Bärbel Wetenkamp, COO GPD Food packaging
Mex, Switzerland – GPD Foodpackaging installs two fully automatic BOBST MASTERFOLD 75 folder-gluers for the annual production of 750 million pizza boxes and more.
Since January 1, 2022, GDP Foodpackaging GmbH & Co has been producing food packaging on a large scale in its brand new, highly efficient smart factory in Rinteln, Lower Sayony. This includes the production of 750 million frozen pizza boxes, which are processed on two BOBST MASTERFOLD 75 folder-gluers. The two high-speed machines – equipped with robotics and fully automated – are currently still in operation and are equipped with an EASYFEEDER 4 pre-feeder and a CARTONPACK 4 automatic case packer with integrated CASE ERECTOR. The MASTERFOLD 75 achieves working speeds of up to 600 m/min and is not only the most efficient folder-gluer, but also the most automated high-performance line for manufacturing folding cardboard boxes on the market. .
“The BOBST MASTERFOLD 75 is the best folder-gluer to meet the demands of our new plant in Rinteln. It is established in the market and enjoys a reputation among packaging manufacturers around the world for its reliable high performance,” says Bärbel Wetenkamp, Managing Director of GPD Foodpackaging, why they haven’t seen an alternative to this folder-gluer. “Furthermore, the exceptional versatility and very short set-up times of the MASTERFOLD 75 enable rapid production changeovers – another crucial advantage of the machine.”
The MASTERFOLD 75 and its peripherals EASYFEEDER 4 and CARTONPACK 4 work reliably with a wide range of different packaging materials, another important criterion for GPD Foodpackaging. “The plans for our new factory aimed to achieve significant savings, particularly in energy and paper consumption, compared to the manufacture of conventional packaging. One way to achieve this is to replace cardboard made from virgin fibers with recycled cardboard,” explains Bärbel Wetenkamp. Rinteln’s two MASTERFOLD 75 lines will work with GD2 chromo duplex cardboard blanks at grammages of 200 to 500 gsm.
Regarding production, GPD Foodpackaging is innovating in this plant in several ways. It uses a reel offset printing system with in-line rotary cutting specially developed for printing cardboard and unique in Europe. It works with food-safe EB-curable ink and its above-average print speed delivers impressive productivity.
The proven technology of the two BOBST folder-gluers has earned them a place of choice in this innovative and fully automated production process. Bärbel Wetenkamp: “Customers are impressed by our confidence in this state-of-the-art technology for processing finished packaging blanks.
The smooth interaction of the MASTERFOLD 75 with its peripherals ensures that the factory can count on maximum productivity thanks to an uninterrupted folding and gluing process. EASYFEEDER 4 pre-feeders guarantee fast, smooth and consistent delivery of blanks to the folder-gluer feeder, avoiding production stoppages. At the end of the MASTERFOLD 75 lines, the CARTONPACK 4 automatic packaging machines gently fill shipping cartons up to 200,000 packages per hour, while offering GPD Foodpackaging different packaging options. GPD can save settings for individual production orders in the MATIC control of its folder-gluers and retrieve them at any time for repeat orders, further shortening the setup time for those orders.
In addition, plant management can access machine data at any time via BOBST’s productivity apps and use it for process analysis and optimization. “We look forward to working with these high-end machines. They fit perfectly into our revolutionary production process”, is how Henning Diedrich, CEO of GPD Foodpackaging, looks to the future with hope.
“BOBST promotes a desire to profoundly transform the packaging industry by making the entire production chain more agile and sustainable. The main cornerstones are digitization, connectivity, automation and sustainability. With the new factory in Rinteln, GPD Foodpackaging is taking a big step towards packaging production in line with BOBST’s vision for the future. The high level of automation, productivity and reliability of our MASTERFOLD 75 lines will provide ideal support for this innovative process,” says Hans Dreistein, Sales Manager at Bobst Meerbusch and contact person for GPD Foodpackaging.