DE202018006058U1 - Production plant for the production of packaging material - Google Patents

Abstract

Manufacturing plant for the production of packaging material for further processing into blanks and / or coats as a starting material of cardboard-based packaging solutions, which is controlled such that at least one manufacturing process step for coating and / or printing partial weakening of packaging material and / or introduction of score lines and at least one production process step DB = EPODOC & ... PN = EP0494201 for the separation of roll web material into sheets or blanks, characterized in that a device for introducing at least one hole and / or a register control is arranged in a rewinder, wherein a control is designed such that the at least one production process step brings partial weakening of the packaging material in one Production stage takes place in which the packaging material is in sheet format.

Description

The invention relates to a production plant for producing packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions comprising at least one production process step for coating and / or printing partial weakening of packaging material and / or introducing score lines and at least one production process step for singling from roll web material to sheets or blanks,

In order to pack, portion, store, and the like various goods, products, foods, and other items requiring protection, a variety of packaging solutions varying in their characteristics, configurations, and techniques are employed.

In the packaging and / or portioning of foods and in particular pourable or flowable foodstuffs such as juices, teas, milk, soups, sauces, powders, granules, glass containers, plastic bottles, tubular bags, blister solutions and cardboard packaging are provided as packaging solutions.

Cardboard-based packaging solutions for flowable or pourable products basically have the task of reliably picking up, storing and releasing the product to be packaged, at least temporarily. If the pourable or pourable products to be packaged are foodstuffs in the broader sense, further requirements can be added to the packaging solution. These include, in particular, protective functions that at least temporarily store the food in such a way that the food occupies or maintains the properties and conditions required for consumption.

An important protective function in this context is the reliable removal of mostly external influences on the packaged food. Very important for the durability, that is, the maintenance of food-biological properties at the time of packaging is the protection against harmful microorganisms such as germs, spores, unicellulars and so on. When germs come into contact with the food in question, biological processes are triggered which lead to spoilage of the food and thus to inedibility.

Another important protective function with regard to exposure to light, and in particular also its formation in various electromagnetic wave spectra, may be required depending on the food to be packaged. Light effects, for example, can lead to the destruction of infrared or ultraviolet light-sensitive vitamins and other constituents, so that the quality and nutritive content of foods are reduced or worsened. Light effects can also cause unsightly and unappetizing discoloration.

If cartonage-based packaging solutions are used for flowable or free-flowing products and in particular foodstuffs, measures must be taken to implement the necessary protective functions.

Cardboard as the primary material for cartonage-based packaging solutions is a basic material made of pulp, waste paper and / or wood pulp of various types of wood, which does not support, not readily or inadequately, the aforementioned protective functions.

In order to implement at least one of the protective functions in cartonage-based packaging solutions and / or to produce the characteristic of hermetic tightness which is important for liquid or flowable products or foods, multilayer so-called packaging materials for such packaging solutions are created. In the case of these packaging materials, the cardboard serves as a primary material practically as a carrier and base material for realizing the mechanically required properties and / or the structural integrity. The cardboard is supplemented by at least one coating material applied on one or both sides.

Coating materials for realizing, for example, a light barrier to prevent or reduce exposure to light may be aluminum. Aluminum in various forms, for example as a web or sheet, as vapor-deposited particles or dissolved in a suspension can prevent the action of light when the layer thickness is sufficient.

Coating materials for the realization of, for example, a hermetic packaging material impermeability can be formed from various plastics such as polyethylene (PE), ethylene-vinyl alcohol copolymer (EVOH) or polypropylene (PP) and have barrier and / or adhesion promoter properties to varying degrees. Additively or alternatively, plastic-based coating materials can impart further functional properties to the carton-based packaging solution or to the packaging materials, such as good printability, surface properties, surface finishes, and the like.

Among other things, the mechanical properties of paperboard materials depend on the base material, the type of wood used, the fiber orientation, the respective production steps, the added additives, the material density or its grammage and the material thickness and can also be local due to fiber types, density and their orientation Material vary with the result that there is an at least partially and directionally anisotropic base material.

In addition to the aforementioned tasks, characteristics and requirements for packaging solutions for various goods, products, food and other items requiring protection, it may be necessary to achieve the opening of the packaging solution and / or the resealing of the packaging in the case of only partial removal of products. For this purpose, various variants are used which correspond to the basic idea of influencing or modifying the mechanical properties and / or the structural integrity of the strength-determining base material cardboard in a targeted and partially limited manner in a manner suitable for the opening and possibly the (re-) closing.

Often, the opening or closure assisting modification is a partial weakening of the strength properties and / or removal of a patch of the basestock.

