Into a second century with a finishing speedster

• Special press for innovative finishing
• Automated production processes for print, post-press and logistics
• Expanded capacity

Ralf Sammeck, CEO Koenig & Bauer Sheetfed (right), and Dirk Winkler, head of print technology (left), congratulated Bretschneider managing director Wolfram Zehnle on the company centenary and the installation of a new Rapida 106.

Packaging and finishing specialist Richard Bretschneider in Braunschweig in Northern Germany recently celebrated the company’s 100th anniversary together with customers and suppliers. The occasion also heralded the transition to an even more successful second century in the company’s history – with future-oriented technology, a new development centre, and innovations in automation and robot systems.

Bretschneider’s vision has for a long time been to seek recognition as a premium supplier of complex and highly refined packaging, but that nevertheless on the basis of industrial production. The company has thus deliberately positioned itself between the major packaging groups on the one side and smaller craft-oriented businesses on the other. Already today, Bretschneider is a source of exceptional packaging solutions – folding cartons and mailings with special constructions, gift sets, advent calendars and displays – for beauty, food and non-food products, as well as for the automotive segment

Innovative finishing options

Punctually for the jubilee, a Rapida 106 was installed and taken into service. With six printing units, coater, intermediate drying ahead of a further printing unit and coater, extended delivery and pile logistics, it is very different to the presses used by other packaging printers. Managing director Wolfram Zehnle explains: “We wanted to be even more variable in our finishing options.” Classic double coating applications can be complemented with innovative methods which set Bretschneider apart from its competitors.

The decision to invest extensively in new technologies was also driven by increasing customer demands and needs. A team of nine in-house staff works solely on product development. They design the most varied packaging solutions for subsequent realisation in the production centre. On the basis of 3D PDFs, 3D renderings or ultimately a white sample, customers can then reach a final decision on the packaging to be produced.

Only one press but nevertheless expanded capacity

It is immediately evident that the printers really enjoy work on the new press with all its automation features. Despite now having just a single press, the company is reckoning with significant additional capacity. The halving of makeready times and the higher production speed mean that the jobs printed on both previous presses can now be completed in just two shifts. The third shift is thus available for new projects. That will also be necessary, because customers are increasingly looking for pure board alternatives to their currently mixed production. Experience in Braunschweig even shows that this is given priority over a lower price in many cases.

Comprehensive process automation

Bretschneider is also implementing comprehensive process automation far beyond just the print production stage. An automated packer optimises the boxing of folding cartons and mailings. Subsequently, a palletiser robot takes care of closing, labelling, palletising and removal of the full boxes. A further fully automated production line with state-of-the-art robot equipment raises co?packing performance to new levels. Up to 30,000 articles can be packed every hour with parallel optical inline quality control.