Board Converting News, April 6, 2020

General Converting (CONT’D FROM PAGE 24)


“In printing we gained efficiencies in both productivity and speed as well as changeover time,” Barry says. Pri- or to their installation, Heidelberg told GCI it could expect changeover times of 45 minutes on average. “With the older equipment we were at a two-hour changeover time so we estimated it would be about an hour with the new equipment,” he says. “After about four months we had our changeover time down to 36 minutes on average, and 95 percent of our jobs run at the max speed of the press.” The average press run is 25,000 sheets per order. Pressroom Manager Mike Harper has been with GCI for 10 years and has worked in the carton industry for almost 40 years. His office sits between the two Heidelbergs at eye level with the press operators. He says GCI’s ap- proach to business and equipment investments is inspir- ing. “I’ve been in printing a long time and this is a different level, with the automation on the equipment. How do you compete against this? Eighteen thousand sheets per hour — that’s five sheets a second — all day long.”


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He points out the full logistics load handling on the press, which makes the press operators’ jobs easier. “They’re not material handlers. We want pressmen who look at and inspect the sheet and use all the tools that are available to them instead of worrying about making a load change,” he says. Quality First With the increased printing volume combined with sig- nificant annual sales growth — 20 percent in 2018 and then another 8.5 percent in 2019 — the need for more ca- pacity in diecutting and gluing became apparent. Last year GCI installed a Bobst Mastercut 106 PER diecutter and a Bobst Masterfold 110 A3 folder-gluer. The Mastercut is Bobst’s top of the range machine, de- livering high productivity, exceptionally short setup times, and high quality finished product. The Matic systems allow the operator to save 25 to 30 percent in makeready times. When a repeat job is recalled, the machine sets itself au- tomatically. The Power Register system virtually eliminates CONTINUED ON PAGE 28 Pressroom Manager Mike Harper, center, with press operators Bob Singraber, left, and Felipe Jamaica in front of the 8-color Heidelberg press.


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April 6 , 2020

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