A first variant may be, for example, to remove a surface piece, usually in the form of a circular hole, before coating the base box therefrom. Subsequently, the required coating materials are applied over the whole area, that is to say above the cardboard and the removed surface area. In this way, the packaging material is partially modified in an opening and / or closing-supporting manner. This modification is particularly advantageous in the use of opening aids, closures and in particular screw caps or drinking straws, which interact with the partial modification.

Another variant supports the opening of the packaging solution by the partial weakening of the packaging material or of the at least partially coated base cardboard to a packaging material. For this purpose, a perforation of different geometrical design is introduced into at least two layers of the packaging material or of the packaging material. Preferably, the perforation is provided in the base board or in the base board and at least one coating material. In order to maintain the barrier properties with respect to exposure to light, it may be advantageous not to perforate the aluminum coating.

The production of packaging material takes place in a variety of manufacturing steps, starting from a base box, which is usually available by the meter on a roll. The dimensions of such cardboard rolls can be more than 1000 mm in width and several thousand meters in length, so that a variety of blanks in the longitudinal and transverse directions of the meter goods can be applied.

An arc or packaging material sheet is used when a partially or completely constructed packaging material with coatings of the piece goods is separated in such a way that several blanks of the preferably rectangular sheet are included. From a blank one speaks at a isolated packaging material section for subsequent packaging, which is further processed by a longitudinal connection to a shell and ultimately further processed by each frontal closure to a (closed) packaging.

In order to realize packaging weakenings such as holes, cuts or perforations with different geometrical configurations (for example so-called cuts, webs or half-cut), different production methods and tools are used, for example laser cutting or mechanically based perforation insertion by rotationally moving stamped sheets or segments or by linear motion kinematics, for example on one flatbed die cutter.

Packing weakenings at various stages of packaging material production and / or before filling a packaging solution with a product to be protected can be introduced. For this purpose, slitters, coating equipment, printing machines, stamping machines, longitudinal seaming machines, rewinders, sheeters (that is to say roller sheet-cutting machines) and / or filling machines can be equipped with correspondingly suitable devices.

• - Öffnungshilfen mit Schneidelementen basieren auf Vielzahngeometrien,
• - Öffnungshilfen mit einer oder zwei Zähnen aufweisend unterschiedliche Bewegungskinematiken in einer oder mehrerer Raumrichtungen,
• - Öffnungshilfen mit Schneiden geeignet auch für Karton oder nur für Beschichtungsmaterialien,
• - Öffnungshilfen in Form von Grifflaschen zur manuellen Entfernung eines Flächenteilstückes,
• - Öffnungshilfen basierend auf Drückfunktionen mit Bewegungskinematiken in vorwiegend einer Raumrichtung.

Packaging material weakenings and / or overcoated patches of the aforementioned type can interact functionally with different opening aids:

• - Opening aids with cutting elements are based on multi-tooth geometries,
• Opening aids with one or two teeth having different movement kinematics in one or more spatial directions,
• - Opening aids with cutting suitable also for cardboard or only for coating materials,
• - Opening aids in the form of grip tabs for the manual removal of a surface section,
• - Opening aids based on pressing functions with motion kinematics in predominantly one spatial direction.

Packaging solutions, packaging materials and packaging material can have considerable problems and / or disadvantages, in particular in connection with opening aids or with opening or closing-supporting modifications of the base board by partial weakening of the strength properties and / or removal of a partial surface element.

Due to the locally reduced strength properties, the sensitivity of the packaging material in its web-shaped or arcuate shape is considerably increased, together with the risk of unintentional damage, for example during further production, handling or transport.

In many cases, the opening or closing-supporting modifications of the base box and the preparatory or subsequent production steps are expensive, complicated and / or complicated. Also, special machine designs of the manufacturing equipment may be required.

In the production engineering realization of the opening or closing supporting modifications by laser cutting, quality deficits can result from exposure of the laser beam during the cut (discontinuous laser beam) or as a result of deviating, that is, in particular time-delayed start and stop effects.

Another problem with the partial weakening of the strength properties and / or removal of a partial surface element of the base box and / or the packaging material or the packaging material by or by means of laser cuts may result from the physical effect of this manufacturing form. Laser or more generally bundled and usually highly concentrated light results in a thermal cutting process. Due to the partial action of very high temperatures, the base board and / or other packaging material components may suffer local delaminations, burns, smoldering effects and / or other charring. Effects of this kind can have a negative effect on the food to be packaged.

In order to counteract the reduced strength properties by the weakenings introduced in an early phase of the packaging material production process, the respectively subsequent production steps and handling / transport processes are problematic in various ways.

A first possible production step sequence may consist in that weakenings in the form of holes are first introduced into the base or raw cardboard present in web form on rolls.

