InFocusOctober 2019

w-d.de

// Looking ahead to the trade fair

year 2020

// Diaper machine conversions

another joint project of W+D

and BICMA

// W+D Inserting TIPs, Episode 3

// W+D Direct Mail Days gave a

significant look into the future on

how direct mail can grow

// Mayer-Kuvert orders

10 W+D Halm i-Jet 2

// Inserts what others can’t:

the W+D BB700 S2 at BMS

// PM Solutions closes the

production loop with a

W+D Halm i-Jet 2

2 InFocus

medium to long runs (see pages 4-5)

and you can look forward to even

more innovative solutions in the areas

of service and envelope inserting. We

will also be continuing our series of

innovations in envelope production

and finishing and look forward to re-

ceiving your feedback.

The exhibitors and visitors are already

looking forward to drupa in June of

next year and have high expectations.

It is currently the largest industry plat-

form for presenting newly developed

printing and converting technologies

to a broader expert audience. In any

case, W+D is well prepared: Among

other new developments, we will be

presenting mature versions of re-

cently introduced mail systems and

demonstrating their capabilities to

you in Düsseldorf. We will also show

you what innovative solutions mean

for your production and your product

portfolio so that you are well positi-

oned for the future – embrace the

future of the envelope!

Looking ahead to trade fair year 2020

You’ll find us in hall 16 again. Plan

to stop by our booth and don’t miss

the opportunity to take a look at the

future of envelope production, finish-

ing and intelligent envelope filling – it

will be worth your while.

At index 2020, the international plat-

form for the hygiene industry, which

will take place in Geneva in April, the

two brands W+D and BICMA will be

exhibiting together for the first time.

Besides the current range of ma-

chines and retrofits, we are pleased to

be able to present a completely new

development to you there. The new

system will supplement our portfolio

in the personal care / hygiene area

with promising products for an im-

portant business segment. You can

also get an overview of the solutions

we are currently developing that offer

you clear advantages in terms of the

efficiency of the systems, especially

with regard to flexibility and the short-

est possible changeover times.

As you can see, 2020 will be an inno-

vative year we’re looking forward to!

For us, next year will be marked by two important international trade fairs: index for the nonwovens indus-try will take place in April and for the paper converting and printing industry drupa will open its doors in June.

Of course, you can expect many in-

novative solutions from us again in

2020. After presenting a completely

new generation of machines at the

last drupa, including the W+D 410

Easy Enveloper, the envelope machi-

ne for small and medium runs, W+D

Halm inkjet digital printing machines

followed at Direct Mail Days 2017 and

2018. At this year’s Direct Mail event,

we successfully launched the new

W+D 628 as an envelope machine for

Looking ahead to trade fair year 2020 . . . . . . . . . . . 2

Diaper machine conversions another joint project of W+D and BICMA . . . . . . . . . . . . . . . . . . . . 3

W+D Inserting TIPs, Episode 3 . . . . . . . . . . . . . . . . . . 3

W+D Direct Mail Days gave a significant look into the future on how direct mail can grow . . . . 4

Mayer-Kuvert orders 10 W+D Halm i-Jet 2 . . . . . . . 6

Contents

Inserts what others can’t:the W+D BB700 S2 at BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PM Solutions closes the production loop with a W+D Halm i-Jet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

We are W+D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Practical tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Trade fair dates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Frank Eichhorn, W+D Managing Director

3InFocus

The focus here was on the so-called

elastic “ears” or ear kits on modern

diapers. In contrast to the classic

production of diapers, in which the

product is cut from a wide web of ma-

terial, these elastic ears are attached

to the side of the absorbent core. This

process is particularly sustainable and

almost no waste results from the pro-

duction of the baby diapers.

As a joint project of W+D and BICMA,

the customer therefore had its baby

diaper machines upgraded to this

economical product design. The plants

in Poland and Russia are now using

BICMA modules to manufacture mo-

dern and custom-fit diaper products.

W+D was able to work on additional cooperative projects together with its subsidiary BICMA Hygiene Technolo-gie GmbH in Mayen: A global manuf-acturer of medical, care and hygiene products needed a reliable partner to modernize its production facilities. Since he has been a BICMA customer for years and appreciates the expert advice and professional implemen-tation of modifications by BICMA, he decided to order three rather advan-ced conversions from BICMA, which were then assembled at W+D in Neu-wied and put into operation with the help of the experts at BICMA.

