Deal
Heidelberg's reputation for service also played a pivotal role in Proteus Packaging's purchase decision. "Heidelberg's service organization provides the best coverage in the industry," Wayman said. "There are simply more people available to help." As with all new presses from Heidelberg, the shop's XL 145 is protected by Systemservice 36plus, which is aimed at minimizing unplanned downtime and improving the overall productivity of the press. It also includes all repair services, parts and 24/7 support for three years, as well as regular preventive maintenance. In the early production stages, the company also has made frequent use of Heidelberg's Remote Diagnostics and eCall notification services, and has been extremely pleased with the quality and the speed of response from service organizations both here and in Germany.
For Proteus, the decision to go with Heidelberg came down to an alignment of superior technology, press performance and timing. The folding carton manufacturer relocated from downtown Milwaukee to a new facility two years ago with the intent to buy efficient new machines within a few years. "The timing was perfect," Wayman said. "As we began to discuss our upgrade plans, we were ready to listen to what Heidelberg had to offer in this category."
"At the time we purchased the press, we felt that high performance based on improved production speed and makeready would pay for this press," Wayman said. Now, with production ramping up, he adds, "That turns out to have been an accurate prediction. We truly are delighted."
Heidelberger Druckmaschinen
A technology provider and partner in the print media industry
Heidelberger Druckmaschinen AG (Heidelberg) is with its sheetfed offset printing machines one of the leading solution providers for the print media industry. All over the world, the name Heidelberg is synonymous with state-of-the art technology, top quality, and closeness to the customer. The core business of this technology group covers the whole value-added and process chain for the 35 x 50 cm (13.78 x 19.69 in) to 121 x 162 cm (47.64 x 63.78 in) format classes in the sheetfed offset sector.
Heidelberg develops and produces precision printing presses, platesetters, postpress equipment, and software for integrating all the printshop processes. Environmental protection has an enduring importance in this regard. Solutions for the development, production, and utilization of presses help to conserve resources, reduce emissions, and cut wastage. The Heidelberg portfolio also provides general and consulting services ranging from spare parts and consumables to the sale of remarketed equipment, and training at the Print Media Academy.
Based in Heidelberg, Germany, with development and production sites in seven countries and around 250 sales offices across the globe, the company supports around 200,000 customers worldwide. All Heidelberg presses destined for the world market are manufactured at the Wiesloch-Walldorf site in line with strict quality standards. Standardized presses in all standard format classes and folding machines for the Chinese market are produced by Heidelberg in Qingpu near Shanghai.
Heidelberg presses worldwide produce high-quality print products such as business cards, brochures, posters, and folding cartons.
In financial year 2008/2009, Heidelberg recorded sales of EUR 2.999 billion. As at March 31, 2009, the Heidelberg Group had a workforce of 18,926 worldwide, including 707 trainees.
Media contacts:
Tim Henschel
Manager, Public Relations Heidelberg USA, Inc.
+1-770-419-6554
timothy.henschel@heidelberg.com
