Following the installation this summer of a high-performance Diana X 115 folder-gluer and Diana Packer packing system from Heidelberg, Proteus Packaging aimed to make the most of its step up to the fast, efficient production of short- and long-run folding cartons for the pharmaceutical, food and other markets. Now, with several months’ worth of production under its belt, the company claims to have exceeded its expectations in every regard.
Ups and Downs
Folding carton gluing machines from Heidelberg offer converters like Proteus an opportunity to produce a broad spectrum of premium folding cartons in a highly economic way. Hallmarks of the technology include superior processing quality, short makeready times, and outstanding ease-of-use in processing up to 200,000 cartons per hour, depending on the size of the blank.
“What made sense for us, given the speed of the Diana X 115, was to put a packer on it to reduce the need for manual labor, and we’re very happy that we did,” said executive vice president and COO Tim Wayman. “The performance of both machines has been a revelation. The full-rated speed of the Diana Packer is two- to four times what we experienced with hand packing. We’re now able to handle a greater number of high-volume jobs faster and with greater efficiency than ever before. In addition, our output is up, and our per-piece costs are down.”
In this initial phase, Proteus has placed an emphasis on becoming proficient with run speed maximization. Once that is accomplished, Wayman said, the company will focus on further minimizing set-up times on both Diana machines.
Quality control gets a boost from an efficient ejection system that electronically identifies and quickly removes faulty cartons from the manufacturing process, even at the highest speeds.
Diana X 115
Heidelberg’s Diana X 115 embodies cutting-edge technology combined with versatility, top-quality results, and outstanding ease-of-use. The modular structure enables converters to create configurations tailored to their individual needs. A high level of automation ensures exceptionally short makeready times, with an assist from pneumatically lifted side walls and feed gates that facilitate quick, convenient setup from job to job. Additional features include an extra-long folding station that promotes smooth, precise material processing and exceptional folding quality. Likewise, the optimized interplay of the feeder and blank alignment module ensures a continuous supply of precisely aligned cartons.
The fast, flexible Diana Packer maximizes the efficiency of folding carton production and helps realize the full potential of high-speed folding carton gluers like the Diana X 115 and other members of the Diana family. Automatic calculation of setting values and a smaller number of components to set nearly halve the time needed for makeready. A touch screen makes for easy operation. Cartons can be deposited in the shipping cases so they rest on the second or fourth creaseline or the closure flap, depending on the requirements of downstream filling machines.
At Proteus, the Diana X 115 and Diana Packer support an equipment lineup that includes a Speedmaster XL 145 VLF press, a Speedmaster XL 105, and, in postpress, a Dymatrix 145 die cutter.