SUCCESS STORIES - Presse-, Druck- und GmbH
Reliable load securing for the printing industry
In the printing industry, strapping technology has proven to be the most cost-effective and usually the fastest method of securing transported goods with the least amount of material and energy. Many well-known printing and publishing houses rely on strapping technology from Mosca, as does Presse-, Druck- und GmbH in Augsburg.
In addition to other newspaper products, the "Augsburger Allgemeine Zeitung" is produced here daily. With a total circulation of 370,000 copies and 24 regional editions, it is one of the largest subscription newspapers in Germany. Today, the newspapers are produced on the modern rotary printing presses with up to 48 pages, printed in 4 colors throughout in Rheinish format. Up to 15 inserts per copy can be commissioned for specific target groups. Every year, 25,000 tons of paper and 350 tons of printing ink are processed in Augsburg. All automation components have to work together perfectly and, of course, shipping must not become a "bottleneck". This is why Presse-, Druck- und GmbH attaches great importance not only to state-of-the-art technology in the actual printing process, but also in further processing. After all, nothing is as old as yesterday's newspaper and delays in further processing can practically no longer be compensated for.
Strapping machines with integrated top sheet applicator
The Swiss company Ferag was responsible for modernizing the mailroom technology. An important issue was the securing of transported goods, which had to meet high standards of functionality and reliability. Fully automatic strapping systems from Mosca were chosen: fully automatic SoniXs strapping machines with an upstream laser printer and integrated cover sheet applicator are in use on all 12 lines.
"This integrated cover sheet feeder with upstream laser printer for our delivery bills was an important criterion for us when making our selection," explains Robert Scheuffelhut, Head of Postpress at Presse-, Druck- und GmbH. "After all, we were able to save between 60 and 70 cm of space on each line and reduce the annual printing costs of the delivery bills. In addition, the cover sheet is fixed in place by the longitudinal strapping as soon as it is placed, so it can no longer slip or even get lost. The machine is also very flexible. If required, special cover sheets can also be fed manually and if a delivery bill needs to be ejected again, this is also no problem."
The longitudinal strapping connects directly to the compensating stacker. The machines' (adjustable) integrated side guides prevent the stacks of newspapers, which can be up to 35 cm high, from slipping before strapping. "This is particularly advantageous for newspapers with many inserts," continues Scheuffelhut. The stacks, which are provided with cover sheets and strapped lengthwise, are then wrapped in film and strapped crosswise by another SoniXs strapping machine.
| SoniXs TRI-Connect | |
|---|---|
| Operating mode |
Fully automatic |
| Performance |
Up to 37 parcels/min |
| Frame width |
500 mm |
| SoniXs TR-Connect | |
|---|---|
| Operating mode |
Fully automatic |
| Performance |
Up to 45 parcels/min |
| Frame width |
Up to 1000 mm |
Ultrasonic sealing technology
Both machine types work with modern ultrasonic sealing units, a technology that also impressed the Augsburg-based company: "The high cycle times that can be achieved with the machines were by no means the only decisive factor for us," emphasizes Scheuffelhut. "With the hot wedge process, residues and adhesions repeatedly form on the weld tongues, which reduce the sealing quality and then require additional, usually unplannable maintenance measures." There is no need to worry about this with the ultrasonic process, as there are no heating times. Energy is only consumed during the pure sealing time; in contrast to the hot wedge process, no specific temperatures need to be maintained.
"This all has a clear impact on energy consumption," continues Scheuffelhut. "We can also run the SoniXs in standby mode at times when the package throughput is low. As the ultrasonic unit is immediately ready for use, it only needs to be activated when a seal is being applied. In addition, the strapping machines only use electromechanical presses and stops, which saves us the energy and cost-intensive pneumatics that would otherwise be required."
And last but not least, energy consumption is also reduced by the fact that the brushless and practically wear-free DC drives used exclusively in the units operate with extremely high levels of efficiency. At the same time, the direct drives reduce the number of mechanical wear parts used in the past, thereby helping to minimize maintenance costs.
Satisfied customer
Pallet wrapping presses with integrated film wrapper
The strapping machines on the dispatch lines work at speeds of up to 30 strappings per minute, could be easily integrated into the higher-level automation network and have since proven themselves in practical use. The Augsburg site is satisfied with the choice made and intends to work with Mosca GmbH again in the future.
"We will also use the advantages of ultrasonic sealing technology for palletized printed products. Two fully automatic KZV-111 pallet strapping systems with integrated film wrappers will soon ensure that the palletized goods are reliably secured for transport to the customer," explains Scheuffelhut. The versatile combination systems can strap up to 40 Euro pallets per hour four times in a vertical direction. In addition to the film wrapper, a 2 t packing press is also integrated.
"After all, we were able to save between 60 and 70 cm of space on each line and reduce the annual printing costs of the delivery bills. In addition, the cover sheet is fixed in place by the longitudinal strapping as soon as it is placed, so it can no longer slip or even get lost."