InFocusApril 2019

w-d.de

// Creative collaboration pays off –

for both sides

// W+D Halm i-Jet already sold 35 times

// W+D and Mac Papers achieve

69% reduction in changeover

times by holding SMED workshop

// Premiere of new W+D technologies

at Direct Mail Days 2019

// W+D Inserting TIPs, part 2

// W+D Inserting division relocates

from Löhne to Bad Oeynhausen

// Hunkeler Innovationdays

a big success for W+D

// W+D student trainee awarded

VDMA Young Talent Prize

June 5-6, 2019 at W+D in Neuwied

2 InFocus

direct mailings as an integral part of their multi-channel marketing mix. They are also aimed at helping marketing agencies attract and retain customers through the cross-media use of traditional elements, dynamic color printing, mobile and other new technologies.

70% more direct mailingsThe “Tactile, Sensory and Interactive

Mailpiece Promotion” was launched

in February and lo and behold: So far,

there has been a 70 percent increase

in the volume of direct mailings in

the US compared to the previous

year! By comparison, 34 percent

more mailers participated in it and

took advantage of the discount. Not

only are we pleased with this success,

but also with the fact that the USPS

is advertising for the campaign with

a sample envelope from W+D in

shape-cut form.

Creative collaboration pays off – for both sides

Frank Eichhorn, President of W+D

Europe is still waiting for incentives

from national postal operators, but

developments in other countries,

such as the US, speak for themselves.

It looks as if initiatives to promote

personalized, creative direct mail

are slowly gaining ground. The

FEPE was also active in this sense in

February and sent out a mailing to all

Members of Parliament in advance

of the European elections to draw

their attention to this advertising

opportunity.

Last, but not least, our Direct Mail

Days are part of these initiatives, and

we would once again like to invite

you to our event in Neuwied this year.

This time it will be held from June

5-6, 2019. See page 5.

If you’d like to learn more about the

USPS’s mailing promotions:

https://mailomg.com/2019/02/28/update-

2019-usps-mailing-promotions-calendar/

Considering the declining figures in some areas of the European letter market, one could complain – or take countermeasures. That’s exactly what US Postal Service did and launched its “Mailing Promotions” in October 2018. These post-owned promotions are intended to encourage mailers to try out new things and continue to use

Creative cooperation pays off – for both sides . . . 2

W+D Halm i-Jet already sold 35 times . . . . . . . . . . 3

W+D and Mac Papers achieve 69% reduction in

changeover times by holding SMED workshop . . . 4

Premiere of new W+D technologies at

Direct Mail Days 2019 . . . . . . . . . . . . . . . . . . . . . . . . 5

W+D Inserting TIPs, part 2 . . . . . . . . . . . . . . . . . . . 6

W+D Inserting division relocates from Löhne

to Bad Oeynhausen . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Contents

Hunkeler Innovationdays a big success for W+D . . 6

3 days instead of 3 weeks: W+D replacement

modules convince ICT Group due to drastically

shortened changeover times . . . . . . . . . . . . . . . . . . 7

Industry 4.0 – W+D student trainee awarded

VDMA Young Talent Prize . . . . . . . . . . . . . . . . . . . . 7

I am W+D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

3InFocus

More cost-effective than offset printingThe W+D Halm i-Jet 2 serves the

market for small and medium-sized

orders from 1 to 30,000, in individual

cases also up to 70,000 envelopes.

The W+D Halm i-Jet 2 is the best

choice where traditional offset

presses cannot be used at all or only

marginally profitably, as make-ready

times and waste are eliminated almost

completely. It doesn’t matter whether

the prints are static or variable. The

W+D Halm i-Jet 2 also offers up to ten

times higher output and significantly

lower ink costs compared to smaller

desktop inkjet or desktop EP systems

(electrophotographs/laser printers).

Costs for wear parts such as print

heads, cleaning rollers, etc. also

speak for themselves and the Memjet

printing system used.

Talk to your W+D contact or come to

this year’s Direct Mail Days, where we

will demonstrate the W+D Halm i-Jet

2 live. See event program, p. 5.

W+D Halm i-Jet already sold 35 times

The world’s fastest digital inkjet printing machine for envelopes, the W+D Halm i-Jet, is being well received in the market: So far, 35 presses have been ordered, most of them in the US. The W+D Halm i-Jet 2 is also winning over European customers with its print quality, repeat accuracy and almost complete avoidance of start-up waste. W+D has really been able to fill the order book thanks to this machine in recent weeks.

