Model is all about the wave
Packaging: Weinfelden is home to one of Europe's leading corrugated cardboard packaging suppliers.
Packaging Weinfelden is home to one of Europe's leading suppliers of corrugated board packaging.While the success of commercial printed matter cannot be measured directly, or only rarely, the success of packaging quickly provides information on whether it "goes down well". Packaging and its consumer-friendliness as well as packaging design have been proven to play a major role in the sales success of products. This is a challenge for marketing strategists and product developers - but also for packaging designers. Creativity is therefore in demand, and an understanding of how packaging is produced as well as how it is filled is also helpful.Model relies on the waveUnchallenged at the top of the list when it comes to packaging is transport packaging. We visited a company that, on the one hand, specializes in the production of corrugated cardboard packaging and, on the other hand, has modern equipment. This packaging can be die-cut, slit, but also printed in a variety of ways. Model has already received national as well as international awards for its creative ideas. As a special feature, Model AG - a subsidiary of the Model Group, which is active in many European countries - also produces the raw materials for packaging and/or displays.
The packaging produced at Model is based on a wide variety of base paper grades. The raw material of this multilayer packaging material is either primary fiber or secondary fiber papers (see box on the right). These secondary fiber papers are produced by two machines of Thurpapier, which is located on the premises of Model AG, but as a profit center has to take care of its own profitability. One paper machine produces the base material testliner at a speed of up to 600 m/minute, while the second machine produces the corrugating medium base paper. The output here is 400 m/minute. After production, the paper is wound into rolls 2.5 m wide. In this way, 120 rolls of raw material are produced daily or 138,000 tons/year.
In the corrugated board production line, these corrugated board base papers are used to produce the corrugated paper webs by means of corrugating rolls. From the 1.2 mm thick F flute to the 5.2 mm thick A flute and various flute combinations, the corresponding papers are glued together here with starch. The resulting corrugated board is first cut to the required format with a longitudinal cutter and then with a cross cutter.
Precise planningBy means of production schedules, customers can be informed when their required corrugated carton type is currently being produced in Weinfelden. In some cases, Model has online access to its customers' systems and can take over the scheduling of packaging requirements: "On request, we can determine the customer's requirements in their system and schedule them accordingly. This helps us with capacity planning, and for customers it minimizes the need for storage," explains Markus Rechsteiner, Head of Application Technology at ModelTec, which is part of the group of companies.
After production, the corrugated board is temporarily stored for about 24 hours so that the paper layers can solidify and dry. What happens next depends on the order: Standard and individual packaging is produced in the inline production area or in the die-cut and glued packaging area, depending on the design.
In the direct printing process, up to six colors can be applied using flexographic printing. High-quality subjects are printed directly onto the corrugated cardboard sheets using the company's own color mixing system and corresponding clichés. The sister company Inoflex, which is located on the same site, produces the cutting dies. Inliner production, on the other hand, eliminates the need for customer-specific tools, as adjustable rotary cutting knives are used here.
Asked about the special characteristics of corrugated board, Rechsteiner explains, "Corrugated board is advantageous compared to other packaging materials and convinces with its enormous stability." He sees Model Group on the one hand as a mass producer of packaging, and on the other hand as a solution provider for very specific needs.
As much packaging as necessary Whether it's a single package or larger quantities of customized packaging solutions, the philosophy at Model is always: advice, optimization - and only as much packaging as necessary. Model solves this with a large standard range that is immediately available from stock, or at the customer's request, a customized solution can be found.
Rechsteiner describes the efficiency of the development department as a particular advantage. "Thanks to CAD support, know-how and appropriate cutting plotters, we are able to produce packaging samples quickly and true to the original". In parallel, the optimization potential is shown to the customer during this phase.
Action instead of reaction "In order to be able to produce creative packaging solutions per packaged unit of output, market proximity, analysis of purchasing habits and knowledge about the use of packaging are the basis for success," says Karin Bächer, responsible for communication in the Model Group. To achieve this, ongoing market observations and participation in development platforms are the norm. In all these activities, an in-depth, well-founded process analysis of the packaging process is essential.
Various awards confirm this proactive development spirit at all Model companies. This year, for example, the Weinfelder Group received two awards: In May, the iF Product Design Award 2006. The "Papillon Maxi Twist" and "Sprüngli Grand Cru" packaging produced by the Model PrimePac offshoot held its own against its competitors.
The company also recently scored points with a Toblerone display developed for Kraft Food at its headquarters in Weinfelden. The display solution was the winner of the Swiss Star 2006, which is awarded annually by the Swiss Packaging Institute (www.svi-verpackung.ch) in various categories. Quote from the jurors: "A lot of product and not much display.
Developments such as the display developed for Kraft Foods represent the top of the value-added pyramid at Model: "The display solutions are the most interesting technologically - and they are also image-enhancing. However, the development is also the most cost-intensive," explains Rechsteiner. "The trend in recent years, thanks to enormous creative input and improved printing possibilities in direct printing, has led to Model making a name for itself today as a proven display producer" explains Markus Rechsteiner.
Model GroupThe Model Group
specializes in the manufacture and production of solid and corrugated board packaging and displays. Under the umbrella of Model Holding, there are production facilities at various locations in Switzerland: Model AG, Inoflex and Thurpapier (Weinfelden), Model Emballages SA (Moudon), Model PrimePac AG (Au/Romanel-sur-Lausanne), Model InoPac AG (Flamatt) as well as PackShops in Dietikon, Flamatt, Geneva, Romanel and Weinfelden. Production facilities and/or PackShops are also located in Germany, Austria, the Czech Republic, Poland, Croatia and Slovakia.
The roots of the group, which employs a total of 2700 people, go back to 1882.
