KBA North America, a global press manufacturer based in Dallas, Texas, announces that Hanover Packaging, a premier packaging firm based in Hanover, Pa., is installing a new KBA Rapida 106 41-inch six-color sheetfed press with conventional and UV capabilities during the summer of 2009.
 
"We chose KBA due to the high quality, flexibility and environmentally-friendly properties of the company's Rapida 106 press," says Larry Chatzkel, president of Hanover Packaging. "We also wanted to provide a cost-effective solution for our customers. This press is the world record holder for the number of jobs run in a production shift and it has extremely short makeready times. In addition this press will run at speeds up to 18,000 sheets per hour. The fastest makereadies and highest production speeds translate into cost savings for our customers."
 
There were two primary factors that led Hanover Packaging to purchase the press: its low impact on the environment and the quality of its performance on a wide range of substrates. "First, we were looking for a press that would be as environmentally-friendly as possible," explains Chatzkel. "The KBA Rapida 106 emits zero VOCs when printing UV, which was a huge plus for us. Secondly, because we manufacture packaging in all substrates, we wanted a press that could excel in printing on both board and plastic. The Rapida 106 is the first press in which we had the confidence that we could achieve these goals."
 
Since its establishment more than 80 years ago, Hanover Packaging has been known as an innovative and customer-focused organization, with absolute dedication to anticipating and meeting its customer needs. The firm prides itself on exceeding customer expectations throughout the process of creating packaging, from beautiful designs for new product launches and re-launches, through high quality manufacturing to – for many of its customers – full service co-packing or "fulfillment" of the packaging it manufactures. Hanover's attention to detail and high standards ensures that all of its products are of the highest quality, and its turnkey manufacturing facility allows for quick turnaround, high quality and on-time deliveries.
 
To maintain this high level of customer satisfaction, Hanover is constantly evaluating its customer demands and upcoming trends in the market. "Many of our customers are requesting short-run orders, as well as maximum productivity for long runs," says Chatzkel.  This will allow us to run multiple short runs with extraordinarily low waste, and therefore more cost effectively. Due to the press's ability to deliver very short set up times, a high level of accuracy and performance, and very low waste, we expect to be able to provide our customers with the highest level of quality and efficiency. Many of our customers, this year in particular, are asking for just in time deliveries and this press enables us to be even more responsive to this need. For long runs, the press has a maximum speed of 18,000 sheets per hour, which makes it an industry leader and a cost effective solution. UV technology also permits us to print many special effects such as dimensional printing and metallic inks applied with analox rollers that closely mimic foil stamping. Plus, the format on the new Rapida 106 aligns with the rest of our production equipment and ensures high resolution on the outer edges of the sheet. This is very important for us and for our customers in that it ensures the print quality that they desire."
 
Environmental aspects were another important component to Hanover's decision. Hanover Packaging is powered 100% with renewable energy and just completed an audit to determine its carbon footprint. The company has now purchased offsets which subsidize carbon reduction efforts making Hanover carbon balanced. The firm is also at the forefront of sustainable packaging production, including the use of recycled materials, such as RPET with a very high recycled material composition. Chatzkel learned about the KBA Rapida 106 at DRUPA in 2008 when it was introduced and recognized by the EU for its low environmental impact. The addition of this press to Hanover Packaging is an important element in its continued sustainability initiatives.
 
The new KBA press is equipped with a bevy of new technology, including an 18,000 sph output, ultra fast makeready times, and cutting-edge automation. Automation options include the KBA DriveTronic dedicated drives and simultaneous plate mounting system, as well as the DriveTronic feeder, with its pre setting capabilities. The press also features the GATF InterTech award-winning sidelay free infeed, DriveTronic SIS. Hanover's Rapida 106 is a hybrid press that allows the company to print both UV and conventional depending on the needs of its customers. In order to make quick makereadies between conventional and UV, Hanover had the press equipped with dual wash-up systems. The firm wanted to ensure that the press could run varied thicknesses of stock so it is equipped to run from 40 lb paper to 48 pt board and E flute. A fully-automatic plate changing system ensures fast makereadies and the new shaftless DriveTronic feeder will help to reduce waste and allow for rapid job changes. The Rapida 106 with servo-motors drives the inkers and plate cylinders for one-minute plate changes on all units at once. "We went all out to make sure that this press would be equipped with the latest technology that would carry us into the future," notes Chatzkel.
 
Hanover Packaging has a history of investing in the latest technology in order to keep current with its customers' changing needs. Over 90% of its packaging is manufactured with equipment purchased in the last five years. "We believe that continued investment in the latest technology keeps us competitive in both the domestic and world markets," says Chatzkel. "This latest addition of our KBA press follows that trend. As a manufacturer of a variety of packaging solutions, the KBA press was able to best meet all of our needs for a variety of materials and sizes."
 
"Since this is Hanover's first KBA press, we're proud that they chose our equipment over other press manufacturers based on our technology, ability to deliver high quality, and environmental commitment," says Edward Heffernan, sales representative for KBA North America.
 
Prior to the arrival of the press, Hanover began to implement training and install a new state-of-the-art Kodak prepress system to quickly integrate the Rapida 106 into its workflow. As for its facility, Hanover only needed to pour a pad for the new press; its facility is already large enough to fit the new press. Chatzkel does, however, see a need to seek more employees as the installation of the new press and prepress system will create new jobs at his firm.
 
Since it inked the press contract, Hanover has been building a solid relationship with KBA. The firm plans to send its pressmen to KBA's German headquarters for training. "We believe in providing training for our employees," says Chatzkel. "We regularly send employees to school at our machine manufacturers' facilities. It results in bringing new ideas for efficient production back to our facility and is a great opportunity for personal development for those who attend. We have found that training away from the demands of production is a great learning environment."
 
Founded in 1925, Hanover Packaging is a leader in the design and manufacture of innovative packaging. The company is proud to count among its customers many market leaders in the cosmetics, gourmet food, health and beauty, publishing and consumer products industries. Its manufacturing capabilities include rigid boxes, hinged boxes, folding cartons, transparent cartons in PVC, APET and RPET, and windowed cartons, all of which are manufactured in its 125,000 sq. ft. state-of-the-art manufacturing facilities in Hanover, Pa.