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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
Ezio Foresti, Business Development Director mall//herlan Group
Innovations of mall//herlan
THE BOTTLE-CAN
BottleCanTake the best from two worlds….
Ezio Foresti, Business Development Director mall//herlan Group
mall//herlan customers produced a variety of Alu bottles
Ezio Foresti, Business Development Director mall//herlan Group
Differentiation
PrintingLine concepts
Shaping
Ezio Foresti, Business Development Director mall//herlan Group
Half body shaping
7Ezio Foresti, Business Development Director mall//herlan Group
Full body shaping
8Ezio Foresti, Business Development Director mall//herlan Group
Asymmetric shaping
Ezio Foresti, Business Development Director mall//herlan Group
Embossing
10Ezio Foresti, Business Development Director mall//herlan Group
Bottlenecks
Ezio Foresti, Business Development Director mall//herlan Group
With 80 stations for greatest possible variety in body shaping
Ezio Foresti, Business Development Director mall//herlan Group
Necking machine 40 (80) stations
Ezio Foresti, Business Development Director mall//herlan Group
Necking machine 56 and 84 stations
Container development
Ezio Foresti, Business Development Director mall//herlan Group
Präzisa
Ezio Foresti, Business Development Director mall//herlan Group
Opportunities mall//herlan
PrintingLine concepts
Differentiation
Ezio Foresti, Business Development Director mall//herlan Group
Can body formingDecorationNecking
IE and DWI process
Ezio Foresti, Business Development Director mall//herlan Group
IE line layout
Extrusion pressNecker
Front-EndDecoration areaBack-End
Ezio Foresti, Business Development Director mall//herlan Group
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
Ezio Foresti, Business Development Director mall//herlan Group
IE DWI - Bottles
Ezio Foresti, Business Development Director mall//herlan Group
DWI line layout
Front-EndDecoration areaBack-End
Necker CupperBodymaker
Ezio Foresti, Business Development Director mall//herlan Group
Test Center in Pfinztal
• Material saving DWI: Up to 40%
• Aluminium and steel possible - Changeover < 1 shift
Ezio Foresti, Business Development Director mall//herlan Group
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)
Ezio Foresti, Business Development Director mall//herlan Group
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
Ezio Foresti, Business Development Director mall//herlan Group
Growing your production following market demand
Customized & Flexible Conversion to a C2C Line: 500 bpm
DWI - Backend layout 500 bpm
Ezio Foresti, Business Development Director mall//herlan Group
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.
Ezio Foresti, Business Development Director mall//herlan Group
Customized & Flexible Conversion to a C2C Line: 600 bpm
Growing your production following market demand
Postwasher 600 bpm
Ezio Foresti, Business Development Director mall//herlan Group
Leak detector 600 bpm
Ezio Foresti, Business Development Director mall//herlan Group
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
Ezio Foresti, Business Development Director mall//herlan Group
C2C - can upgrades
Daiwa Can, Japan: dia.45x108mm with 28 ROPP 2002
Showa Aluminum, Japan:dia.66mm DWI bottles with 38 ROPP in 2005
Ezio Foresti, Business Development Director mall//herlan Group
Daiwa Can Japan: dia.45x108mm 100ml DWI Minibottle with 28ROPP
Supply of 1xC200.56 Indexing Necker in 2002
DWI containers: our reference products & canmakers
Ezio Foresti, Business Development Director mall//herlan Group
Showa Aluminum Japan: dia.66mm DWI bottles with 38ROPP
Supply of 1xC200.56 Indexing Necker in 2005
DWI containers: our reference products & canmakers
Ezio Foresti, Business Development Director mall//herlan Group
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
DWI containers: our reference products & canmakers
Ezio Foresti, Business Development Director mall//herlan Group
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
DWI containers: our reference products & canmakers
Ezio Foresti, Business Development Director mall//herlan Group
Ezio Foresti, Business Development Director mall//herlan Group
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
DWI containers: our reference products & canmakers
Ezio Foresti, Business Development Director mall//herlan Group
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
DWI containers: our reference products & canmakers
Ezio Foresti, Business Development Director mall//herlan Group
The world's first monoblock steel can
Ezio Foresti, Business Development Director mall//herlan Group
Monoblock versus actual 3_pc can
Ezio Foresti, Business Development Director mall//herlan Group
Opportunities mall//herlan
PrintingLine concepts
Differentiation
Ezio Foresti, Business Development Director mall//herlan Group
wifag//polytype Metal Packaging
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
Ezio Foresti, Business Development Director mall//herlan Group
Advantages & Opportunities of Digital Printing
Individualization Participatory Marketing
Extreme high Flexibility to answer the new market requirement
Ezio Foresti, Business Development Director mall//herlan Group
Opportunities of Digital printing
Ezio Foresti, Business Development Director mall//herlan Group
Opportunities mall//herlan
DigiRoundHybrid
Digital
Ezio Foresti, Business Development Director mall//herlan Group
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)
Ezio Foresti, Business Development Director mall//herlan Group
wifag//polytype Metal Packaging
DigiRound
DigiRound
Ezio Foresti, Business Development Director mall//herlan Group
Machine Concept
Ezio Foresti, Business Development Director mall//herlan Group
Pre-treatment
Cya
n
Mechanical design - today
Ezio Foresti, Business Development Director mall//herlan Group
Horizontal turret heads
Today: 18 mandrels driven with servomotors
Future: ++ mandrels
Mechanical design
Ezio Foresti, Business Development Director mall//herlan Group
Printhead
LED
Today: 10 print stations (2 per colour)
Future: ++ stations
wifag//polytype Metal Packaging
Hybrid printing process
Printing technologies
Dry-offset
Flexo
Thermo Transfer
Silk-screen
Hot stamp
Digital
Hybrid Printing
Ezio Foresti, Business Development Director mall//herlan Group
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
Ezio Foresti, Business Development Director mall//herlan Group
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
Ezio Foresti, Business Development Director mall//herlan Group
Digital Printing
Ink cost to be considered ...
Pricing of printing inks:
Offset: 3 – 10 €/Kg
Digital: 80 – 150 €/Kg
Ezio Foresti, Business Development Director mall//herlan Group
Digital print on aerosol cans
Ezio Foresti, Business Development Director mall//herlan Group
Digital print on bottles
Possibilities with Digital printing
Ezio Foresti, Business Development Director mall//herlan Group
Thank you
Any further questions ?
Visit our tabletop
Ezio Foresti, Business Development Director mall//herlan Group