PAWI Packaging moves into new folding carton plant in Singen, Germany

Management Singen PAWI Packaging GmbH: Olaf Müller-Funke, Andreas Keller, Ralf Kautzmann, Jürgen Graf, Ivo Forster (from left).In 2012, PAWI Verpackungen AG, just 35 kilometers from its headquarters, took over the folding carton company Lago Print GmbH and renamed the company, which is located in Rielasingen, PAWI Packaging GmbH. It was already clear at the time of the takeover that a new production plant was to be built in the near future. An ideal site for building a plant was offered nearby in the Tiefenreute industrial area in the town of Singen. Of the 16,000 m2 of building land, half was built over for the construction of the new production facility for lean folding carton production.The plant was designed according to the latest findings in the packaging industry and equipped with state-of-the-art technology. The associated high-bay warehouse has space for 1,600 pallets. Great attention was paid to the requirement for food safety. From the outset, the press is operated only with migration-free inks based on vegetable oil, thus ruling out cross-contamination with conventional inks. The entire company premises are fenced off. High demands are also placed on hygiene. For example, production is separated from administration and the high-bay warehouse and can only be entered through hygiene gates. Incoming goods, which are delivered on wooden pallets, are reloaded onto plastic pallets to guarantee maximum cleanliness.Ecology and sustainability are not just empty words. The 2300 m2 roof area was used for the installation of a photovoltaic system. Thus, solar energy is used for more than 60 % of the electricity needs for the production facility. The capacity is 350 kWp and results in an energy production of 325'000 kWh/year. The avoided CO2 emissions are 195'000 kg/year. Ecology and sustainability are central topicsFrom now on, customers will also be offered the option of climate-neutral printing. The CO2 footprint of the new plant was determined and shows an excellent value. Climate-neutral production means that the CO2 emissions generated are offset in the same amount via a climate protection project. PAWI Packaging GmbH is convinced that it has taken an important and correct step and that it can offer its customers added value.New machineryInvestments were made not only in the land and the building but also in the machinery. For example, a 6-color Heidelberg XL 106 offset press with coating unit in 75 x 106 cm format was purchased. This is matched by two high-performance die cutting machines from Bobst in the same format. In the prepress area, a new offset platesetter (Kodak) and a high-performance cutting plotter (Kongsberg) complete the extensive investment package. The remaining machinery, including two modern folder gluers, a window gluer and a tray erector, was completely overhauled. The new building and the machine acquisitions are aimed at optimally setting up production for food-compliant, rational and lean folding carton production. In Germany, the company is aiming for above-average growth. The Winterthur plant produces various specialties as well as folding cartons in digital and offset printing, but in smaller runs and with a higher degree of finishing.As recently as 2015, investments were made in a Gietz Foilcommander, which can be used to produce very high-quality finished products. Winterthur is the only plant in Switzerland that still produces bags. The proximity of the two production sites and the specializations mean that synergies can be exploited. Growth is also expected in Winterthur in 2016.Design expertise and prepressAlpha Impress, part of the PAWI group of companies, is a full-service provider with consulting expertise for sophisticated marketing projects in the packaging sector. A team of 10 people produces unique and creative design and graphic solutions. In addition to printing expertise, the employees are also familiar with the special competencies in hot and cold foiling and the various finishing options through varnishing.PAWI Packaging GmbH employs around 50 people at the new location, while Alpha Impress has ten. In Switzerland, 200 people are employed. The group achieved sales of EURO 42.8 million in 2015.