Elaborating on current demand, he stated, “UV LED, and EB in particular, is getting more and more popular. We do have equipment with EB on it, as well as UV. We are seeing more requests for it. EB UV and UV LED are coming on. We have the capabilities to implement it.”
Innovation
Turning the discussion to examples of what’s currently being offered, he pointed first to linear drives and solid frames. Drivetronic recaptures energy from slowed down motors. It speaks to the push toward sustainable and environmentally friendly practices.
“Printronic sets us apart—It sets print impression automatically by itself. No special markings and no camera system tool assists are required. With labor shortage concerns, it makes for an easier transition for people to step up from assistant to operator. The tool is very accurate and also reduces start-up waste. Printronic is very intuitive.”
“The Ergotronic console, associated with Printronic, is the basis on all machines. We take how a person thinks about operating a machine and apply the mindset so HMI is intuitive and easy to learn,” Renschler reports. “The touchscreen is laid out so the operator is seeing the functions of the press just like the material runs through it. Operators can touch the screen to change the pressure of the nip rollers, automatic turn on rewind, access job recall, etc. All job settings are saved and stored and can be easily recalled. It’s a massive time saver! Plus, it’s easy for new people to learn. We’re seeing dramatic reduction in changeover times.”
Renschler maintained that Printronic and Ergotronic are both features that support the skill development process. “A user interface that is very graphically oriented makes it so much easier. It’s a package we offer customers that adds value, especially since we offer training in our factory where application specialists teach customers the ins and outs of the system on site.
“Washtronic is our auto-wash system that can be customized to wash down all stations simultaneously or individually,” Renschler added. “With light, medium and heavy cycles that require just minutes, it affords operators the opportunity to prep the press in other areas.”
Automation
“Integration of service and sales activities allows for fast reaction time—it’s one of our major benefits to help grow market share in this industry, from film to giftwrap to folding carton,” Renschler decreed.
He immediately acknowledged the Internet of Things (IoT) is facilitating progress, evidenced by what he terms “Bots in machines.” What’s the benefit? Renschler accommodated FLEXO’s question. “Data generated is continuously monitored and an endless amount of data can be analyzed. Robots monitor data flow and if abnormalities develop, the bot detects it, then sends messages to the service team indicating there might be a problem. Technicians are dispatched. Parts go out. IoT and Industry 4.0 manage data proactively by letting us inquire about issues that might come up in the future. This is the direction we are heading in on all our platforms.
“Seeing a problem coming, preparing for it and striking just before it hits, is the epitome of proactive vs. reactive maintenance. It’s a game changer!”
Remote & VR Assists
Additional capabilities, some recently developed and others seen as pending enhancements, tie into an Industry 4.0 platform, according to Renschler. “Customers can now take advantage of this platform and bring in inventory platforms and graphic houses with IoT communications. Today, they can send artwork directly to the press, utilize 100 percent defect detection systems, tie in internal and external MIS with raw materials, work in process, live real time inventory and more. This way, the customer can call up, ask, ‘Where are we?’, and get a report on what’s been printed and where things stand in converting. The response is immediate. Some say it’s ‘unbelievable!’
“PressSupport24, on the service side, allows rapid response,” Renschler proudly noted. “We have a good track record—80 percent of inquires diagnosed are resolved. Data is taken back from the machine and used for service purposes.”
“Augmented reality (AR) data glasses represent yet another feature that helps with uptime,” Renschler detailed, referring to his company’s 2019 FTA Technical Innovation Award win for DataGlass Remote Support. “If there is a problem, the printer gets online with our technical staff, 24/7, US or Europe—and together they see what each individual is seeing. The result: more uptime and productivity, plus far less downtime.”
Future
“Today’s flexo print quality is paramount. Quality will continually increase in the future and a major focus will be on sustainability and total cost of ownership,” Renschler exclaimed. Then, he confided, “Additionally in the future I can see an expanded digital portfolio as the next logical step. Koenig & Bauer does have digital print systems that print on metal, cardboard and papers. So, the logical evolution points to a digital print solution for wide format flexible packaging. Again, development will help to set us apart.”
Addressing coming trends, Renschler predicted, “Likely refinements in flexo technology are coming!” The forecast is rooted in history. “Big changes occur every seven-to-10 years. The Ergotronic, Printonic platforms are recent examples. I have seen the highest-quality linescreens coming off the press. It surprises people. We have such little dot gain and it really contributes to print quality.
“Raising the bar in the industry is our goal,” Renschler concluded. “Continuous improvement is expected, particularly in automation, process control and ease of operation. Our intuitive operating systems, available on all our presses, will become more and more automated. We are on it.”