Kraft or testliner as a baseFor the production of corrugated or also solid board
folding carton producers rely on kraft or testliner papers, depending on their requirements. Kraftliner consists of bleached or unbleached sulfate pulp, which is also called kraft pulp. This type of paper has particularly high strength and is also very resistant to moisture. Testliner is used as cover papers and consists of 100 percent recovered paper. These papers are now the most important raw material in the corrugated board industry. Depending on the quality of the recycled materials, manufacturers distinguish between three grades of testliner, known as T1, T2 and T3. Jürgen Franck
The packaging produced at Model is based on a wide variety of base paper grades. The raw material of this multilayer packaging material is either primary fiber or secondary fiber papers (see box on the right). These secondary fiber papers are produced by two machines of Thurpapier, which is located on the premises of Model AG, but as a profit center has to take care of its own profitability. One paper machine produces the base material testliner at a speed of up to 600 m/minute, while the second machine produces the corrugating medium base paper. The output here is 400 m/minute. After production, the paper is wound into rolls 2.5 m wide. In this way, 120 rolls of raw material are produced daily or 138,000 tons/year.
In the corrugated board production line, these corrugated board base papers are used to produce the corrugated paper webs by means of corrugating rolls. From the 1.2 mm thick F flute to the 5.2 mm thick A flute and various flute combinations, the corresponding papers are glued together here with starch. The resulting corrugated board is first cut to the required format with a longitudinal cutter and then with a cross cutter.
Precise planningBy means of production schedules, customers can be informed when their required corrugated carton type is currently being produced in Weinfelden. In some cases, Model has online access to its customers' systems and can take over the scheduling of packaging requirements: "On request, we can determine the customer's requirements in their system and schedule them accordingly. This helps us with capacity planning, and for customers it minimizes the need for storage," explains Markus Rechsteiner, Head of Application Technology at ModelTec, which is part of the group of companies.
After production, the corrugated board is temporarily stored for about 24 hours so that the paper layers can solidify and dry. What happens next depends on the order: Standard and individual packaging is produced in the inline production area or in the die-cut and glued packaging area, depending on the design.
In the direct printing process, up to six colors can be applied using flexographic printing. High-quality subjects are printed directly onto the corrugated cardboard sheets using the company's own color mixing system and corresponding clichés. The sister company Inoflex, which is located on the same site, produces the cutting dies. Inliner production, on the other hand, eliminates the need for customer-specific tools, as adjustable rotary cutting knives are used here.
Asked about the special characteristics of corrugated board, Rechsteiner explains, "Corrugated board is advantageous compared to other packaging materials and convinces with its enormous stability." He sees Model Group on the one hand as a mass producer of packaging, and on the other hand as a solution provider for very specific needs.
As much packaging as necessary Whether it's a single package or larger quantities of customized packaging solutions, the philosophy at Model is always: advice, optimization - and only as much packaging as necessary. Model solves this with a large standard range that is immediately available from stock, or at the customer's request, a customized solution can be found.
Rechsteiner describes the efficiency of the development department as a particular advantage. "Thanks to CAD support, know-how and appropriate cutting plotters, we are able to produce packaging samples quickly and true to the original". In parallel, the optimization potential is shown to the customer during this phase.
Action instead of reaction "In order to be able to produce creative packaging solutions per packaged unit of output, market proximity, analysis of purchasing habits and knowledge about the use of packaging are the basis for success," says Karin Bächer, responsible for communication in the Model Group. To achieve this, ongoing market observations and participation in development platforms are the norm. In all these activities, an in-depth, well-founded process analysis of the packaging process is essential.
Various awards confirm this proactive development spirit at all Model companies. This year, for example, the Weinfelder Group received two awards: In May, the iF Product Design Award 2006. The "Papillon Maxi Twist" and "Sprüngli Grand Cru" packaging produced by the Model PrimePac offshoot held its own against its competitors.
The company also recently scored points with a Toblerone display developed for Kraft Food at its headquarters in Weinfelden. The display solution was the winner of the Swiss Star 2006, which is awarded annually by the Swiss Packaging Institute (www.svi-verpackung.ch) in various categories. Quote from the jurors: "A lot of product and not much display.
Developments such as the display developed for Kraft Foods represent the top of the value-added pyramid at Model: "The display solutions are the most interesting technologically - and they are also image-enhancing. However, the development is also the most cost-intensive," explains Rechsteiner. "The trend in recent years, thanks to enormous creative input and improved printing possibilities in direct printing, has led to Model making a name for itself today as a proven display producer" explains Markus Rechsteiner.
Model GroupThe Model Group
specializes in the manufacture and production of solid and corrugated board packaging and displays. Under the umbrella of Model Holding, there are production facilities at various locations in Switzerland: Model AG, Inoflex and Thurpapier (Weinfelden), Model Emballages SA (Moudon), Model PrimePac AG (Au/Romanel-sur-Lausanne), Model InoPac AG (Flamatt) as well as PackShops in Dietikon, Flamatt, Geneva, Romanel and Weinfelden. Production facilities and/or PackShops are also located in Germany, Austria, the Czech Republic, Poland, Croatia and Slovakia.
The roots of the group, which employs a total of 2700 people, go back to 1882.
Kraft or testliner as a baseFor the production of corrugated or also solid board
folding carton producers rely on kraft or testliner papers, depending on their requirements. Kraftliner consists of bleached or unbleached sulfate pulp, which is also called kraft pulp. This type of paper has particularly high strength and is also very resistant to moisture. Testliner is used as cover papers and consists of 100 percent recovered paper. These papers are now the most important raw material in the corrugated board industry. Depending on the quality of the recycled materials, manufacturers distinguish between three grades of testliner, known as T1, T2 and T3. Jürgen Franck