The sheet-like paperboard starting material is fed from the raw paperboard roll in a preferably continuous unrolling process to a coating machine with a rotary punch and one or more holes are punched next to each other and / or in the roll length into each subsequent pack blank. The roll width usually corresponds to a plurality of package heights and the roll length of the package width.

To realize the shape and position tolerance specifications significantly precise tools are required. For example, the hole punching tool can be adjusted in width, that is the subsequent packing height and has to ensure a defined and precise hole punching distance of the holes to each other in the cardboard longitudinal direction a fixed diameter. As a result, a different tool is used for each package width.

A very significant problem due to the loss of strength associated with the punching holes and the associated locally different expansion behavior at the beginning of the production process results from the webbing of the raw board by the meter in and between the individual subsequent production steps or stations. So that the hole spacings in the length of the web position and position exactly match the blanks to be separated later, the board web is pulled in the longitudinal direction, that is, subjected to longitudinal stresses and passed through the coating system. This is accomplished, for example, by driving transporting roller pairs and / or rotary punching tools with slightly differing rotational speeds, so that the respective rotational speeds are asynchronous or different.

The introduction of holes into the green cardboard web realized after a hole punching in the first station of a coating installation can be supplemented by subsequent coating steps. This means that the perforated cardboard roll is coated with one or more layers and wound with preferably also a high tensile stress into a roll with a predetermined winding characteristic. This winding orientation, that is the respective position of the coatings on outer or inner diameter of the roll to be wound can be done depending on the coating material. Usually one differentiates with regard to this criterion between plastic coatings such as polyethylene (PE) or aluminum.

After the coating system is usually a printing of the perforated and coated cardboard roll. For this purpose, the roll is mounted in the unwinding device of the printing press usually provided for this purpose and - to support a continuous production process - train impact to train impact or overlapping attached to the previous tail edge.

The printing machine is equipped to detect the hole positions in the web with measuring devices that allow, for example optically, to detect the positional positions of the holes within a web or on the impact-adjacent web interfaces and positions, controls or in turn adjusts the hole pattern position relative to by varying transport speeds the printing cylinders, so that the printed image is applied in the correct position to the hole pattern.

Again, the varying transport speeds result in high Bahnlängszugspannungen with the result that the sensitive, membranous thin over-coated holes are often at least partially subjected to changing and often highly dynamic tensile stresses.

A further mechanical stress results in the weakened by the holes web areas in that are induced by the required during the rail transport deflections by so-called deflecting transverse and thus shear stresses in the cardboard material.

Adhesive inaccuracies in the roll change can lead to strong tension fluctuations at the beginning of the roll at the butt joints. The same applies to the changing winding characteristic with decreasing roll diameter during the unwinding of cardboard web material from the roll. Often this is associated with production errors, which results in rejects at the roll start and end.

In the method of partial packaging weakenings with perforation eliminates the hole detection. Due to the necessary winding characteristics in the reeling and the rising trains between the individual printing units, a high web tension is still necessary to support the position tolerance accuracies.

• - Perforation mit einem Perforationswerkzeug nach dem letzten Druckwerk;
• - Perforieren mit einem dem rotativen Stanzen nachgelagerten Fertigungsschritt;
• - Perorationseinbringung vor der Rillung und Längsnahtsiegelung.

Unlike the hole punching variants are available for introducing perforation:

• - Perforation with a perforation tool after the last printing unit;
• Perforating with a production step downstream of the rotary punching;
• - Peroration introduction before grooving and longitudinal sealing.

Following an optional perforation, the implementation of longitudinal score lines, cross and diagonal score lines, longitudinal cuts and cross sections is frequently performed. These production steps are carried out in particular at least partially in a punch. For this purpose, rolled-up web goods with the processing state then present after the coating installation are hooked into a unwinding device and fed to the web of the punch. As before, in front of the printing press, in order to support a clocked or continuous production process, the roll ends are also attached or glued to the web at the web end or overlapping at the previous web end edge. This can be supported by a web memory such that in a continuous manufacturing process with up to 500 meters web speed per minute roll change is done on the fly.

The attachment shock to impact is required in particular before the punch, so that the punching tools are not damaged by otherwise present Bahndopplagen.

Also, the punch is equipped to detect the hole positions and / or control marks in the printed image in the web with measuring devices that allow, for example optical way to detect the positional positions of the holes and / or control marks within a train or on the impact-adjacent rail interfaces and positioned controls and or in turn regulates the hole pattern position relative to the punching tools by varying transport speeds, so that the score lines and cuts are introduced in the correct position.

The implementation of the longitudinal creasing lines, transverse and diagonal creasing lines, longitudinal cuts and cross sections is carried out by combined or individual rotary punching tools. The various score lines, perforations and cuts have different immersion depths in the coated material. As a result, combined tools are difficult to set and very expensive. Also, a new tool is needed for each packing geometry. As a result of this manufacturing step, the blanks isolated from the web are present, which are scaled, that is pushed together and stacked.

