model box no 98 - spring awakening
TRANSCRIPT
No. 98 – Spring 2016
Spring Awakening
BOX
03 Editorial
04–06 Annual review
07 Milestone
08–09 Our locations
10–11 Organisation
12–17 Investments in 2015
18–19 Interview Wolford AG
20–23 World of Cardboard
23 Publication details
02–03 MODEL BOX
EDITORIAL
DEAR READER
If, by night, I think of Switzerland, I lose sleep. I see declining prices,
falling volumes, weakening sales, shrinking profits and job losses, while
health insurance costs rise, shopping ‘tourism’ just over the border in-
creases, the number of laws, the unemployed and refugees grow, and
the public-sector budget surplus expands. If, by day, I turn to Europe, I’m
mainly on the lookout for the things I like: free markets in which suppli-
ers and consumers can interact in such a way that they are able to have
an effect on volumes and prices. Yet on the money market – that market
of all markets – this is not the case. The European Central Bank deter-
mines how high prices (interest rates) and how large volumes should be,
justifying its commands with a lie that can be seen in any newspaper on
any day: “We have to do this so that the faltering economy can gain
momentum”. The effect of this assertion is two-fold: it distracts us from
the real motive – namely to keep interest rates so low for heavily in-
debted governments that they do not have to downsize their inflated
political systems – and it suggests that the economy is a permanently
ailing patient. It is in no way reassuring that there are people so powerful
that they (apparently) know what is good for us, and it is even less reas-
suring to see the result of this constant, compulsory dosage of stimula-
tory medication: things are done that would not be done if interest rates
were to develop naturally. That is why we in the remaining ‘free’ markets
have less and less idea of what constitutes genuine demand, and what
should be attributed to bubbles created by an overstimulated, consum-
erist society. At least we have a partial explanation for why cases of
burn-out are on the rise: many people do things based on an illusion –
the illusion of money – and illusions and bubbles are close relations.
In the meantime, Model is expanding into new geographical markets.
We are promoting innovation – from the beginning of the value chain, by
turning waste products into recyclable materials – right up to printing
packaging, and taking the pressure out of printing in the process. We
continue to prefer quality over quantity, and to rely on a tried and tested
currency: joy in what we do.
Yours
Daniel Model
04–05MODEL BOX
Switzerland The Swiss National Bank’s decision on
15 January 2015 to abandon its strategy
of maintaining a minimum exchange rate
between the Swiss franc and the euro
rendered the budgets of all Model opera-
tions in Switzerland useless and led to
Model AG’s worst results in decades.
The increase in working hours to 45 per
week in response to this shock, and vari-
ous investments in automation and flow
optimisation, did improve productivity, but
this was not nearly enough to offset the
margin erosion.
The merger of all Swiss operations, which
began in 2014, was formally concluded
last year as an important step in the
Group’s reorganisation.
The highlight of the year was the new
digital printing machine going online in
Weinfelden. It has revolutionised the cor-
rugated board business by creating scope
for new applications.
Paper production increased by an impres-
sive 6%. The key Fibre Evolution Project,
initiated in 2015, will drive our business
forward in both environmental and eco-
nomic terms. The starch project with
Weinfelden-based Meyerhans Mühlen AG
has similar aims (please see Model
Box 97).
Results from folding box production gave
cause for concern in Au, Canton St. Gal-
len, and were disappointing in Hanau (Ger-
many). With both volumes and prices fall-
ing for our international products, the ratio
of personnel costs to income has become
extremely high.
The outlook for 2016 is characterised by
further change as we endeavour to return
to sustainable business performance.
Czech RepublicThe Model plants in the Czech Republic
had a relatively successful year in 2015,
despite it being the first without our tradi-
tional business partner Mondelez. Thank-
fully, before long orders from new and
existing customers were largely compen-
sating for the loss of this major customer.
Among other things, 2015 was a year of
management changes at our plants.
He man Goldmann retired as Head of
Sales in Opava and was replaced by Dali-
bor Klein, Roman Ková took over from Ji í
R ži ka as Head of Production in Nym-
burk, and Walo Hinterberger, long-serving
CEO of the Central Region, handed the
reins to Roman Jamnický.
In the Czech Republic, real gross domes-
tic product surged by 4.7% in 2015 against
a backdrop of record-low inflation. With
the possible exception of the corrugated
Lower revenue despite volume growth
ANNUAL REV IEW
The Model Group generated consolidated sales of CHF 613.3 million in the 2015 fiscal
period, corresponding to a year-on-year fall of 13.5%. At constant exchange rates, the
figure would have been just 7.9%. The average workforce came to 3,260, which is an
increase of nine over 2014. Capital spending totalled CHF 55 million.
Elisabeth Model, COO Switzerland
The largest investment in the Czech Re-
public was the installation of automated
conveyor systems at the plants in Nym-
burk (Minda) and Opava (Dücker). The
construction of a new production hall in
Hostinné was another major project.
PolandThe Polish market for corrugated board
packaging is one of the fastest-growing in
Europe. When all manufacturers – includ-
ing those who do not belong to the Polish
paper industry association – are added to-
gether, some 3.6 billion square metres
was produced in 2015. This is around 6%
more than in 2014. Growth forecasts for
the next five years assume that this rate
of expansion will continue. In terms of
output volume, Poland already ranks fifth
in Europe. The Model Opakowania plants
took the opportunities presented by such
a positive market climate and sold a total
of 229 million square metres of packaging
last year – 9% up on the previous year.
board plant in Opava, this boosted the
positive business performance of all of
our Czech plants.
