A new generation of digital printing systems for folding carton production

Ready to launch this year – the VariJET 106

Market developments in packaging printing essentially depend on three factors: flexibility, agility and the ever shorter lead times between the initial idea and the finished product (time to market). Consequently, it is imperative for packaging printers to venture previously untrodden paths to meet the changing demands of their future markets. The VariJET 106 with its hybrid approach offers ideal prerequisites for this. It pairs the strengths of inkjet printing with those of a classic offset process.

Where it used to take around four months to complete a product launch, and then a further year and a half for a global roll-out, the corresponding periods are dramatically shorter today. Brand owners need only a few days to develop an idea into a market-ready product, and its subsequent launch is effected simultaneously all over the world. In addition, product diversity has also increased up to fiftyfold. Changes like these call for significantly greater flexibility and agility on part of packaging producers, alongside a readiness to embrace new production methods, to allow products to be launched within a drastically shorter time. Another ever more frequently encountered requirement is for seasonal, regional and target-group-specific differences to be taken into account.

“By combining the best components of the Rapida system from Koenig & Bauer with seven-colour digital printing technology from Durst, we were able to develop a press which promises ultimate productivity and uncompromising reliability when it comes to print quality. This offers folding carton producers countless opportunities to exploit the potential of digital printing, for example in the production of customised packaging.” Robert Stabler, joint venture CEO, Koenig & Bauer Durst

Complementary digital and offset systems

The VariJET 106 offers solutions for these changing scenarios. Its digital printing system is ideal for the implementation of last-minute changes. As a complement to offset printing, it enables jobs of all lengths to be produced in comparable print quality, whether that means a single copy or a million sheets. The VariJET 106 is developed and manufactured by the joint venture Koenig & Bauer Durst, while distribution has been placed exclusively in the hands of the Koenig & Bauer Sheetfed sales organisation. The new printing system marries the time-tested press engineering of the Rapida 106 with the latest generation of single-pass printing technology from inkjet pioneer Durst. Due to the modular design of the overall system, the digital printing unit can be perfectly integrated into other units based on the Rapida platform to produce a hybrid solution. This makes high-quality product finishing with one or more inline coaters possible, while also allowing die-cutting processes to be implemented. The configuration of the VariJET can therefore be tailored precisely to the specific needs of the individual user.

Personalised and individualised

The key to personalised and individualised folding carton production is the inkjet printing unit. The sheets are transported through the unit while lying flt on a metal suction belt. This defines the clearance to the printing heads exactly over the full sheet length and width. Board and other flexurally rigid materials can be printed in offset quality. A seven-colour (CMYK-OVG) water-based inkjet process from Durst is used to achieve a larger colour gamut. The ink is delivered using Fuji Dimatix Samba printing heads with variable drop size. The system also incorporates an automatic cleaning function. Engineered for production speeds up to approx. 5,500sph, the VariJET 106 prints sheets up to format 750 × 1,060mm (29.5 × 41.7in). The VariJET 106 is controlled using a console featuring touchscreen operation. Error diagnostics and remote maintenance are integrated in the same way as they are in all sheetfed offset presses. Similarly, inline quality monitoring and control with the established QualiTronic components is possible.

“With the VariJET 106, industrial digital folding carton production is becoming established in the packaging printing branch. New business models facilitate profitable growth for our customers. Print is becoming agile, individual, modern – and we are set-ting the standards.” Maik Laubin, sales director for digital solutions, Koenig & Bauer Sheetfed

Economical production for ultra-short runs

The VariJET 106 delivers individualised print products in consistent quality. The strengths of this press can be found in the economical production of test packaging, new packaging designs and packaging for special campaigns. Folding cartons with high regional, seasonal or channel-specific diversity can also be realised in a highly flexible manner. Accordingly, print providers can react immediately to sudden changes in market demands. Modifications can also be made at short notice at later points in the production chain. The VariJET 106 makes folding carton production economically viable for ultra-short, short and medium run lengths. Print-on-demand capabilities strengthen customer ties and optimise the supply chain. The full costs for intermediate storage can be saved as well. Brand owners have adapted every aspect of their market activities. The generations X, Y, Z and α are revolutionising markets, along with their expectations. These young ‘digital natives’, in particular, are enablers of what can be termed masscustomisation – this being customer-specific mass production. This megatrend is forcing brand owners to focus on catering to the needs of their customer demographic better. Classic mass production does, of course, still exist. And that is why digital and offset systems – the VariJET and the Rapida – complement each other perfectly.

Martin Dänhardt

Enquiries:

Maik Laubin

Background photo: Digital and hybrid – the VariJET 106 in its basic configuration with an inkjet pretreatment unit and coater