In order to ensure in this process stage that the shape and position tolerances of the introduced holes or over-coated holes or hole spacings as well as the printed images in the length of the web position and position exactly match the creasing and cutting lines and thus the blanks to be separated later, the board web high train in the longitudinal direction, that is subjected to longitudinal stresses and passed through the punching system. Again, this is accomplished, for example, by driving pull-roller pairs and / or rotary punching tools with slightly different rotational speeds, such that the respective rotational speeds are asynchronous or different.

In order to ensure the vertical longitudinal guidance and to avoid lateral drifting of the web web edge monitoring and control systems are used, which counteract a trajectory by Transportwalzenansteuerungen. These longitudinal guidance measures can lead to increased web tension and / or shear forces.

A combination of the manufacturing process steps of printing and punching in a process station is possible by means of suitable in-line pressure punching devices. Instead of punching out holes, it is also possible, for example by means of laser devices or rotary perforation tools, to introduce local weakening of the packaging material.

For a package type, costs of several hundred thousand euros may be required for a tool set to realize hole, pressure and perforation.

After the initially and as described above perforated and / or perforated as well as printed, coated and cut to pieces packaging fabric can be further processed into a finished packaging container solution takes place the often required intermediate storage of the usually stacked blanks on pallets.

In a longitudinal seam sealing machine, the arcuate blanks are further processed into a jacket. For this purpose, blanks are passed through after a previous separation of the stack individually through the longitudinal seam sealing machine and carried out before the actual longitudinal seam seal via linear shaping a Längsnahtbrechung. The coat produced in this way is then scalped, combined into stacks and packed in cartons, paper or other packaging material.

In the method of partial packaging weakening with perforation, the weakening in the shingled sheath can be made by means of a laser.

This production process or the sequence of steps of the individual process steps is oriented to the process of first producing the rolled green cardboard web to a packaging material, then further processing into blanks and subsequently into coats. The sequence described can vary in its machining sequences, so that the machines required for the production are different in their arrangement, tool combination and / or their basic structure.

One possible variation is the roll-shell production process printing on cardboard with partial weakening of the packaging material and / or over-coated hole or perforation in the printing press. Here, the cardboard roll is printed and at the end of the printing machine the perforation or perforation and the creasing lines with optional embossing and register controls are tolerated position and position exactly to the printed image produced. The printed board web is coated in the next manufacturing step with one or more plastic and / or aluminum layers.

In addition to the very adverse longitudinal stress loads caused by the train during rail transport through the manufacturing plant and cross strains due to the necessary path deflections, there is the further disadvantage that then present in over-coated state crease lines have a significantly higher kink resistance and the buckling process requires higher forces. The risk of damage to overcoating material, especially aluminum, is increased. It also follows that a possible perforation of the inner and / or outer coatings made of plastics is sealed with the resulting consequence that the perforation has higher and usually undesirable opening resistance.

In the next production step, the printed and coated roll web product is cut with several sheet webs above the roller conveyor width in the slitter to several single rolls, each with a curved path.

By a different variation of the processing and production sequence, the roll-sheet-sheath production process pressure on a plastic coating with partial packaging material weakenings or hole can be realized.

After at least one coating step of the paperboard base roll, the Sheet webs cut by respective longitudinal sections of the coated web. Subsequently, the sheets are printed and separated into blanks by cross section. Holes can be implemented in parallel with the singulation. A downstream longitudinal seam processing and longitudinal seam sealing of the blanks results in coats.

If one modifies the production step sequence in the sense of a roll-roll production process pressure on cardboard with partial weakening of packaging material and / or hole insertion in the filling machine is again starting from the base cardboard present as web on rolls first printed or printed and grooved, then with at least one coating material and at least one-sided coated. The sheet webs are cut into sections by respective longitudinal cuts of the coated web and with a parallel or subsequent cross-section. Subsequent longitudinal seam processing and longitudinal seam sealing of the blanks results in sheaths. Holes and other partial packaging weakenings are realized as a jacket on the packaging solution. This step can also be done in the filling machine.

It is the object of the invention to further develop the production or production of cardboard-based packaging solutions as well as the production apparatuses and at least partially reduce the disadvantages existing in the known production methods and sequence steps.

The teaching of the invention recognizes that the requirements for shape and position tolerances, packaging material stress in production and parallelism of processing steps can be positively influenced by the appropriate change in the manufacturing process sequence, in particular with regard to the introduction of holes, perforations or other partial weakening of packaging material. Depending on the exemplary embodiment of the invention, further advantages with regard to economic efficiency, logistics, production devices and waste reduction can be added.