Production of folding boxes fell by 16%
year-on-year, but sales of laminated fold-
ing boxes increased by a full 32% during
the same period.
Last year was relatively successful for the
Pack Shops in Opava and Prague, but less
so for the one in Bratislava. In volume
terms, total sales of co-packing services
were around 4% lower than in 2014, but
revenues at the Opava plant rose by 26%.
There is strong market demand for co-
packing services. Customer wishes are
evolving all the time, leading to a steady
increase in the requirements that the
Model Copack Plus Team must satisfy.
Today’s customers are requesting more
and more services in a far more complex
form than was the case a few years ago.
In taking on this challenge, we need to
adapt to this shift as quickly as possible,
and fundamentally change how we look at
this business area.
The reporting year brought advances with
the investment process that is intended to
increase the production capacity and po-
tential of both plants. A further facer mod-
ule was installed in the BHS corrugated
board line in Czosnów in March 2015. This
investment enables the plant to produce
five-ply corrugated board with BC, EB and
BB flute profiles, in addition to four-ply
board. One of the world’s most state-of-
the-art glueing machines – the BTX 1700
– was also installed in Czosnów. In addi-
tion to improving its performance base,
this enables the plant to glue six-point
boxes in larger formats. The construction
of a modern high-bay warehouse in
Biłgoraj was completed in December
2015. The new hall has an efficient mobile
shelving system, a floor area of 4000 m²
and is 12m high. In the long term, it will
accommodate 8,500 pallets of finished
products and permit a lead time of ap-
proximately eight days even at times of
higher output. This reduces the costs of
rental and logistics at external ware-
houses.
The 2015 financial year also rang in
changes in the organisational structure of
Model Opakowania. Jerzy Zub was ap-
pointed Head of Production in Nowa Sól,
while Grzegorz Gmyz took on the same
role at Model Czosnów.
Roman Jamnický, COO Czech Republic
06–07MODEL BOX
ANNUAL REV IEW
SALES BY MARKET IN %MODEL GROUP IN FIGURES
17.8 Czech Republic
9.5 Germany
2.1 Slovakia
0.2 Ukraine1.9 Croatia
31.6 Switzerland
2.1 Austria
15.3 Poland
6.1 France
13.4 Other 2015 2014 2013
Consolidated sales in million CHF 613.6 709.1 688.7
Investment in million CHF 55.0 60.3 49.7
Corrugated board production 789 757 710
in million m²
Litho-laminated corr. board packaging 47.5 36.8 35.7
in million m²
Cardboard packaging in tonnes 24,000 26,000 * 29,100
Container board production in tonnes 375,500 354,800 348,000
Average headcount 3,260 3,251 3,158
*restated0
20
40
60
80
100
120
Effective 1 October 2015, Krzysztof
Ja d yk was appointed the company’s
COO, with responsibility for managing the
plants in Biłgoraj and Czosnów, as well as
the new plant in Nowa Sól.
The strategic decision was made in 2015
to invest in a third plant in Poland.
The factory in Nowa Sól will enable Model
Opakowania to strengthen its position not
just in the west of Poland, but also nation-
wide. As we enter 2016, the greatest chal-
lenges for Model Opankowania this year
and next will be to integrate Model Nowa
Sól (MNS) into local structures, with the
related investment and the tasks of build-
ing up the workforce and becoming estab-
lished in the market.
Krzysztof Jazdzyk, COO Poland. .
MILESTONE
P-WELL Group employs more than 880 people in Berka/
Werra (Thuringia), Bad Bentheim (Lower Saxony), Alten-
berge (North Rhine-Westphalia), Ochtendung (Rhine-
land-Palatinate) and Elterlein (Saxony). It posted annual
sales of almost EUR 200 million in 2015. Germany’s
independent competition authority, the Bundeskartell-amt, approved the completion of the takeover at the end
of January.
The acquisition of P-WELL Group is an ideal geographical
addition to the Model Group’s existing corrugated board
plants in Poland, the Czech Republic, Croatia and Swit-
zerland. Model already has three plants close to the Ger-
man border: Weinfelden (Switzerland), Nymburk (Czech
Republic) and the recently announced new plant in Nowa
Sól (Poland). The acquisition makes it possible to supply
existing major customers throughout Germany and the
Benelux countries, in addition to Switzerland.
Furthermore, P-WELL’s preprint method is the only one
not previously represented within Model, and its speci-
alities such as heavy-duty and fanfold corrugated board
are interesting additions to the product portfolio. Its fleet
of about 150 trucks is also vital for ensuring high service
quality.
Model Group acquires P-WELLVia direct subsidiaries, Model Holding AG has acquired 100% of the P-WELL group of companies, which specialises
in the production and sale of corrugated board formats and packaging.
