Packaging
Proteus Packaging Trades Old Iron for State-of-the Art Heidelberg VLF Press
Friday 28. August 2009 - Company Is First in U.S. To Enter Production with Speedmaster XL 145
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 todays 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 145s performance so far, thats 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 145s 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. “Its amazing, really.”
Proteus pressmen received extensive training on the new technology at Heidelbergs state-of-the-art Print Media Demonstration Center in Kennesaw. “We were very impressed by how efficiently and thoroughly Heidelbergs 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
Heidelbergs reputation for service also played a pivotal role in Proteus Packagings purchase decision. “Heidelbergs 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 shops 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 Heidelbergs 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.”