According to the invention, it is provided to carry out the production steps in the primary context with the introduction of holes, perforations or other partial weakening of the packaging material, in particular when the web material has been processed into sheets, blanks or sheaths. The invention recognizes, takes into account and utilizes the various properties of the starting material raw board and its changes during the manufacturing steps towards packaging material and in a special way the respective formats available web and rolls, sheets, blanks and coats. In addition to the changing mechanical properties during the production of packaging material, the invention also considers the positional and positional requirements that arise in each case and optimizes their dependence on tolerance specifications to be complied with.

A first possible embodiment of the invention may be formed by the roll-shell production process printing on cardboard roll with partial packaging weakenings in the form of over-coated hole or perforation of the cardboard roll in the printing press.

The first manufacturing station is formed by a printing machine. The cardboard roll is printed and at the end of the printing machine can optionally tolerances the hole and / or perforation and / or the score lines with register controls for printing by optionally provided punching tools are introduced.

The printed and optionally perforated, perforated and grooved board web is coated in the next manufacturing step with one or more coatings, preferably plastic such as polyethylene (PE) and / or aluminum.

Subsequently, the printed and coated and optionally perforated, perforated and grooved paperboard web is cut in a roll-type sheet-cutting machine so that sheets are present.

In the case of optional holes, perforations or other partial weakening of the packaging material, it is provided according to the invention that a register control controls the longitudinal and cross-sectional tools in order to maintain distance dimensions and tolerances relative to the cutting lines. For this purpose, position information can be optically, opto-electronically or manually recorded and used for register control. The regulation takes place via correction factors determined by target / actual comparison.

In the then present production process stage there are bends with optional holes and / or partial packaging weakenings.

The printed and optionally perforated, perforated and grooved sheets are fed in the next production step of a Hubstanzenstation and punched into blanks and - if not yet realized optional - introduced the creasing lines and perforations.

The optional creasing lines and blanking cuts must be introduced in the lifting punch with tolerances to the cutting lines and / or optional holes and / or partial weakening of the packaging material.

This can be done manually by the operator or by a camera system based on optical or optoelectronic operating principle, which determines the distance between the cutting lines and / or optional holes and / or partial packaging weakenings and / or to the score lines.

A modification of this first inventive embodiment of the invention may consist in that the present as a roll of raw cardboard first printed, coated and then as roll with perforation or the then over-coated hole in the lifting punch with a register control as a role and introduced.

A further modification of this first inventive embodiment of the invention may be that produced in the raw cardboard printed coated sheets or rolls without holes, perforation and / or other partial packaging weakenings in the lift punch with register control or sheet cutter with register control.

Another variation of this first aspect of the present invention may be to form sheets with holes in the blank board printed coated sheets or rolls without holes, perforation, and / or other partial weakening of the packaging in the register controlled sheet cutter. This means that the optional holes and / or partial packaging weakenings are introduced into the sheet first.

A further embodiment according to the invention can be that the mentioned variants of the first embodiment according to the invention are first printed in sheet form.

In the next production step of the first embodiment of the invention and its variants, the longitudinal seam is produced and the blank is formed into a jacket - the result is a jacket with optional over-coating hole or perforation and / or perforation or at least partial weakening of the packaging material as starting element for further processing in a filling machine ,

So far, the over-coated holes (ÜBL, ie holes which are overcoated after their introduction into the packaging material, for example, plastic and / or aluminum) and perforations and other partial weakening of packaging material only printed by roll processes, punched and closed by means of the known manufacturing processes or known production sequences Cut blanks.

The teaching of the invention supports a now possible sheet production for all packages with closures and in particular screw caps combined with ÜBL. The invention recognizes that in contrast to the processing of roll material, the sheet processing is suitable to counteract the disadvantages of the known manufacturing processes at least partially.

Primarily, this is caused by the action on the packaging material or precursor material in one plane (two spatial directions), which is present during sheet processing, while the material processing of the rolls is of course of a spatial nature (three spatial directions).

