Located between the river Rhine and the Black Forest, Nestler Wellpappe has built its reputation on high-quality packaging, short lead times and consistently reliable production standards. The new BGM installation supports this strategy by combining state-of-the-art printing technology from Göpfert with the proven folding expertise of Bahmüller. This is already the third BGM Bahmüller & Göpfert Inliner at this location.
At the heart of the system are the Göpfert printing units, designed for maximum precision and full automation of all axes. The latest concept featuring a carbon chambered doctor blade system in combination with ceramic anilox rollers ensures optimal ink transfer – even at highest machine speeds. This allows stable print quality across a wide range of applications while maintaining high productivity.
The machine concept is clearly focused on maximum availability. Automated job setup functions enable the system to adjust itself quickly and reliably to new orders, reducing manual intervention and minimising setup times. Smart options such as the Flap Cutter and the Serrapid quick-clamping system further reduce changeover time to just a few minutes, significantly increasing effective production time.
To ensure perfect print registration between the individual printing units, the system is equipped with Register Control. This assistant-based solution supports the operator during job setup and continuously monitors the register during production, ensuring consistent quality even during long runs.
Following Göpfert’s philosophy of “Think outside the box”, the machine offers advanced options such as extended slotting and extended die-cutting, giving Nestler greater flexibility in product design and enabling a broader portfolio for end customers – because not even the sky is the limit.
- Ready for MULTIBOX, the system can run up to three boxes glued out of one sheet to gain maximum performance with in the specified parameters;
- Short job-change and high efficient drives guarantee low carbon footprint by max availability of the system;
- As a new feature, the machine reports its production status and several data direct to the IT-infrastructure.
For maximum flexibility the folding system has been equipped with a Bahmüller servo-driven Taper TST. In combination with PUSH TOGETHER UNIT for performance increase for taping and stitching mode, the output can be boosted to a new level. With this device Nestler is able to provide not only glued boxes, but also taped and combined sealed products, to the wide range of customers.
Since the inauguration of the Bahmüller TST Taping unit in 2013, several customers rely on the high performing system to seal the cases in a proper, economical way.
- BGM midline series CL is also available with stitching system, with the right preparation even for retrofit;
- The well-proven SAT counter ejector enables max capabilities in MULTIBOX output;
- Interface to state-of-the-art strapping system grant proper data transfer and change overs by as little as possible human interaction.
The MuK-RO-HE robot palletiser completes the line in a congested area like in Lahr. Installing a machine line with a length of 36m (excluding auxiliaries) into an existing building is always a challenge.
From the initial project phase, the requirement was clear: a high-performance machine had to be integrated into a confined space without compromising productivity, accessibility or future operability.
During the planning phase, close coordination between Nestler and BGM allowed operational, spatial and technical aspects to be considered in detail. Practical experience from previous installations and a solid understanding of real production conditions helped to develop a machine layout that realistically reflects day-to-day operation.
The result is a compact installation that makes efficient use of the available space while still offering good accessibility for operators and maintenance staff and allowing the system to run at highest performance.
The successful realisation of this project once again demonstrates how complex constraints can be resolved through well-founded planning and cooperative project execution.