P-WELL GmbH, Germany
08–09MODEL BOX
OUR LOCATIONS
Production sites – modelgroup.com
SwitzerlandModel AG Industriestrasse 30CH-8570 WeinfeldenT +41 71 626 71 11F +41 71 626 17 [email protected]
Model SA Route du Devin 3Case postale 262CH-1510 MoudonT +41 21 905 85 00F +41 21 905 85 [email protected]
Model AG Auenstrasse 5CH-9434 Au (SG)T +41 71 747 91 91F +41 71 747 91 [email protected]
Model AG
Langackerstrasse 2CH-5013 NiedergösgenT +41 62 858 51 51F +41 62 858 54 [email protected]
CroatiaModel Pakiranja d. d. Kanalski put 14aP.P. 183HR-10002 ZagrebT +385 1 240 96 19F +385 1 2404 [email protected]
GermanyModel Kramp GmbH Otto-Hahn-Strasse 41D-63456 Hanau (Steinheim) T +49 6181 6750 0F +49 6181 6750 [email protected]
Model GmbHWaltrup 16D-48341 AltenbergeT +49 (0) 2505 9309 0F +49 (0) 2505 9309 [email protected]
CE-PE-WELLKISTEN GmbH + Co. KGWaltrup 16D-48341 AltenbergeT +49 (0) 2505 9309 0F +49 (0) 2505 9309 [email protected]
Model GmbHStockholmer Str. 40D-48455 Bad BentheimT +49 (0) 5924 2998 0F +49 (0) 5924 2998 [email protected]
CE-PE-WELLKISTEN GmbH + Co. KGStockholmer Str. 40D-48455 Bad BentheimT +49 (0) 5924 2998 0F +49 (0) 5924 2998 [email protected]
CE-PE-LOGISTIK GmbH + Co. KGStockholmer Str. 40D-48455 Bad BentheimT +49 (0) 5924 2998 0F +49 (0) 5924 2998 [email protected]
Model GmbHWildecker Str. 12D-99837 Berka/WerraT +49 (0) 36922 80 200F +49 (0) 36922 80 [email protected]
CE-PE-WELLKISTEN GmbH + Co. KGWildecker Str. 12D-99837 Berka/WerraT +49 (0) 36922 80 300F +49 (0) 36922 80 [email protected]
CE-PE-LOGISTIK GmbH + Co. KGWildecker Str. 12D-99837 Berka/WerraT +49 (0) 36922 80 200F +49 (0) 36922 80 [email protected]
P-PRINT GmbH + Co. KGWildecker Str. 12D-99837 Berka/WerraT +49 (0) 36922 80 350F +49 (0) 36922 80 [email protected]
CE-PE-WELLKISTEN GmbH + Co. KGBassenheimer Str. 456299 OchtendungT +49 (0) 2625 95378 0F +49 (0) 2625 95378 [email protected]
CE-PE-WELLKISTEN GmbH + Co. KGGewerbegebiet 6D-09481 ElterleinT +49 (0) 37349 666 0F +49 (0) 37349 666 [email protected]
PolandModel Opakowania Sp. z o. o. Ul. Szwajcarska 1PL-23-400 BiłgorajT +48 84 686 91 00F +48 84 686 92 [email protected]
Model Opakowania Sp. z o. o. Ul. Dunska 1PL-05-152 Czosnów/WarsawT +48 22 767 30 00 -1F +48 22 767 30 [email protected]
Planned production start autumn 2016
Model Opakowania Sp. z o. o. Ul. In ynierska 167-100 Nowa Só[email protected]
Czech RepublicModel Obaly a. s. Tešínská 2675/102CZ-746 01 OpavaT +420 553 686 111F +420 553 686 [email protected]
Model Obaly a. s. I. Herrmanna 363CZ-543 71 HostinnéT +420 499 500 111F +420 499 500 [email protected]
Model Obaly a. s. K Hor e 1572CZ-676 01 Moravské BudejoviceT +420 568 409 611F +420 568 420 [email protected]
Model Obaly a. s. K Letišti 2219CZ-288 02 NymburkT +420 325 544 111F +420 325 514 [email protected]
Model Holding AGIndustriestrasse 33CH-8570 WeinfeldenT +41 71 626 76 21F +41 71 626 76 [email protected]
Head office
Co-packing locations – copackplus.com
SwitzerlandModel AG Copack Plus Langackerstrasse 2CH-5013 NiedergösgenT +41 62 858 52 85F +41 62 858 52 [email protected]
Czech RepublicModel Obaly a. s. Copack Plus Tešínská 2675/102CZ-746 01 OpavaT +420 553 686 444F +420 553 686 [email protected]
Model Obaly a. s. Copack Plus K Letišti 2219CZ-288 02 NymburkT +420 325 544 590F +420 325 514 [email protected]
Sales offi ces
SwitzerlandModel AG Pack ShopIndustriestrasse 30CH-8570 WeinfeldenT 0842 626 626 F 0842 727 [email protected]
Model SA Pack Shop 124, Chemin du Pont-du CentenaireCH-1228 Plan-les-OuatesT 0842 626 626 F 0842 727 [email protected]
Model SAPack Shop Route de Neuchâtel 8CH-1032 Romanel-sur-LausanneT 0842 626 626 F 0842 727 [email protected]
AustriaPack Shop Linz GmbH Winetzhammerstrasse 7Postfach 552, A-4021 LinzOrder hotline 0800 22 10 08T +43 732 386 04 10 F +43 732 386 [email protected]
Czech RepublicPack Shop Opava Nádražní okruh 23CZ-746 01 OpavaT +420 553 622 751F +420 553 622 [email protected]
Pack Shop Praha Becovská 1279/15CZ-10400 Praha 10 – UhrínevesT +420 272 705 926F +420 274 877 [email protected]
SlovakiaPack Shop Bratislava Opletalova ulica 7287SK-841 07 BratislavaT +421 220 422 [email protected]
CroatiaPack Shop Zagreb