• • Keine Umlenkung der Bahnrollenware und/oder der Zuschnitte mit ÜBL mehr wie beim Rollenverfahren - die Umlenkung durch sogenannte Umlenkrollen ist für den Bahntransport erforderlich und verursacht im Bahnmaterial hohe Zugspannungen und/oder Quer- und damit Schubspannungen die im Bereich der lokal durch das Loch verursachte Schwächung in Beschädigungen münden kann. Wird das ÜBL oder eine andere partielle, lokale Packstoffschwächung in einen Fertigungsschritt nach den erforderlichen Umlenkungen eingebracht, welches erfindungsgemäß bei der Bogenbearbeitung vorliegt, entfällt diese Problematik;
• • Die Erfindung erkennt den parallelen Zusammenhang hinsichtlich der partiellen Packstoffschwächung in Form von Rilllinien unter Zugspannungen induziert durch den Bahnzug beim Längstransport der Rollenbahnware durch die Fertigungsanlage, welche insbesondere das Aluminiumbeschichtungsmaterial beschädigen kann;
• • Verbesserung der Rilllinienqualität hinsichtlich ihrer symmetrischen Ausbildung durch die Verwendung von Linearwerkzeugen bei der Bogenrillung anstelle der bei Bahnrollenrillung erforderlichen Rotationswerkzeuge;
• • Erhebliche Reduzierung des Aufwandes für die Handhabung im Herstellungsprozess dadurch, dass die sehr viel einfacher, kostengünstiger und zuverlässiger zu handhabenden Bögen in einer frühen Phase des Herstellungsprozesses vorliegen und die Bögen als solche erfindungsgemäß weiteren Prozessschritten zugeführt werden. Während Rollenware sehr aufwändige Flurförderzeuge und Greifvorrichtungen erforderlich machen können Bögen zum Beispiel auf Paletten gestapelt mit einfachen Flurförderzeugen wie beispielsweise Elektrostaplern mit mit einfachen Gabeln; Paletten diese Art sind stabelbar; die Transportvorrichtungen haben keinen direkten Kontakt zu den Bögen, was Beschädigungen oder Verschmutzungen reduzieren hilft;
• • Durch die erfindungsgemäße Vereinzelung von Zuschnitten aus den Bögen können sehr viel genauere Zuschnittabmessungen erzielt werden dadurch, dass die vorgesehenen Hubstanzenwerkzeuge im Vergleich zu rotativ arbeitenden Stanzeinrichtungen deutlich engere Maßtoleranzen zum einen und zum anderen eine sehr hohe Reproduziergenauigkeit der Zuschnitte relativ zueinander aufweisen - dadurch haben die Zuschnitte beim Hubstanzenverfahren immer gleichbleibende äußere Abmessungen und konstante Abstände der Rilllinien zu den Schnittkanten und zu den partiellen Schwächungen. Die Toleranzen bei rotativen Stanzverfahren liegen in einem schwankenden Bereich von 1 mm bis 0,3 mm während mit der erfindungsgemäßen Anwendung der Hubstanze konstante Toleranzbreiten 0,3 mm bis 0,1 mm unterstützt sind;
• • Ein weiterer Vorteil ergibt sich infolge der geänderten Bearbeitungsreihenfolge und der damit zusammenhängenden Werkzeugverwendung hinsichtlich Staubund Flusenentwicklung dadurch, dass sehr präzise geradlinige Schnitte an den Zuschnittkanten realisierbar sind. Beim Hubstanzenverfahren wird der Schnitt linear und rechtwinklig, das heißt unter 90 Grad zum Bogen erstellt. Beim rotativen Verfahren wird der Schnitt rotativ ca. 45 Grad zum Bogen erstellt. Infolge der von der Rechtwinkeligen abweichenden Schnittgeometrie des rotativ hergestellten Schnittes wird die Schnittfläche größer, die Kartonfasern werden durch den schrägen Schnitt herausgezogen