The sample folding cartons created in the framework of the Real Life Sample project exceed all expectations. The visitors to the first Packaging Inspiration Forum and the participating companies are highly satisfied with the results of production in Weiden.

The aim of the project is to demonstrate the interplay of design, form and finishing on the basis of a realistic example, produced by means of highly flexible and economical inline production involving various printing and finishing technologies.

The samples were produced on a Gallus ICS 670 in Weiden.

Efficient inline production

The modular machine used for this purpose was equipped with 7 EVA (Easy Value Add) platforms including 5 flexo modules, a cold-foil module and a hot-foil stamping module, inline cutter, inline die-cutting and embossing station, inline waste stripping station, and delivery unit. Intended for use as food-safe secondary packagings for chocolate, two different designs with a high degree of finishing were each produced in two different finishing versions, as mixed forms on two different substrates. In each case, a holographic cold-foil, two different hot-foils, two pigment coatings, UV gloss and haptic soft dispersion coatings were applied in a single pass, with various blind embossing, die-cutting and creasing steps also being performed at the same time.

"Inline production gives you incredible dependability when it comes to technical realisation: the finished blank is ready after die-cutting and can be tested in accordance with the requirements – by the tape test, for example," says Dieter Widmann, Production Manager at Gallus. "In addition to which, the modular structure of the Gallus ICS 670 makes for a very safe investment, because the machine configuration can be adapted to suit the needs of the market and the user."

From the very beginning, the entire development process was characterised by close coordination with everyone involved in the value chain: designers, printers and folding-carton manufacturers, and suppliers. "We wanted to adopt an approach that was as realistic as possible, so as to create real added value for our customers," says Rainer Kuhn, Managing Director of the PrintCity Alliance. "Only if these different skills work together effectively can such good results be obtained."

Form, design and finishing

"The designs complement the very striking, curved shape of the carton," explains Alexander Dort, one of the creative minds behind the samples. "When selecting the finishings, we used this form to demonstrate just what really can be done inline."

"In addition to which, the form gives the carton great stability, which makes it possible to use lighter grammages – a contribution to profit and sustainability," says a happy Philipp Eissner from AR Carton, who developed the 3D design.

All the experience gained in the process, from the design stage to production, has again been summarised in a Tutorial, which is available as a PDF file in English and German (see download at the bottom of this page).

Connection of Competence: the combined expertise of many partners

Alongside the PrintCity members Eltosch (UV driers), Leonhard Kurz (hot and cold-foils), Merck (pigments / Iriodin®), MetsäBoard (board), Océ (digital printing), Sappi Fine Paper Europe (board) and WEILBURGER Graphics (coatings and flexo inks), numerous other partners are also contributing their products and expertise to the project:
AR Carton (3D design), Esko (3D design tools and visualisation), Folien Company (laminating films), Gallus (inline printing presses and finishing machines), Gietz (embossing machines), Hinderer+Mühlich (embossing dies), Marbach (cutting dies), Reproflex (flexo plates), Reproservice (prepress data preparation), Saueressig (gravure cylinders), Sun Chemical (gravure inks) and Zeller+Gmelin (cold-foil adhesives and food-safe UV flexo inks).