Europe also discovering the benefits of inkjet digital printingAfter a prototype of the W+D Halm

i-Jet 2 was first presented at Direct

Mail Days 2018 and following further

tests, the machine, which is now ready

for series production, is also quite

popular among European envelope

manufacturers. The first machines

were already installed in March.

This speaks for the quality of the

inkjet machine, which is convincing

customers not only with its high-

quality logo printing, but also its large

format four color prints for use in

direct mailing.

High repeat accuracy, minimalwasteWhat has impressed customers the

most at various demonstrations has

been the high repeat accuracy both in

terms of register accuracy and color

reproduction. Lengthy adjustments

such as ink-water balance or ink zone

adjustment as in offset are no longer

necessary. In fact, any adjustments it

requires are already made after only a

few sample envelopes; after that, the

W+D Halm i-Jet 2 ensures consistent

quality in production printing. This

makes a significant contribution to

sustainability, as hundreds or even

thousands of envelopes that would

be needed for color settings in

traditional offset printing can now be

saved.

Kent Gundlach, President of

Victor Envelope, IL/USA, and

extremely satisfied users of the

W+D Halm i-Jet discuss their

experiences with this system

on our YouTube channel:

https://www.youtube.com/

watch?v=KE_aDO6ieV8&t=56s

Process analyses and 180 ideas on improvementsThe actual workshop took five

days. In an initial step, the current

changeover process was filmed, and

the resulting video was jointly analyzed

with regard to possible improvements.

Maintenance and upstream processes,

such as material provision, i.e. how to

ensure that raw material is delivered to

the machine at the right time and in

the right quantity, were also important.

The team collected and evaluated

more than 180 ideas on improvements.

In the days that followed, the goal

was to implement as many of the

improvement ideas as possible. “The

results were very impressive: Just

one day after the workshop, the

changeover time was reduced by up

to 69%,” says Tees.

Waste rate reduced by 34%Not only was the changeover time

considerably shortened, however,

Mac Papers, headquartered in Jacksonville, Florida, is a leading paper and printing, packaging and office supplies wholesaler with a history of using multiple W+D 627 envelope production systems. “We simply reached the point where we wanted to optimize our costs by reducing changeover times,” Bob Tees, Vice President and General Manager of Mac Papers, recalls.

Inspired by Formula 1W+D North America was able to

provide targeted assistance as it had

access to the Grow More program

of its sister company PCMC in the

US that contains various Kaizen*

workshop formats. It includes an

SMED workshop (Single Minute

Exchange of Die), a method used

for pit stops in Formula 1 racing, for

example. Here, too, the changeover

time is considerably reduced by

organizational as well as technical

measures involving the entire team.but also the production waste during

setup was reduced by 34% – a rather

significant cost factor. In addition,

the distances the machine operators

have to cover have also been reduced

by around 30%.

“The standardization of processes

we achieved not only simplifies

how we currently work, but will

also help us train new employees

in the future. Communication and

motivation within the team have also

been significantly improved, which

contributes to employee satisfaction

and increases productivity,” Tees

concludes.

Since SMED can be applied to all

machines, three more workshops are

already planned for W+D customers

in the USA.

4 InFocus

W+D and Mac Papers achieve up to 69% reduction in changeover times by holding SMED workshop

“The best takeaway for me, be-

yond the process improvements,

was to participate and witness

the change in enthusiasm and

teamwork that developed over the

course of this event. We plan to

continue with more Kaizen events

going forward.”

Bob Tees, Vice President/General Manager

* Kaizen = many small improvements result in a big change in total

5InFocus

June 5, 2019 12:00 a.m. Welcome Snack and Exhibition

1:00 p.m. Welcome

1:30 p.m. Direct mail in the marketing mix

Thomas Poremba, Managing Director of Impuls Advertising Agency,

Hanover, Germany

2:00 p.m. Coffee Break

2:30 p.m. Leading the way in creative high end direct mail

Scott Evans, President of Kenmore Envelope, USA

3:00 p.m. Advantages and economics of LED UV for high-speed, high-quality

envelope printing

Pat Keogh, Vice President of UV/IR, Baldwin Slough, UK

3:30 p.m. Machine Demos and Exhibition

6:00 p.m. Get Together over a Barbecue

June 6, 2019 8:30 a.m. Welcome Coffee and Exhibition

9:15 a.m. Color Management and Profiling – a must for high-quality digital

printing

Prof. Dipl. Ing. Florian Süßl, Beuth University, Germany

9:45 a.m. Approach and requirements for increasing the flexo quality level

Mike Theisen, Managing Director of Neuefeind GmbH, Germany

10:15 a.m. Coffee Break

10:45 a.m. Opportunities to increase efficiency in envelope production and printing

Richard Kluthe, Marketing Manager of W+D, Germany

11:15 a.m. Machine demos and Exhibition

1:15 p.m. Farewell Snack

2:00 p.m. Optional Factory Tour

Since it debuted at last year’s Direct

Mail Days, the W+D Halm i-Jet 2

ink jet digital printing machine has

been ordered by and shipped out to

customers across Europe. Due to

continued strong demand it will again

be on display at the event. We will also

celebrate a premiere at this year’s DMD

in Neuwied: W+D will be presenting

the new W+D 628 for the first time!