und der Zuschnitt an der Schnittkante instabiler. Bei den nachfolgenden Fertigungsschritten entsteht dadurch mehr Staub. Bei einer Materialstärke von 0,7 mm ergibt sich eine Toleranzlänge bei 45 Grad von 0,7mm und bei 15 Grad von 0,2 mm. Um diese Längenvariationen schwangt der schräge Schnitt zu den 0 mm bei geraden Schnitt. Die mit der verringerten Schnittfläche erzielbare Staubreduktion in einer nachfolgenden Kantenbearbeitung beispielsweise in einem Schälwerk beträgt mindestens 30% und/oder die Flusenreduktion und insbesondere die PE-Flusenreduktion beträgt mindesten 50%;
• • Ein weiterer Vorteil der erfindungsgemäßen Lehre ist, das die im Bogenformat hergestellten Zuschnitte sich nicht so stark wölben und dadurch besser in der Falt-Siegelanlage verarbeitet werden können mit der Konsequenz länger gelagert werden zu können und die Packungsseitenflächen später eine geraderer Form haben;
• • Die Erfindung unterstützt weiterhin wirtschaftliche Gesichtspunkte durch die eröffnete Möglichkeit, für den Herstellungsprozess verstärkt einfachere Standardmaschinen einsetzen zu können anstelle der aufwändigen bahnverarbeitenden Maschinen. Durch die im Fertigungsprozess in einem frühen Prozessstadium vorliegenden Bögen ist die Nutzung von leicht modifizierten Standardmaschinen für den Bogendruck und die Bogenstanzung anstelle der rotativ arbeitenden Pedante vorgesehen. Sowohl der Prozessschritt Bedrucken als auch der des Stanzens kann ergänzt sein durch die Packstoffschwächungseinbringung für die Faltschachtelherstellung, welche durch den komplizierten Mehrschichtaufbau gekennzeichnet ist. Darüber hinaus ist die Verfügbarkeit von Standardmaschinen auch weltweit gegeben. Weiterhin wirken folgende Zusammenhänge kostenreduzierend:
  • o Die notwendigen Werkzeugkosten betragen für die Bogenfertigung = Perforation = 1T€ und Rill-Schnittlinien = 10T€ pro Packungsart gegenüber den Kosten beim Rotativverfahren von mehreren 100T€;
  • o Werkzeugwechsel Bogen = 10 Min. versus Rotativ = 2-4h;
  • o Werkzeugewicht Bogen = 5kg. versus Rotativ = bis und über 1000kg;
  • o Werkzeuglagerung im Regal versus Rotativ = Lagerhalle;
  • o Standardmaschinen unterstützen die Reduzierung von Investitionen in Spezialmaschinen und verringern den Platzbedarf für die Herstellungsmaschinen;
  • o Bedienungspersonal und Mitarbeiter benötigen weniger Kenntnisse und Ausbildung;
  • o Standardmaschinen unterstützen weiterhin die dezentrale Fertigung anstelle der bei Rotativverfahren meist erforderlichen Zentralisierung infolge des Spezialmaschinenbedarfs; Denkbar ist auch die Lohnfertigung - dadurch kann eine dezentrale kundennahe Mantelherstellung in vielen Fertigungswerke anstatt Zentralwerken erfolgen;
  • o Die Packstoffschwächung wird zentral in der Beschichtungsanlage eingebracht und in Bogenform dezentral weiterverarbeitet oder dezentral in Bogenform eingebracht;
  • o In wirtschaftlich vorteilhafter Weise unterstützt die dezentrale, das heißt lokale Fertigung vor Ort
    • ■ eine flexiblere und/oder kürze Lieferzeit (Druck nahe beim Kunden),
    • ■ die Reduzierung von Transportwegen,
    • ■ die Umsetzung eines wirtschaftlichen Mehrwegsystems;
• • Anlagentechnische Vorteile ergeben sich durch die mit Standardmaschinen meist kombinierbaren zusätzlichen Werkzeugstationen.