rnkove ka 1 C Žitnjak Vrtni putHR-10002 ZagrebT +385 1 24 09 638 / 24 09 639F +385 1 24 09 [email protected]
Pack Shop locations – packshop.com
Berka/WerraElterlein
Hanau
Ochtendung
Levallois-Perret / Paris
Plan-les-Ouates
Moudon
Romanel-sur-Lausanne
NiedergösgenWeinfelden
Au
Villingen-SchwenningenLinz
Zagreb
Bratislava
Martin
Opava
Nymburk
Hostinné Biłgoraj
Lviv
Czosnów
Nowa Sól
Praha
Altenberge
Bad Bentheim
Moravské Budejovice
GermanyModel AG Sales Offi ce GermanyKarlstrasse 47–49D-78054 Villingen-SchwenningenT +49 7720 997 530F +49 7720 941 [email protected]
FranceModel Kramp Sales Offi ce France18, rue Mathilde GiraultF-92300 Levallois-PerretT +33 147 57 93 13F +33 147 58 61 [email protected]
Slovakia Model Obaly s.r.o.Sales Offi ce Slovakia E. B. Lukáca 2SK-03601 MartinT +421 434 248 684F +421 434 301 [email protected]
UkraineModel Pak Sp. z o. o. Sales Offi ce UkraineChervonoi Kalyny Avenue, 62 AUA-79049 LvivT +380 322 95 36 76F +380 322 95 36 [email protected]
10–11
ORGANISAT ION 2016
MODEL BOX
Dr. Daniel Model Chairman
Thomas Amstutz Member
Benedikt Goldkamp Member
Dr. Daniel Model CEO
Elisabeth Model COO Switzerland
Roman Jamnický COO Czech Republic
Krzysztof Ja d yk COO Poland
Elisabeth Model COO
Christoph Haefeli Sales
Edoardo Finotti Production
Urs Stutz CFO
Roman Jamnický COO
Zdena Vokurková CFO
Radomír Sype na Business Application
Ji í Matýsek Operations
Josef Chalupný Sales
Dalibor Klein Sales
Roman Ková Production
Petr Etrich Production
Petr Benda Production
Radek Recmann Production
Ji í Gavenda Human Resources
David Byrtus Quality
Krzysztof Ja d yk COO
Krzysztof Ozdoba Sales
Grzegorz Gmyz Production
Maciej Spirkowicz Production
Iwona Polowczyk CFO
Jerzy Zub Project Operations
Jurica Brki Sales
Franjo Skok Production
Davorka Maderi CFO
Group Executive Platform
Board of Directors
Executive Board Switzerland
Management team Czech Republic
Management team Poland
Managment team Croatia
Elisabeth Model Managing Director
Michael Krapp Sales
Bernhard Roth Production
Dr. Daniel Model Managing Director
Christoph Haefeli Sales
Dr. Bernd Leibeling CFO
Tino Lorenz Operations Bad Bentheim
Harry Klimpel Operations Berka/Werra
Martin Lauer Human Resources
Andreas Rufer Purchasing
Pierre Jégu Sales
Andreas Klumpp Operations Thurpapier
Michael Wilms Production Aarepapier
Ulrich Niklaus Plant & Technology Aarepapier
Germany Company Management Model Kramp GmbH
Company Management Model GmbH
Paper Trading & Planning
Paper Production
MODEL GROUP
12–13MODEL BOX
Switzerland – investments throughout the process chain
Our investments continue to centre on process optimisation, automa-
tion and productivity gains. Across all of our plants and production pro-
cesses in Switzerland, we work with our partners to develop innovative
solutions, in some cases going beyond the standard range of options.
Innovative mill starch project: Newly developed mill starch was suc-
cessfully introduced at the Weinfelden paper plant in 2015, and has
been continually refined together with the Meyerhans Mühlen company.
The processing facility was completed at the beginning of 2015 and the
use of starch on an industrial scale started in March. The new starch
type has been in widespread use at the paper plants since May.
Development of a new hot water system: The plant is operated
mainly using exhaust heat, which is a very low-cost way to meet hot
water needs. The water is used to run the processing systems required
for the mill starch, enhancing the appeal of the latter project yet further.
Installation of a new pick-up roll in Paper Machine 2: This roll has
made it possible to significantly stabilise pickup of the paper webs, thus
reducing breakage frequency.
Installation of a new pick-up screen: The new system has markedly
reduced the fibre content in reject material, cutting the waste rate by
around 2%.
Corrugated board manufacture: We have equipped the corrugated
board line at Weinfelden with a new roll stand for the application of self-
adhesive strips and tear tapes. This innovative solution enables us to
apply these to the corrugated board much more precisely and at greater
speed. Given the increasing demand for shipping packaging from online
retailers, this is a welcome investment.