The W+D 628 is the further development

of the W+D 627, a system that has well

established itself over many years. It

also incorporates various features of the

popular W+D 410 Easy Enveloper and

technology enhancements designed

to reduce change-over times and

production waste on medium and long

run jobs. The W+D 201 flexo printing

press has also been further developed

to support new inline printing and

coating possibilities like LED UV.

Furthermore, the enhanced, more

productive W+D BB700 S2 envelope

inserting system which will feature a

larger, easier-to-use HMI and faster

input channel, will also be presented at

the event.

Be there when we demonstrate these

systems under production conditions

from June 5-6, 2019. Kindly register

at direct-mail-days@w-d.de or our

website direct-mail-days.com.

Premiere of new W+D technologies atDirect Mail Days 2019

Direct Mail Days program 2019

Thomas PorembaImpuls Ad Agency, Hannover

Pat KoeghBaldwin Slough, UK

Mike TheisenNeuefeind GmbH, Ochtendung

Scott EvansKenmore Envelopes, USA

Prof. Dipl. Ing. Florian SüßlBeuth University, Berlin

Richard KlutheW+D, Neuwied

Our business partners

June 5-6, 2019 at W+D in Neuwied

6 InFocus

W+D Inserting division relocates from Löhneto Bad Oeynhausen

W+D continues to invest in the future of envelopes and its Mail Solutions/Inserting division. The Inserting division has therefore relocated its activities from Löhne to the neigh-boring town of Bad Oeynhausen. Inserting systems and modules from W+D have been developed, built and delivered from the new site since the beginning of 2019.

In the new production hall, we were

able to optimize the arrangement of

the flow assembly of our high-quality

inserting systems and thus make the

assembly even more efficient and

faster. In the service and develop-

ment area, the distances have also

been shortened so that improved

internal and external communication

is guaranteed.

The individual contact data of our

employees has been retained, however

there is now only one main fax number.

The new address is:

Winkler+Dünnebier GmbH

Bad Oeynhausen, site

Valdorfer Straße 3

32545 Bad Oeynhausen, Germany

Phone: +49 5731 744 0

Fax: +49 5731 744 199

info.ins@w-d.de.

By permanently installing one or

more W+D ramps in the material

feed below the RF2 or HF2 feeder,

the desired product sequence of

your jobs can be directly controlled.

You save time-consuming feeder

conversions and your job changes

can be done much more easily and

efficiently.

For processing critical materials, we

have also developed a cost-effective

retrofit kit for your installed hybrid

feeder, the W+D HF2 Modification

Kit, which is available in two upgrade

versions.

If you have any questions, please

contact your W+D service contacts

in the area of inserting.

Every two years, Hunkeler Innovation-

days offer an excellent opportunity to

meet important industry participants

on just a few days, as was the case this

year. Mainly visitors from the German

speaking countries, but also many

customers from France, the UK, the US

and Eastern Europe and Asia gathered

for intensive discussions at the W+D

booth.

The pleasing result: The sale of 4

more W+D Halm i-Jet 2 was sealed by

handshake.

W+D Inserting TIPS, part 2

Hunkeler Innovationdaysa big success for W+D

7InFocus

Three days instead of three weeks:W+D replacement modules convince ICT Groupdue to drastically shortened changeover times

Massimo Nofori, Converting Division

Director of ICT Group.

Cost-effective new value repair for higher productivity “We have now ordered four re-

placement modules from W+D, two

folding cylinders and two crosscutting

modules as a preventive measure,”

continues Nofori. “This has many

advantages for us: W+D supplies us

with completely refurbished units, we

install them within one to two days and

can restart production immediately. We

used to be out of action for a month

or more when we sent in a module

for repair. Oftentimes the need to take

further action was determined there,

which resulted in additional costs and

time. Now, on the other hand, we

purchase the modules at a fixed price,

integrate the replacement into our

usual maintenance intervals and lose

no more time.”