State-of-the-art technology works almost without waste Thanks to the current strong growth

in Eastern Europe, further production

facilities in Poland and Russia needed

to be converted in the latest project.

To perform a format change on the

W+D BB700 14k or 16k, fast and

precise adjustment of the conveyor

belt at the envelope feeder is neces-

sary to ensure trouble-free machi-

ne operation without interruption at

maximum production speed. By in-

stalling the W+D handwheel, the

conveyor belt can be brought into the

ideal position for the envelope feeder

with maximum efficiency.

We have also developed optimized cam discs for products up to C5 (162

mm removal length) for your installed

rotary feeders to avoid double or mis-

sing sheets. This improved product

flow technique allows for a better

feeding behaviour.

W+D-Inserting-TIPs, Episode 3

Diaper machine conversions another joint project of W+D and BICMA

More information about our Insert-

ing TIPs can be obtained from your

contact at W+D.

proaches and new equipment. Scott

also talked about how well Kenmore’s

new W+D machines meet these chal-

lenges. From the first installation on

to the marketing of their wide range

of direct mail products, their turnover

rose immediately.

InFocus: For the first time ever, a number of US customers visited Direct Mail Days. How did they benefit from the event?

Schipke: The proven power that direct

mail has, when used in an omni chan-

nel marketing mix, is the reason why

there are about 60 billion direct mail

envelopes in the US mail market alone

per year. Direct mail professionals are

demanding quicker turn times, more

colors, more haptic finishing, better

quality, new envelope substrates as

well as more pressure on pricing. So,

forward thinking US envelope conver-

ters like Scott and his US colleagues

attending Direct Mail Days are now

looking for new, faster and more effi-

cient solutions, especially in print, with

less production touches and more in-

line finishing.

W+D Direct Mail Days offered them

the chance to see not only new run-

ning solutions for envelope conver-

ting, but also running inserting and

inkjet technologies. To talk with other

companies in the mail value stream

Andrew Schipke, Vice President of Sales and Marketing for W+D North America, has been active in the com-mercial offset and flexo printing mar-kets for about 42 years now. Here are his views on the latest Direct Mail Days.

InFocus: Mr. Schipke, one of the key speakers at Direct Mail Days this year was Scott Evans, President/CEO of Kenmore Envelopes in the US. What made his presentation so special?

Schipke: Scott gave a passionate pre-

sentation about how they successfully

transformed their envelope convert-

ing company into an even more pro-

fitable and future-orientated business

with new thinking, new selling ap-

are top-of-mind issues for envelope

stakeholders, too. This not only gave

them a better understanding of the

inserter demands that are placed on

their envelopes, but with inkjet print-

ing market penetration increasing,

envelope converters are now seeing

new inkjet converting opportunities

that may be on the near horizon for

them.

InFocus: What were the highlights of the event for you?

Schipke: I would say that I took the

most memorable or impressive take-

aways that I heard about pertained to

the new W+D 628:

/ W+D 628 flexo LED UV printing that looked as good as any offset

The new W+D 628 is a major im-

provement in folding, but a quantum

leap in print technology features, i.e.

high-quality web flexo printing in-

line. Adding value in print, coating

or inline finishing is one of the future

growth opportunities in the US direct

mail market and surely everywhere

else.

4 InFocus

W+D Direct Mail Days gave a significant look into the future on how direct mail can grow

From left to right:Frank Eichhorn, Managing Director of W+D, Andrew Schipke, Vice President of W+D North America, Shaun Kilfoyle, President/CEO of W+D North America

Jacob Margulies, President of Continental En-velope, Chicago, (holding the microphone), experienced W+D Direct Mail Days as a “very valuable event with great networking.”

5InFocus

InFocus: W+D is engaged in all three major segments of the mail value stream. How is that received by customers?

Schipke: Most envelope converters

don’t do inserting, but clearly are in-

volved with mail service providers

and inserters who use their envelo-

pes. This, however, is changing and

the lines are getting blurred in the US.

/ Ease of use and design efficiency improvements to the new W+D 628

US envelope converters are deal-

ing with an ageing adjuster/opera-

tor base and a lack of qualified re-

placements, as in other markets. So

they are asking for simpler, more

automated and efficient solutions

to their manufacturing that will al-

low envelope converters to more

easily cross train adjustor/operator

staff between models. The W+D

628 presentation of the new simpler

and intuitive HMI interface with new

design offerings like automated fle-

xo wash-up (see p. 8), dryer chain

runout, care-free gummer moiste-

ning, and laser-guided paper align-

ment, clearly showed that W+D

engineering was listening to their

customers. As a result, the first

W+D 628RC web machine with

flexo as well as the first 628C blank-

fed litho convert only machine are all

coming to the US in 2019.

