the bottle can · wifag//polytype metal packaging ezio foresti, business development director...

wifag//polytype Metal Packaging

Ezio Foresti, Business Development Director mall//herlan Group

The Bottle Can Evolution to a Premium Product

Packaging for a modern lifestyle, first-class eventsand demanding markets!

Leading supplier of alu and steel aerosol can and bottle lines

100 YEARS OF SUCCESSFUL BUSINESS

mall//herlan group


Innovations of mall//herlan

THE BOTTLE-CAN

BottleCanTake the best from two worlds….


mall//herlan customers produced a variety of Alu bottles


Differentiation

PrintingLine concepts

Shaping


Half body shaping

7Ezio Foresti, Business Development Director mall//herlan Group

Full body shaping


Asymmetric shaping


Embossing


Bottlenecks


With 80 stations for greatest possible variety in body shaping


Necking machine 40 (80) stations


Necking machine 56 and 84 stations

Container development


Präzisa


Opportunities mall//herlan


Differentiation


Can body formingDecorationNecking

IE and DWI process


IE line layout

Extrusion pressNecker

Front-EndDecoration areaBack-End


From Hamburg to Windhoek, from Berlin to Vilnius or nonstop to Ras al-Khaimah - the Warsteiner Aluminium Bottle flies around the world. For their 60th anniversary Germanys largest airline is serving Warsteiner Pils in an aluminum bottle – manufactured on a mall//Herlan canlineof Canmaker Ardagh – on domestic and international flights

60 years of Lufthansa

Upgrading IE into DWI

IE - line

Press

DWI upgrade

CupperBodymaker

2nd Necker

PreWasher Uncoiler


IE DWI - Bottles


DWI line layout

Front-EndDecoration areaBack-End

Necker CupperBodymaker


Test Center in Pfinztal

• Material saving DWI: Up to 40%

• Aluminium and steel possible - Changeover < 1 shift


DWI Lines - scope of supply

New linesDWI line 200 + 400 bpm

DWI UpgradingUpgrade existing IE- lines

Multi use C2C lines for bottle-cansProduction following market demand (170 340 510 600 bpm)


Palletizer

3. Necker 170 bpm

2. Necker170 bpm

1. Necker170 bpm

Infeed Zipper

Post washer 500 bpm

Leak detector500 bpm

Step 1.Step 2.Step 3.

Line 170 bpmLine 340 bpmLine speed 500 bpm

C2C Line 1000 -

3500 bpmStorage

De-Palletizer

Palletizer


Growing your production following market demand

Customized & Flexible Conversion to a C2C Line: 500 bpm

DWI - Backend layout 500 bpm


Palletizer

3. Necker 170 bpm

2. Necker 170 bpm

1. Necker 170 bpm

Infeed Zipper

Post washer 600 bpm

Leak detector600 bpm

Step 1.Step 2.Step 3.

Line 170 bpmLine 340 bpmLine 510 bpm

C2C Line 1000 -

3500 bpmStorage

De-Palletizer

Palletizer

Line speed 600 bpm

4. Necker 170 bpm

Step 4.


Customized & Flexible Conversion to a C2C Line: 600 bpm

Growing your production following market demand

Postwasher 600 bpm


Leak detector 600 bpm


DWI Containers: our reference products & canmakers

Since early 2000, Frattini before and now as Mall-Herlan is the most market leader in bottle installations in the different continents:- Japan

- USA

- Europe

- China

with the largest variety of bottle applications, as:

different sizes 45mm, 53mm, 58/59mm, 66mm

different closure interfacesROPP, Crown, Maxi-P

different beverage market segmentsCSD, Beer, Energy drinks, Wine, Coffee, Tea


C2C - can upgrades

Daiwa Can, Japan: dia.45x108mm with 28 ROPP 2002

Showa Aluminum, Japan:dia.66mm DWI bottles with 38 ROPP in 2005


Daiwa Can Japan: dia.45x108mm 100ml DWI Minibottle with 28ROPP

Supply of 1xC200.56 Indexing Necker in 2002

DWI containers: our reference products & canmakers


Showa Aluminum Japan: dia.66mm DWI bottles with 38ROPP

Supply of 1xC200.56 Indexing Necker in 2005



Exal Usa: dia.53mm C2C shaped bottles 25cl with 28ROPP and Standard Crown

Coke bottle: first CSD bottle application on the worldwide market !

Supply of 2xShaping Machine + 2xC200.56 Indexing Necker in 2007-2009



Rexam Europe: dia.53,3 & 57,7mm DWI Fusion 25cl & 33cl bottles

with 28ROPP, Crown and Maxi-P

Solutions for the most technically challenging bottle applications, as RedBull !

Supply of 1xShaping Machine + 1xC200.84 Indexing Necker in 2008




C2C cans upgrade – China Coffee/Tea bottle

Dia. 66mm 38ROPP bottle

Moravia Cans: Alu DWI dia.45mm Aerosol Can

Alu DWI light weight can > 20% less Alu

Supply of 1 x line in 2016



TCC Usa: Steel DWI dia.66x160(x220)mm round shoulder Aerosol Can

Steel DWI dia.66mm aerosol can for Automotive aftermarket to replace existing 3_pc cans

Supply of #1 Steel DWI HiFlex lines in 2014



The world's first monoblock steel can


Monoblock versus actual 3_pc can




Differentiation



Dry-Offset

9 colour printing unit for greatest possible variety in decoration

Dry-offset printing machine

Optical specials

Thermochrome Colours

Performance east LCR Hallcrest

coldwarmwarm cold

Fluorescent prints


Advantages & Opportunities of Digital Printing

Individualization Participatory Marketing

Extreme high Flexibility to answer the new market requirement


Opportunities of Digital printing



DigiRoundHybrid

Digital


mall//herlan Digital machine concepts

• DigiRound 100% digital printing

• Hybrid printing process Dry-Offset and Digital printers integrated in-line

Shiftable (either / or / in combination)

• DigiRound as bypass solution Independent production

(whilst main line operates at full capacity)



DigiRound

Machine Concept


Pre-treatment

Cya

n

Mechanical design - today


Horizontal turret heads

Today: 18 mandrels driven with servomotors

Future: ++ mandrels

Mechanical design


Printhead

LED

Today: 10 print stations (2 per colour)

Future: ++ stations


Hybrid printing process

Printing technologies

Dry-offset

Flexo

Thermo Transfer

Silk-screen

Hot stamp

Digital

Hybrid Printing


Hybrid Printing technology

Combining the best of two worlds

Digital printing

1. for photos (Hexachromatic color range)

2. for personalization

3. for promotions, bar- and QR codes, lot- and expiry info

Offset printing

1. for large area uni-color, full-tone

2. for sharp text printing

3. to preserve pantone

Digital

Offset


Hybrid printing: Quick change and most flexible

Optimize your print change over by using 2 independent printers in-line

One is a standard offset printing deck

Second is a digital printer

Printer 1Standard Offset Printer

Printer 2Digital Printer


Digital Printing

Ink cost to be considered ...

Pricing of printing inks:

Offset: 3 – 10 €/Kg

Digital: 80 – 150 €/Kg


Digital print on aerosol cans


Digital print on bottles

Possibilities with Digital printing


Thank you

Any further questions ?

Visit our tabletop


the bottle can · wifag//polytype metal packaging ezio foresti, business development director...

Documents