Demand at W+D increases continuously W+D is currently experiencing an ever-

increasing demand for the offer as

other customers discover this service

solution for themselves. W+D not only

cleans, checks, repairs or replaces, if

necessary, important elements such

as bearings, sealing surfaces of the

vacuum control valves, etc., but also

makes the correct pre-settings. As part

of this repair that restores value, the

customer receives the usual warranty

on these components.

Please contact your W+D represen-

tative for further information.

Founded in Italy in 1976, Industrie Cartarie Tronchetti SpA (ICT) is now one of the largest tissue manufacturers in Europe with close to 1,500 employees and 610,000 tons of processed paper per year. For over 20 years, the ICT Group, which operates plants in Italy, France, Spain and Poland, has had a good working relationship with W+D and today produces handkerchiefs exclusively with the high-speed systems from the W+D 624 series or W+D FLOWTOS.

Clever solution from W+D rapidly reduces downtimesWhen W+D approached ICT with

the proposal to order replacement

modules for folding cylinders and

cross-cutting modules for its W+D 624

machines, any skepticism was quickly

dispelled after the first installation:

instead of having to accept three weeks

of unforeseen machine downtime at

unwelcome times, now only about

three days of changeover time need

to be planned for both modules –

an enormous time saving. “For us,

these modules offer the possibility

of minimizing the downtimes of

our systems and thus enormously

increasing their productivity,” says

* German Machinery and Plant Engineering Association

Industry 4.0 – W+D student trainee wins VDMA Young Talent Award

Tobias Sohny, a graduate in industrial engineering and technology at Koblenz University of Applied Sciences, was awarded 1st prize by the VDMA* for the best master’s thesis in this field. As part of his master thesis for the chair of Prof. Dr. Ing. Helmut Bollenbacher in Koblenz, he designed a machine data acquisition interface (MDE) at W+D that provides the user with machine data in real time. With the help of the new interface, meaningful production figures such as the effectiveness of the entire system (GAE/OEE) can be generated for both machines that have already been put to use and new machines.

from left to right: Frank Jungbluth (W+D), Tobias Sohny, Prof. Helmut Bollenbacher, Philipp Oster (W+D)

Massimo Nofori, Converting Division Director of ICT Group

Kodak‘s AED takes edge control to a new micro level

Advanced KODAK DIGICAP NX Patterning

A range of patterns – expertly engineered to optimize ink transfer for the widest range of print conditions.

With the right combination of anilox roller and surface microstructure of the flexographic printing plate, printing ink

can be applied more evenly and with virtually no annoying pinholes. The edge sharpness of the printing result is also

significantly higher due to more defined edges around all of the printing elements, and there are fewer pinch marks.

The use of appropriately selected microstructure patterns results in higher densities for larger areas and better color

compared to plates without surface structures. The Advanced-Edge-Definition (Outline) around all printing elements

helps prevents ink from squeezing out and ensures precise and clean printing results. More even ink application

becomes a quality advantage in production. Alternatively, a similarly high density value can be achieved with less

anilox roller volume and possibly a different structure. This leads to savings in coating or ink and thus to further

production advantages in drying and machine speeds.

In order to determine the ideal structure of the printing plate surface, a test should

be performed with two to three different anilox rollers and a test form. This allows

the best combination of anilox roller volume and structure to be determined.

The prints we produced at last year’s Direct Mail Days were produced using Kodak NX digicap flexographic printing plates and

SteppedHex anilox rollers from Zecher. Similar

products are also available from other plate and

anilox roller manufacturers.

8 InFocus

I am W+D

In October 2018, W+D was able to recruit Ralf Doherr as its new Product Manager Service & Solutions.

After many years in various areas of the envelope industry, he knows W+D from a customer perspective and has been responsible for our Dutch customers as Service Sales Manager since January 2017. He has now expanded his scope

of responsibilities to include product management and will develop fresh ideas in the area of service with his hands-on mentality.At W+D and in his new job, he is enthusiastic about the new challenges he faces almost every day and the fascinating combination of working with people, business and technology aspects.

Ralf Doherr is married and has a son who loves sports just as much as he does.

Optimized flexo printing due to the matching surface structure of the printing plate

PRACTICAL TIP

W+D trade fair dates Direct Mail Days June 5-6, 2019 W+D, Neuwied, Germany

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

Imp

rin

t

Responsible: Frank Eichhorn, Managing DirectorEditors: Kerstin Zander (W+D), Katrin Striegel (IMC, Mainz)Layout, Printing: Typo-Schlick GmbHPhotos: Winkler+Dünnebier GmbH, Kodak, VDMA, PCMC, F. Süßl, M. Theisen, P. Keogh, T. Poremba, B. Tees, M. Nofori, youtube

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.