InFocus: Those in attendance were impressed by the LED-UV coated “Barbecue” envelopes that were produced live.

Schipke: Yes, the 4-color flexo prin-

ting with a 70 l/cm (175 l/inch) screen

on coated paper on the new W+D 628

met with enthusiasm with the US

participants. The print quality and gloss

coating of the optional W+D 201 in-

line printing unit were able to keep

pace with everything sheet-fed offset

can achieve in the US. In addition, the

envelopes can be produced inline

faster, with fewer production steps, and

thus efficiently and cost-effectively.

Now the traditional envelope conver-

ters very much have inkjet printing on

their mind, as it penetrates envelope

production to a greater extent. The

fact that W+D has taken leading posi-

tions in all segments was much talked

about and gives our entire customer

base confidence that we have know-

how on the full range of the mail value

stream.

The inspiring presentation by Scott Evans, President/CEO of Kenmore Envelopes in the US, has now been published on YouTube and has been viewed almost 500 times by the envelope community . A short version is also available (see QR-Code or “Program” at www .direct-mail-days .com) .

Prof. Florian Süßl,Beuth University, Berlin

6 InFocus

Inserts what others can’t:the W+D BB700 S2 at BMS

The family-run company BMS Tech-nologies was founded in Bend, Ore-gon, in 1997. In the meantime, it has developed into a state-of-the-art service provider that combines tra-ditional mailing services with state-of-the-art technology.

BMS focuses on three areas: postal

voting documents, utility bills and,

increasingly, direct mailings. The dis-

patch of postal voting documents in

particular places high demands on

the performance of its employees and

machines due to the usually very tight

deadlines. “Our strict focus on custo-

mer service is the basis of our suc-

cess. With our experienced staff and

the most advanced technology, every

customer, large or small, receives the

same high level of service,” says Presi-

dent Nick Di Spaltro.

The company recently purchased two

W+D BB700 S2 multi-format envelo-

pe inserting systems to further accele-

rate its processing speeds and thus its

growth. With up to 16,000 envelopes

per hour of output across the entire

format range, this machine handles

all tasks with unsurpassed reliability

and performance – quickly, flexibly

and intelligently. It thus delivers the

highest net figures for complex, high-

quality direct mailings.

On-schedule dispatch of postal voting documents

Although none of its employees had

any experience using W+D systems,

the team was able to process com-

plex postal voting documents (with

up to five enclosures) at up to 15,000

pieces/hour in only a very short period

of time. “The fact that our employees

only rarely had to rely on W+D for

support speaks for the systems’ ease

of use and ability to handle different

and difficult to handle substrates,” Di

Spaltro explains. “And the few times

we needed W+D, the team supported

us very well.”

The W+D BB700 S2’s intelligent

error compensation and the Auto-

Mismatch and Sequence-Recovery,

which automatically detects and

corrects sequence errors when pro-

cessing multiple personalized pro-

ducts, have also proven their value: In

the last election, all documents were

not only sent within the specified

deadlines, but also without a single

error.

Mayer-Kuvert orders 10 W+D Halm i-Jet 2

At Direct Mail Days, Mayer-Kuvert Network (MKN) cele-brated the purchase of ten W+D Halm i-Jet 2 printing presses that were launched last year . With the purchase of the four-color inkjet overprinting machine for envelopes, MKN hopes to get off to a good start with digital printing technology for envelopes . In the meantime, almost all of the new W+D Halm i-Jet 2 presses have already been delivered and installed at MKN .

from left to right: Thomas Schwarz, MKN, Frank Eichhorn and Thorsten Jost, W+D

Sam and Nick Di Spaltro, BMS Technologies (from left)

7InFocus

PM Solutions closes the production loop with a W+D Halm i-Jet 2

the best possible way. “We are thus

now in a position to better meet our

customers’ growing demands,” Ron

Davidson notes.

W+D training and support leave no questions unanswered

PM Solutions has been working with

W+D since 2010 and already has two

W+D BB700 inserting machines with

closed loop integrated processing and

an upgrade to a new W+D BB700 S2.

This relationship was further enhan-

ced during on-site training on the

new Halm i-Jet 2.

