Desmedt scores another first!

“It’s not about speed, it’s about improving productivity by increasing uptime and reducing waste” said Henri Köhler, CEO at Desmedt and part of the fourth-generation ownership of a company that began life in Brussels in 1889. His point counters one of the major misconceptions about automation on presses of any type, that performance and productivity relate only to running speed. 

For Desmedt, the concept of automated production is an intrinsic part of the company’s DNA. Looking to move his label converting capability out of the ‘me too’ market, Mr Köhler was initially looking to replace one of his older flexo presses back in 2013. What transpired was a complete shift in his investment philosophy that saw three Mark Andy Performance Series P7 flexo lines installed, all of which were fitted with Martin Automatic MBSF series non-stop unwind butt splicers.

By 2024, Köhler had added two more P7 flexo lines and was looking to replace his existing digital capacity, which while essential to the company’s production capability, had never sat well with the Desmedt ethos. “As flexo presses became more efficient in terms of set-up and changeover, we moved much of our short-run work back from the digital press – in fact the latest P7 was installed specifically to handle our shorter runs.”

The issue was not the fact that digital could offer more customization and handle ultra short runs, even at low speeds; the problem was the downtime involved in manually changing the rolls from one job to another and one substrate to another. Best-way calculations put this at five minutes of lost production time per roll change with the press stood still, and the reality was probably more.

When the time came to renew digital capacity, Desmedt turned to long-term partner Mark Andy and one of its hybrid lines, the Digital Pro MAX. This followed successful print demonstrations, ROI analyses, and the guarantee of reliable technical support. The DPro MAX is the latest version of Mark Andy’s toner-based digital engine mounted on a Pro series flexo platform that provides a raft of converting options. It has a 330mm web width and is capable of between 20m/min and 40m/min depending on jobs.

The press at Desmedt has a web cleaner and corona treater followed by one Pro series flexo station mounted either side of the 5-color CMYK + W digital engine. The press is also fitted with a web turn bar, laminator, a semi-rotary vertical die station and a slitting unit. Crucially, the DPro MAX is of modular construction, allowing for retrospective upgrades as demand and need change.

Speaking for Mark Andy, Sales Manager Timo Donati commented: “The DPro MAX offers low cost-to-print at an affordable price entry point, making short run digital printing an attractive proposition. What appeals to Desmedt is its short changeover times, inline finishing and excellent print quality. This hybrid concept combines dry toner digital with servo-driven flexo units on a fully upgradeable platform that is flexible and scalable, so it offers the future-ready solution that Desmedt needed to replace its existing roll-to-roll digital press.”

To complement its small overall footprint, a Martin Automatic MBSC (C for compact) unwind butt splice was specified and installed. Sales Manager for Martin, Bernd Schopferer, explained: “We have built butt splicers for digital applications that can run in either direction. Here, with the Mark Andy DPro MAX, it runs from right to left. This MBSC can load two full 4,000-meter rolls at a time and has a web storage that has been adjusted to the production speed of the digital hybrid line to prevent having too much web in the process.”

The MBSC is a fully featured compact version of Martin’s well-established MBS model, including the Martin EOPP package that guides the operator through the preparation process and ensures no step is missed, so no splice is missed. With the laser-assisted tape alignment system, the operator can make sure the tape is positioned perfectly, preventing matrix breaks owing to misalignment.

According to Mr Kohler: “I calculate the DPro MAX and MBSC combination give me one extra hour of production per shift. We work a three-shift pattern five days per week so you can do the calculation yourself, but I’d say around 750 extra hours of production per year!”  This makes another calculation easy – ROI. The payback time for the investment, coupled with the working-life expectancy of the equipment, makes perfect economic sense.

But the benefit does not stop with production-time gained; it includes the significant reduction in wasted material that inevitably occurs with manual roll changes. By maximizing the use of each roll down to the core and making it easy to reload part-used rolls, all without stopping the press, there is a value-added benefit that often goes unseen, except on the bottom-line.

The Desmedt plant is rapidly turning into a showcase of 21^st-century label production. When the current program is completed, it will be the most highly automated narrow web production facility in the world, which indicates that it’s not size that matters, it’s insight and a commitment to invest in and utilize the very latest technology. Currently employing 45 and generating sales of around Euro 15m a year, Henri Köhler is looking to add significantly to his production capacity with more flexo presses – inevitably fitted with automatic non-stop unwind/splicers.