Intralogistics: At our Moudon plant, the process from the corrugated
board line through to downstream processing and dispatch has been
completely automated. This has optimised the entire intralogistical pro-
cess, and gives us significantly more space to work with in the interim
storage facility.
Digital printing: Smaller ongoing investments have been made in opti-
mising the Bobst digital printing press with a view to driving the techno-
logy forward, enhancing the already impressive productivity in three-
shift operations, and expanding the product range.
Offset printing: At Au in Canton St. Gallen, we have upgraded a Hei-
delberg printing press and invested in UV technology. This enables us to
reduce waste in set-up and production, and to improve productivity.
Hot-foil embossing: We are breaking new ground with hot-foil em-
bossing, and together with our machine partner we have commissioned
two innovative new developments for the sheet feed and embossing
section. Productivity gains are another key motivating factor here.
Printing plate cleaning: Cleaning stereotypes may be no big deal, but
it’s still something that has to be done. With the commissioning of a
prototype we have developed a unique system together with our long-
standing machinery partner for the fully automated cleaning of printing
plates.
Die-cutting: One robot carrying out the palleting for two machines – is
that even possible? It is if you think outside the box and work together
with partners in tackling the challenge. Then anything is possible. Two
existing die cutters have each been equipped with a layer storage sys-
tem, and the palletiser’s smart technology allows it to switch between
the two.
Investments in 2015
Cleaning printing plates
Die-cutting: There are two options for die cutting – rotary and flat bed.
And at our Weinfelden location, we are now offering both. This will
enable us to meet the needs of the market even better than before, and
with an unparalleled degree of automation. The combination die-cutting
machine features two printing units, enabling us to produce and deliver
very high volumes in the shortest possible time.
Combination die cutter: Rotary or flat bed? This question crops up time
and again when deciding on investments in die cutting. Having the choice
of both processes is a significant advantage in the packaging develop-
ment phase, and in coordinating with the customer and their unpacking
processes. With the fully automated combination die cutter we are en-
hancing our product portfolio with a technology that is not in widespread
use in Europe, and above all not in Switzerland. The ability to process
large volumes with high productivity and very short delivery times is
therefore a welcome addition. Integrated in a fully automated blank sepa-
ration, palleting and intralogistics system, this combination die cutter
meets all the requirements of a modern line for the Production 4.0 era.
Digital – flat bed – rotary: a unique combination that gives us free rein in
the creative process for developing and manufacturing packaging.
Gluing: Working to stringent quality requirements frequently presents
us with opportunities to enhance our systems and processes. We have
commissioned a whole array of systems at our plant in Weinfelden, in-
cluding a code reader (to prevent mix-ups), bottom gluing machines,
nozzle systems for glue application, glue monitoring, ejection systems,
and last but not least a prototype for bundling the packaging with broad
bands to ensure it arrives in perfect condition. This all-encompassing
approach is aimed at making the process much more stable and effi-
cient, and gearing it up for the future.
Gluing: The investment spree in our quest for innovative solutions was
rounded off with an automated system for gluing compartments into
packaging. At our plant in Moudon, situated in the heart of an attractive
wine region, we have commissioned a new compartment insertion and
gluing machine.
Fleet expansion: Delivering packaging is part of our range of services,
and logistics – in particular with regard to transport – is one of our core
competencies. Our fleet ensures that both we and our customers are as
flexible as we can be, particularly when speed is of the essence. Added
to this, we are increasingly picking up the raw material for our paper
plants, i.e. waste paper, from collection points and transporting it di-
rectly to our facilities, thus closing the paper recycling loop and avoiding
empty runs. We added five tractor units to our fleet last year, and ten
semi-trailers. The tractor units are the latest Renault trucks and comply
with Euro 6 emission standards.
We will continue to invest in new solutions out of our long-held love of
packaging and our desire to protect and present your products in the
best possible way.
Combination die-cutter
14–15MODEL BOX
MODEL GROUP
Investments in Germany
The second Bobst Expertcut was commissioned in Hanau in November
2015. Model Kramp now has a state-of-the-art, high-performance plant
for embossing and die cutting, and can thus offer its customers services
that meet even higher standards of flexibility and quality.
The installation of the manroland InlineFoiler 2.0 cold foil module on an
existing machine has opened up a range of new finishing possibilities.
Cardboard finishing and multi-colour printing, including varnishing, can
be combined in a single run. Embossing, effect coating and spot varnish-
ing can also be combined, ensuring the efficient production of packag-
ing guaranteed to catch the eye.
Coding technology was enhanced further at the end of the year. The
commissioning of the Omega printer family means Hanau can now de-
liver coding at high speeds and with high resolution using UV inkjet
printing. For our customers, this means that labels can now be inte-
grated flexibly to deliver sophisticated numbering, encoding, and per-
sonalised solutions.
These measures ensure flexibility and increase productivity, and im-
prove customisation options in both quality and volume terms.
Investments in the Czech Republic
Polyjoiner: The successful installation of the new Bahmüller BTX 2300
folder gluer in August last year further expanded the existing adhesive
bonding facility at the Opava corrugated board plant. The new machine
expands the range of cardboard formats that can be glued, and this
Polyjoiner
means constructions from all die cutters can now be processed. One of
the significant new possibilities offered by the gluer is the processing of
multi-part products. Poly-joined packaging is the best-known example.
The first boxes in this series were glued on 7 August 2015.