W+D initially trained 2 operators

alongside their Production Manager,

with a further 2 operators due to be

trained in the fall. Only minimal sup-

port has been required from W+D

since this initial training was carried

out. “Our operators have thoroughly

enjoyed working with the machine

and it has performed very well in the

first few months of operation. It has

completed over 3 million cycles and

we are confident this will continue.

The support we have received from

W+D is excellent and there has been

constant communication between

our operators and the support staff in

Neuwied,” says Production Manager

Robert McKinnon.

Full process control

“We no longer have to rely on external

printing, but can now print and per-

sonalize envelopes in full color in one

step. This gives us control over the

entire process. And with speeds of up

to 32,000 envelopes per hour, we can

offer our customers faster processing

without compromising quality,” con-

cludes McKinnon.

Established in 1998 by Ron Davidson, the Scottish company PM Solutions has been an expert on direct mail, transactional mail, print and postage for over 20 years and currently pro-cesses 35 million items each year on behalf of their clients. Their ISO9001, ISO14001 and ISO27001 accredita-tions give their clients peace of mind that their data and mail are in safe hands.

In May 2019, the company invested in

a high-speed four-color W+D Halm

i-Jet 2 digital inkjet printing press in

order to close the production ‘loop’

and retain all elements of the mailed

pack under one roof. PM Solutions is

now in an even better position to con-

trol the throughput times of orders

and also has quality control in its own

hands. It was therefore only logical to

implement this capability internally in

left: Ron Davidson (Owner of PM Solutions), Richard Mann (W+D Service Technician for the UK and Ireland), Robert McKinnon (PM Production Manager) in front of the W+D Halm i-Jet 2

Philipp Oster, Bernd Lück, Thorsten Ahlert (from left)

8 InFocus

W+D has set up an additional ser-vice department to ensure that its long-lived machines continue to be future-proof and to be able to offer customers adequate replacement solutions for discontinued compon-ents in their W+D systems: Moderni-zation Program.

In this newly created team, alterna-tives for components and additional features are developed and imple-

mented centrally. The team is led by Philipp Oster and supported by Michael Smith in the US.We are looking forward to this chal-lenge and to receiving your inquiries: W+D Service Team or Michael Smith for the US.

More positive effects of an ink unit washing system:

/ Greater competitiveness, especially with shorter runs: the envelope

machine can be changed over while the printing units are being cleaned.

/ Up to 80% less water consumption and thus lower costs for disposal or

treatment as well as less environmental pollution.

/ Extends the service life of the anilox rollers through particularly gentle and

thorough cleaning, which also prevents “clogging” of the cells.

/ Reduced risk of injury to employees, as not only the anilox roller but also

the razor-sharp chamber doctor blades are cleaned automatically.

Your contact at W+D will be happy to answer any questions you might have.

Up to 80 % time and water savings when changing colors in flexo printing Do you still clean your flexo printing units manually when changing the color? Experience shows that this is very

time-consuming and adds up, the more printing units need to be cleaned. With only one color change per shift on

more than two ink units, over 200 hours of press downtime can occur over the course of the year! An automatic ink

unit cleaning system, on the other hand, drastically reduces these press downtimes. The simultaneous automatic

cleaning of several ink units saves up to 80 % of production time compared to manual cleaning.

*formerly Labelexpo and PRINT

We are W+D

Michael Smith

W+D trade fair dates PRINT19 October 3-5, 2019 Chicago, USA

MIAC October 9-11, 2019 Lucca, Italy

index March 31-April 3, 2020 Geneva, Switzerland

drupa June 16-26, 2020 Düsseldorf, Germany

Brand Print Americas September 15-17, 2020 Rosemont, IL/USA*

Imp

rin

t

Responsible: Frank Eichhorn, Managing DirectorEditors: Kerstin Zander (W+D), Katrin Striegel (IMC, Mainz)Layout, Printing: Typo-Schlick GmbHPhotos: Winkler+Dünnebier GmbH, youtube, drupa, index, M. Smith, BMS Technologies, PM Solutions, FIT International Inc.

Winkler+Dünnebier GmbH Sohler Weg 65 · 56564 Neuwied · Germanyt. +49 2631 840 · f. +49 2631 84577info@w-d.de · w-d.de

You can object to further promotional mailings from us at any time by writing to the above postal or e-mail address. The contactdetails of our data protection officer and further information on the topic of data protection at W+D can be found at w-d.de.

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