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Mondi Neusiedler has set another world record on its 12-pocket cut-size line. Within 24 hours, the Austrian paper manufacturer converted and packed 614 metric tons of A4 papers and excelled the sonic wall of 600 tons.The highly versatile cut-size line, delivered in 2004 by E.C.H. Will and Pemco, two companies within the Körber PaperLink Group, converted 30 reel sets of 80 g/m² copy paper within 24 hours. Due to the rather small order volumes, sometimes only one Euro pallet (equivalent to 500 kg or 200 reams), the machine operators performed 21 order changes and 10 packaging material changes.
Yet, with all the involved changeovers the cut-size line converted 614 tons of copy paper. This output value represents a line efficiency of more than 95 percent of the theoretically possible output, thus, setting a new benchmark in finishing within the industry. This record could be achieved due to the non-stop technology utilized throughout the entire cut-size line as well as the implementation of a Manufacturing Execution System (MES) from E.C.H. Will. The MES makes it possible to change orders or packaging materials without any production stops or time losses. This allows efficient "just-in-time" production of even the smallest orders and a product portfolio comprising several thousand different packaging designs and various paper qualities.
The record-setting equipment consists of an E.C.H. Will 12-pocket cut-size sheeter type SLK with six non-stop double unwind stations. A dual discharge feeds two Pemco high-speed packaging lines, which are designed to run with laminated paper and BOPP wrapping material. All Pemco modules – ream wrappers, ream labelers, case packers and case labellers – are equipped for non-stop packaging material changes.
The line at Mondi Neusiedler has been running in a three-shift operation with a maximum of five machine operators each shift. Thomas Novak, Head of Business Unit Finishing Department, said: ”In order to set this new record, all parties concerned have shown great commitment. They had to operate the entire line and manage a great logistical challenge in handling reels, labels and packaging materials for the different orders. With the highly versatile and efficient cut-size line from E.C.H. Will and Pemco, we managed to set another extraordinary world record with a complex order structure within our normal production.”
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