Changes in internal logistics: In autumn 2015, the focus at the Opava
corrugated board plant was on remodelling work. At the end of the year,
Dücker installed an intralogistics system comprising plastic conveyors to
replace the original equipment from the 1980s. Another part of this pro-
ject centred on the development of a new strapping and packaging cen-
tre with Mosca and Robopack machines respectively. With the link to
the automatic warehouse facility, the new system and the flexibility it
offers will further enhance development opportunities at the plant.
Laminator: At the end of November 2015, work began in Opava on the
installation of a new specialised finishing machine for packaging – the
AQUA 110 laminator made by the Italian firm Ecosystem Costruzioni.
The use of this machine has significantly broadened our range of pro-
duction options. Laminating was previously carried out at external com-
panies – a protracted and costly process – and this is now being per-
formed in-house instead. This acquisition is aimed at achieving more
flexible delivery dates and new ways of finishing packaging with various
lamination types (glossy, matte, special effects).
Modern CTP system in operation since the summer: The new Kodak
Magnus VLF Q3600Z platesetter was commissioned in August 2015.
This is the fastest and largest of the Kodak CTP systems installed
to date. The machine with the Z-Speed option is the only one of its
kind in the Czech Republic, or indeed anywhere in Central Europe.
Its task is to image printing plates up to a maximum format of
1586 × 2083mm. The machine has the most powerful laser in this very
large format series, and uses the well-known Kodak Squarespot stand-
ard imaging technology.
Robotic prefeeder: At Model Obaly Nymburk, the Martin 618 produc-
tion line was equipped with a new Robofeed III prefeeder made by
Dücker. A new Dücker robotic palletiser was added to the same line in
the first week of March 2016, thus making it fully automated. These in-
vestments will improve the output of the Martin 618 by 25%.
Intralogistics system Laminator CTP system
Robotic prefeeder
16–17MODEL BOX
Investments in the Czech Republic
Fully automated conveyor system: A fully automated conveyor sys-
tem manufactured by Minda was installed at the Model Obaly Nymburk
site at the end of 2015. Work began in September 2015 with extensive
remodelling in the hall, and continued until the end of December 2015.
The new system replaces the semi-automatic palletiser and the manual
transport of the sheets to the converters using highlifters. The installa-
tion of the conveyor system has increased the capacity of the corrugator
and extended the maximum size of the sheets to be processed from
3.3 × 2.5m to 4.2 × 2.5m.
New semi-automatic palletiser: At the beginning of September last
year, a semi-automatic palletiser made by Seco was installed and com-
missioned downstream of the Engico Casemaker at the factory in
Moravské Bud jovice. Coupled with the prefeeder, the completion of
this final element of this large-scale production line has resulted in a
technologically complete plant. This investment not only helps to ease
the physically demanding work of laying the products on the pallets, but
has also increased productivity, which is up 20% compared with the first
six months of 2015.
New green flooring: The construction of the new factory hall in
Hostinné was started in August last year, and work has since been pro-
gressing successfully in line with the set schedule. With the flooring
recently completed, the machines and equipment will soon be moved
into the attractive new premises. The employee facilities are currently
being finished, such as locker rooms, wash rooms, the food counter and
the dining area. The works are likely to be completed in full by the begin-
ning of spring 2016.
MODEL GROUP
Top: Fully automated conveyor system
Middle: Semi-automatic palletiser
Bottom: New green flooring
Investments in Poland
Turbox BTX 1700 gluer: A state-of-the-art Turbox BTX 1700 gluer was
installed at the Czosnów location in October 2015. This machine can
process formats from 130 × 395mm to 1700 × 1500mm at a speed of
250m/min, and can cold glue six-corner boxes. Thanks to its inspection
system, it is possible to monitor whether the adhesive has been applied
accurately at all times, and poorly glued packaging is automatically re-
jected. The new machine’s performance data are much better than
those of the Alpina folder gluer previously used in Czosnów, and the
same can be said for set-up times. In addition to improved performance,
this factory near Warsaw is now able to glue packaging in larger formats
than before, thus opening up the opportunity for higher volumes.
High-bay tool warehouse: A high-bay warehouse for tools was in-
stalled at the Czosnów factory in December last year. In future it will
store all the printing plates and dies at a single location. The dies will be
stored in special containers in the upper bays, with the printing plates
directly beneath them. The bays are accessed by special cranes oper-
ated from below, which are fitted with cameras. The shelves, which can
hold 1,638 dies and 4,050 plates, were erected in a hall built in 2014.
Manufacture of five-ply corrugated board: A second facer module
was installed in the BHS corrugated board line in Czosnów in March
2015. Reaching speeds of up to 450m/min, this is an innovative solution
in the sector. This investment enables the plant to produce five-ply cor-
rugated board with BC, EB and BB flute profiles, in addition to four-ply
board.
High-bay warehouse extended: The construction of a new finished
goods warehouse was completed in Biłgoraj in December 2015. Station-
ary shelves and 9 of 18 double-sided movable shelves were erected in
January 2016. The new warehouse is already in operation, and further
shelving will be added as required.
Prior to this investment, it was possible to store around 5,000 standard
pallets at the site. Over the long term, the new hall, covering an area of
4,000m² and with a height of 12m, will be able to house more than
8,500 pallets. Effective storage space savings on this scale are possible
thanks to the use of mobile shelf systems in addition to the stationary
units. The new warehouse will also feature two additional loading ramps,
allowing us to load six trucks at the same time.
