Indonesia is fast becoming a major market for KBA within the high-growth Asia-Pacific region. Jakarta-based Sansico Group, a manufacturer of high-grade packaging, recently fired up its fourth KBA sheetfed offset press in just a few years at its main plant in Cikarang, about 60km (37.5 miles) east of Jakarta.
An associated company, PT Grafitec, took delivery of a six-colour Rapida 105 universal with coater in April 2009. This was later followed by a five-colour Rapida 105 at a second Cikarang-based group enterprise, PT Printec Perkasa II, which also operates two B3 (21in) Genius 52UV presses from KBA-MePrint. At this facility production is dominated by exclusive packaging for toy manufacturer Mattel. While the Rapida prints folding cartons for Barbie dolls and other Mattel products, the two Genius presses produce the plastic windows.
Global success with niche policy
Sansico evolved rapidly from a local producer to a globally successful specialist in packaging and paper products. Four of its five production plants are in the Jakarta area, the other is in Foshan in China's Guangdong province. The plants specialise in different printing processes (offset, flexo and gravure).
Each company within the group focuses on a specific sector, with the emphasis on customer proximity and service excellence. The Sansico Group employs over 4,000 people (with seasonal fluctuations), and alongside high-grade board and plastic packaging also produces a broad spectrum of paper-based gift- and partyware. Exports to the USA and Europe account for the lion's share of its output.
Close ties between vendor and customer
Sansico's success is founded in no small part on its close ties to customers. Those to Mattel, one of its most prestigious references, date back to almost two decades. A focus on translating customer needs into production and management objectives has enabled the company to evolve on a continuous basis.
Optimised production chain
PT Printec Perkasa II was set up in 1997 next to a Mattel factory. Management at both companies introduced a lean production system based on precisely defined sequence timing. Whether a job entails 100 or 100,000 pieces, the quantity printed must be 100% accurate. A modern laboratory checks compliance with international standards and is constantly seeking ways of networking production even more efficiently.
Managing director Kasim Ghozali says: “We are delighted with the Rapida 105 universal's performance, reliability and service. The level of automation, makeready times and product quality are also outstanding. The Rapida 105 at PT Printec delivered the same standard of excellence right from the start. We are just as impressed with it as we were with the previous investment.”
Lean and green printing
While praising the performance of the Rapidas, Kasim Ghozali also has a criticism: “What we and our customers are looking for in a press is the wow factor. The Genius 52UV was a good example. We favour lean and green printing to the highest standards and do not want to be held back in our development. All our investment is focused on innovation. Originally we had our eye on a keyless, waterless KBA Rapida 74G for UV, but that came to nothing when KBA trimmed its product range. We need fast, flexible printing systems that represent the ultimate in economy and ecology.”
Looking ahead, Kasim Ghozali says: “We shall keep a weather eye on technological advances prior to drupa 2012. There are a number of further projects we could implement with KBA if they offer the right perspectives.”