This results in at least one of the following advantages:

• • No deflection of the web roll goods and / or the blanks with ÜBL more like in the roll process - the deflection by so-called deflection rollers is required for the web transport and causes high tensile stresses and / or transverse and thus shear stresses in the web material locally in the area caused by the hole Weakening can lead to damage. If the ÜBL or another partial, local weakening of the packaging material is introduced into a production step after the required deflections, which according to the invention is present during sheet processing, this problem is eliminated;
• The invention recognizes the parallel relationship with regard to the partial weakening of the packaging material in the form of creasing lines under tensile stresses induced by the web tension during the longitudinal transport of the product through the production line, which can damage the aluminum coating material in particular;
• • improvement of the crease line quality in terms of their symmetrical design by the use of linear tools in the sheet grooving instead of the rotation tools required for web roll grooving;
• Significant reduction of the effort for handling in the manufacturing process in that the much easier, cheaper and more reliable to use sheets are present in an early stage of the manufacturing process and the sheets are fed as such according to the invention further process steps. While rolls may require very expensive trucks and grippers, sheets can be stacked on pallets, for example, with simple industrial trucks such as electric forklifts with simple forks; Pallets this style are bareable; the transporters have no direct contact with the sheets, which helps to reduce damage or soiling;
• By means of the singling of blanks according to the invention from the sheets, much more accurate blank dimensions can be achieved by virtue of the fact that the punching tools provided have significantly narrower dimensional tolerances compared with rotary punching apparatuses on the one hand and a very high reproducing accuracy of the blanks relative to one another Blanks in the Hubstanzenverfahren always consistent outer dimensions and constant distances of the score lines to the cutting edges and to the partial weakenings. The tolerances in rotary punching process are in a fluctuating range of 1 mm to 0.3 mm while with the application of the invention Hubstanze constant tolerance widths 0.3 mm to 0.1 mm are supported;
• • A further advantage results from the changed processing sequence and the associated use of tools with regard to dust and lint development in that very precise straight cuts can be made at the blank edges. When Hubstanzenverfahren the cut is linear and rectangular, that is created at 90 degrees to the arc. In the rotary process, the cut is made rotatively about 45 degrees to the arc. As a result of the divergent from the rectangular cutting geometry of the rotationally produced cut, the cut surface is larger, the cardboard fibers are pulled out by the oblique cut and the blank at the cutting edge unstable. In the subsequent manufacturing steps, this results in more dust. With a material thickness of 0.7 mm, a tolerance length of 45 degrees results from 0.7 mm and at 15 degrees by 0.2 mm. To this length variations, the oblique cut swings to the 0 mm straight cut. The achievable with the reduced cutting surface dust reduction in a subsequent edge processing, for example in a peeling plant is at least 30% and / or the lint reduction and in particular the PE lint reduction is at least 50%;
• Another advantage of the teaching according to the invention is that the blanks produced in the sheet format do not bulge so strongly and can therefore be better processed in the folding-sealing system with the consequence of being able to be stored longer and the packing side surfaces later have a straighter shape;
• • The invention further supports economic aspects by the possibility of using simpler standard machines for the production process instead of the complex web-processing machines. The bows present in the manufacturing process at an early stage of the process envisage the use of slightly modified standard machines for sheetfed printing and sheet punching instead of rotary working pedants. Both the printing and the stamping process step can be supplemented by the packaging material weakening introduction for the folding carton production, which is characterized by the complicated multi-layer structure. In addition, the availability of standard machines is also available worldwide. Furthermore, the following relationships have a cost-reducing effect:
  • o The necessary tool costs for sheet production = Perforation = 1T € and Rill cut lines = 10T € per pack type compared to the costs of the rotary process of several 100T €;
  • o tool change arc = 10 min. versus rotative = 2-4h;
  • o Tool weight bow = 5kg. versus Rotativ = up to and over 1000kg;
  • o Tool storage on the shelf versus Rotativ = Warehouse;
  • o Standard machines help reduce investment in specialized machines and reduce space requirements for the manufacturing machines;
  • o operators and staff require less knowledge and training;
  • o standard machines continue to support decentralized manufacturing instead of the centralization usually required by rotary processes due to the special machine requirements; Contract manufacturing is also conceivable - as a result of which decentralized customer-oriented shell production can take place in many production plants instead of central plants;
  • o The weakening of the packaging material is introduced centrally in the coating plant and further decentralized processed in sheet form or introduced decentrally in sheet form;
  • o In an economically advantageous way supports the decentralized, that is local production on site
    • ■ a more flexible and / or shorter delivery time (pressure close to the customer),
    • ■ the reduction of transport routes,
    • ■ the implementation of a reusable economic system;
• • Plant advantages result from the additional tool stations, which can usually be combined with standard machines.

In the drawing, several exemplary, not conclusive embodiments or some embodiments of the manufacturing method according to the invention with its process steps are shown schematically in a flow chart. 1 shows the process steps and optionally alternative and / or parallel manufacturing steps based on the consideration of the material flow through a manufacturing plant.

Claims (14)

Manufacturing plant for the production of packaging material for further processing into blanks and / or coats as a starting material of cardboard-based packaging solutions, which is controlled such that at least one manufacturing process step for coating and / or printing partial weakening and / or introduction of score lines and at least one manufacturing process step DB = EPODOC & ... PN = EP0494201 for the separation of roll web material into sheets or blanks, characterized in that a device for introducing at least one hole and / or a register control is arranged in a rewinder, wherein a control is designed such that the at least one production process step brings partial weakening of the packaging material in one Production stage takes place in which the packaging material is in sheet format. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 1 , characterized in that the device for introducing at least one hole and / or the register control is arranged in a slitter. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 1 , characterized in that the device for introducing at least one hole and / or the register control is arranged in a roll-sheet cutting machine. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 1 , characterized in that the register control and / or a sensor / camera system is arranged in a sheet-fed press. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 1 , characterized in that the register control and / or a sensor / camera system is arranged in a sheet punching machine. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 1 , characterized in that the register control and / or sensor / camera system for detecting hole / perforation in a roll-sheet cutting machine is arranged. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions according to one of the Claims 4 to 6 , characterized in that the sensor / camera system is suitable for detecting packaging weakenings in the form of perforations or holes. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 1 , characterized in that the perforation tool is arranged in a sheet-fed press. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 1 , characterized in that the perforation tool is arranged in a sheet punching machine. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 9 , characterized in that the perforation tool is a two-stroke perforation tool. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 9 , characterized in that the Perforation tool has additional support groove tools. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 1 , characterized in that the perforation tool and / or the register control is arranged in a rewinder. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 1 , characterized in that the perforation tool and / or the register control is arranged in a slitter. Production plant for the production of packaging material for further processing into blanks and / or coats as starting material for carton-based packaging solutions Claim 1 , characterized in that the device for introducing at least one perforation and / or the register control is arranged in a roll-sheet cutting machine.

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