Turbox BTX gluing machine
High-bay tool warehouse
Extended high-bay warehouse
Manufacture of 5-ply corrugated board
18–19MODEL BOX
Ms Cottier, how is Wolford
different from other leg and
bodywear manufacturers?
Wolford distinguishes itself
from its competitors by
focusing on product inno-
vations and delivering the
extremely high quality that
is characteristic of the
Wolford brand.
The knowledge and expertise that Wolford
has accumulated during almost 70 years
in the business are unique.
To be successful in the long term, it is im-
portant that we as a company work with
new technologies and create new materi-
als. Wolford consistently puts these ideas
into practice. The unique quality that is
such a feature of Wolford begins with the
selection of the highest-quality yarns and
comes through in our special manufactur-
ing techniques, which are still employed
at Wolford’s original location in Bregenz.
Manual quality controls of every single
item, both during and after the production
process, offer guarantee our clients that
we deliver nothing but the best quality.
What was the inspiration for these luxury
tights?
The tights are fashion items that take up
the cool trend for studs. In the usual
Wolford manner, these tights combine
fashion, design and craftsmanship.
Where are they available?
Only 699 pairs of the Limited Edition I
tights were made, and they have already
sold out – so I am afraid they are no longer
available.
Are you planning other limited editions?
There will be more limited editions in the
coming collections. Diamond Shine tights
will be available as of September 2016.
The almost invisible seam gluing tech-
nique applied to Pure 50 – itself a master-
piece – is combined with the sparkle of
17,500 gold-coloured studs, which are ap-
plied right to garter height. Pure 50 tights
are especially soft, making them fabulous
to wear.
What do you expect of a packaging
supplier?
It’s important that packaging suppliers
should also understand our brand and our
product. For this reason, we expect our
packaging suppliers to get to grips with
the brand and learn to understand it, be-
cause that’s the only way to find packag-
ing solutions that are satisfactory for both
parties. Besides this, flexibility and reliabil-
ity are important in all areas.
The Diamond box complements this
exclusive product perfectly, and will make it
highly attractive for consumers. In what
way did Model support you with this
packaging project?
Model’s assistance on this project was
perfect in every way. They understood the
product and the idea of femininity behind
it, and interpreted the concept outstand-
ingly well – from the professional develop-
ment of the packaging to its very precise
Established 66 years ago on the picturesque shores of Lake Constance in Austria, Wolford produces high-quality
legwear, intimates and bodywear, ready-to-wear garments and knitwear as well as accessories, with a clear
focus on style and total comfort. Model AG of Au had the privilege of developing and manufacturing the perfect
packaging to complement Wolford’s Limited Edition I studded tights.
Delivering on the packaging promise!
Katja Cottier,
Director of Corporate Marketing
Wolford AG
L IMITED EDIT ION BOX
Diamond box
execution – and displayed genuine com-
mitment at all times.
What message is the Diamond box intended
to convey to the consumer?
Packaging is particularly important for
every product, as it gives the client a first
impression of the contents. It should
therefore echo the character of the pro-
duct packaged inside, so that the client
will understand it at first glance.
What do you expect of your product packag-
ing?
As Wolford products are manufactured
with the greatest care using the best ma-
terials, it’s essential that the packaging be
of an equally high standard – both inside
and out. This is the only proper way to pre-
sent the product. What’s more, the pack-
aging must offer clients an experience, so
that they recognise just how special our
products are when they unpack them.
The packaging must be visually appealing
and explain the product at first glance. It is
also important that it is easy to handle, so
customers don’t take too long to unwrap
their purchases.
What could the Model team do better?
For our part, we see no room for improve-
ment – collaborating with Model has been
a truly impressive experience.
WORLD OF CARDBOARD
20–21MODEL BOX
Bonbon boxesAn unconventional packaging design
order posed a challenge for the technol-
ogy department in Nymburk. The client
supplies bonbons to various countries,
but its markets have differing require-
ments with regard to the placement of the
access slot. The solution was a unique
construction where the full box can be
opened from both the front and the side,
and can be used as a sales display.
Advent case for PrazdrojThe product development team at folding
box manufacturer Model Opava answered
the call to design an advent case with
cans of Plze ský Prazdroj lager (Pilsner
Urquell).
Made from laminated cardboard, the
packaging was created in such a way that
the individual cans could be easily re-
moved once the windows are opened, the
latter being numbered accordingly on the
front. And just like a real case, the box was
also fitted with a carrying handle.
Becherovka herbal liqueurThe innovation centre in Opava has devel-
oped a new range of gift packaging for the
high-end Czech herbal liqueur Becherovka.
In keeping with the tradition and original
recipe of this drink, the packaging design
was inspired by a sachet for gathering
herbs. Choosing a rustic look also served
to strengthen the image of the liqueur as
a natural product, and the cardboard was
discreetly cold-embossed to heighten the
prestige feel.
Ovoc ák’s poly-joined display shipperThe first poly-joined boxes manufactured
at the Opava corrugated board plant have
paved the way for new packaging ele-
ments, particularly in the case of shelf
ready packaging. The construction makes
it possible to use two different materials,
which can each be offset or flexo printed.
After performing its function in the trans-
port phase, the lid can be recycled and the
goods are ready for display on the shelf in
the more appealing lower section – easy
to access and readily visible for custom-
ers.
Ski pole standA mountain of ski poles inspired the devel-
opment of a sales stand for the company
Völkl. The interesting request from the
sales department in Nymburk was taken
up by one of the designers, who created a
universal stand for several types of ski
pole. The partnership with a technical ex-
pert from Völkl and Model’s graphic de-
signer resulted in a sales stand used by
Völkl in sports stores across the world.
Boss The ScentDark shades of brown were applied to the
classic silver PET base and then finished
with an elegant combination of different
varnishes. The text inside the debossed
bottle image was printed in raised relief,
while the content message was partially
highlighted with a semi-matte varnish and
also debossed. The result is a packaging
that strikes the perfect balance between
refined elegance, self-confidence and
masculine nonchalance.
Digital printing – Uncle Ben’sThe challenge here was to create an oval
display with maximum advertising space,
but stable enough to present three trays
carrying 25 250g packs of rice. Another
special feature is that the packs can be ac-
cessed from both sides. The advertising
space is important here since it is used to
show how easy this new product is to pre-
pare. The complete display including the
cover comprises five separate parts, and
was printed digitally.
Cigarette displayThe customer was looking for a simple,
effective and versatile POS display for
cigarettes. Model SA, Moudon, contruc-
ted a compact stand that is easy to set up.
The same concept was used for several
versions using different digital printing
processes and customised headers, and
cut using the plotter for small runs. Digital
printing means designs can be changed
regularly without incurring tool costs.
22–23MODEL BOX
Postal packagingThis delightfully colourful packaging suit-
able for postal delivery comes in two
sizes. The smaller of the two allows up to
two pairs of socks to be sent as letter
post, leading to a saving on postage costs
guaranteed to please the end customer.
The printing – as colourful as the socks
themselves – was deliberately placed on
the inside of the pack, and printed using
the new Bobst digital printing press. Of
course, the packaging wouldn’t be com-
plete without a tear tape and self-adhesive
strip. Packaging serves as a company’s
calling card – and this is especially true in
this case.
Wall calendar This 2016 calendar is not only devoted to
cardboard, it’s made of it. There are six
sheets for two months each, and a cover
sheet with openings revealing a map with
the production sites of the Model Group.
The calendar pages show photographs of
six Model locations, and feature individual
QR codes linking to further information
online as well as samples of packaging de-
signs. In addition to traditional holidays,
the calendar itself also highlights some
rather unusual days – such as Secretaries’
Day, Office Nap Day, Dreamers’ Day, and
Practising Pay Rise Negotiations in Front
of the Mirror Day. Besides its material and
content, the format is also rather special,
namely a 30×30cm square, which catches
the eye and sparks curiosity. The calendar
can be either hung on the wall or stood up.
The packaging was designed and pro-
duced at the Biłgoraj plant in Poland.
Packaging like a spring gardenThe packaging and the content both play
on the Easter tradition of hiding treats in
the garden. The main packaging evokes a
spring garden, concealing an assortment
of handmade regional delicacies: choco-
late with dried fruit such as cranberries,
redcurrants or apple. The garden motif is
also continued in the design of the indi-
vidual elements.
The packaging is made from three-ply,
corrugated E-flute board. Double-sided
tape is used and is already glued in during
the manufacturing process. This means
the packaging can be folded much quicker
and more easily. The design of the main
packaging is reminiscent of a box of choc-
olates, while the bars themselves are in a
recess with a simple holder to stop them
falling out. The overprint is in four Pantone
colours and also varnished.
WORLD OF CARDBOARD
Many thanks to the following for their contribu-
tions and images
Katja Cottier, Wolford AG
Claudio Lumbiarres, DillySocks AG
Michael Eyer, Mars Switzerland Ltd.
Christophe Terribilini
Model staff
Model Box
Model Group customer magazine
Volume 27, published quarterly
© Model AG, 2016
modelgroup.com
Editor
Iris Brugger, [email protected]
Model AG, CH-8570 Weinfelden
T +41 (0) 71 626 71 11
Design
cocomu gmbh, ch-6300 zug
www.cocomu.ch
Printing
medienwerkstatt ag, ch-8583 sulgen
www.medienwerkstatt-ag.ch
PUBL ICAT ION DETA ILSDIGITAL PRINT ING
Beer (packaging) No – beer-brewing is not our latest ven-
ture. We will stick to what we do best –
manufacturing intelligent packaging solu-
tions!
Do you brew your beer according to sea-
son, sporting event, or by moonlight – but
your packaging (still) lacks a certain some-
thing to make that immediately clear? For
just under a year now we have been using
a world first in digital printing technology
from Bobst SA. It means you no longer
have to choose just one image for your
packaging.
A whole range of designs can be printed
in small or large runs, at no extra cost for
printing tools. 21, 33, 55 – which birthday
are you celebrating next?
PS: If wine is your passion, we can pro-
duce individually printed packaging for you
too.
The new digital printing technology – a brief guide:
promotions
Interested?Contact your Model customer adviser
on T +41 71 626 71 11 or mail us at:
modelgroup.commodelgroup.depackshop.com