PakMarkas implemented an impressive production modernization project in just a year
JSC “PakMarkas” completed the implementation of a large-scale production automation and digitization project, which cost more than half a million euros. The project was funded by the Norwegian financial mechanism 2014–2021 Programme. Norway Grants fund financed 45% of all project costs.
PakMarkas is one of the leaders in product labeling, production automation and robotization services in the Baltic States. The main directions of the company are label and packaging printing, automation of packaging and bottling lines, trade in gears and automation solutions.
PakMarkas has been operating for 30 years, its annual turnover is 30 mln. More than 200 employees work in the company.
The company has a reliable network of partners in Europe, branches in Latvia and Germany. PakMarkas exports a third of its production. The company stands out in the market by offering customers a complete solution from a single source – from design of production lines, its’ installation and service to printing of product labels.
“We aim to increase efficiency and reduce the volume of manual work. The main goal of the project was to modernize production by introducing automation (digitalization) technologies that would allow us to achieve higher work productivity, increase production volumes, fulfill more complex orders and ensure production quality. All this will help maintain and increase the competitiveness of the company in the market. In order to achieve these goals, we consulted with the project partner, the Norwegian company Oddvar Johnsen AS, who shared Scandinavian experience in increasing efficiency and implementing similar projects,” says Ieva Pociūnienė, PakMarkas Project Manager.
The value of the project “JSC “Pakmarkas” investments in production automation and digitization, increasing work productivity, LT07-1-EIM-K05-017” is EUR 537470.12. The Norway Grants fund allocated EUR 242,432.91 in funding (funds of the Norwegian financial mechanism; NOR budget funds of the Republic of Lithuania)
During the implementation of the project, the company purchased new production and software: a shrink sleeve forming device, a steam tunnel for testing shrink sleeves, an automatic table for cutting clichés, a warehouse management system with a set of mobile scanners, clichés and anilox washing devices, UPS device, the company has also updated its Navision system. Thanks to the purchased equipment, JSC PakMarkas will not only speed up its production processes, but also print significantly higher quality products.
New generation devices
One of the main purchases of the project is shrink sleeves forming device from the French manufacturer DCM Usimeca. The most advanced technologies that significantly improve productivity are integrated in this device.
“Previously, it was necessary to stop the equipment at least four times and change the roll of labels, which generated a considerable amount of waste and wasted time. The possibility of a technical defect increases significantly when stopping and restarting the equipment. This new generation label forming machine is fully automated – it allows you to change rolls without stopping the production process, thus eliminating the disturbances listed above. It is equipped with the latest Connectivision software, thanks to which it is possible to monitor the operation of the device, see the main parameters even remotely. These data are saved and serve for analysis, on the basis of which work productivity can be further improved”, explains Andrius Trifanovas, Director of JSC Nuera.
One of the essential links of the printing process is the production of printing forms, where both speed and precise quality play an important role. These parameters will be significantly improved by the automatic table for cutting press forms, so-called clichés. This automated device replaced the manual cutting of forms with a guillotine and now allow to obtain much higher quality clichés. For example, thanks to the device, the size of the place where clichés are joined has been reduced from 2-3 mm to 0.2 mm. The equipment can cut clichés of any shape with ideal quality, which is practically impossible to achieve manually. In addition, during the automated placement of clichés on the polymer sheet, there are no more gaps between them, which significantly reduces the amount of polymer scrap waste.
Instead of the initially planned box palletizing robot, during the project it was decided to purchase washing equipment. It is extremely important in the printing process because even small color residues can change the properties of the subsequent printed product.
The fully automated ultrasonic device with 6 sections of anilox press shafts reduced the washing time to 25 minutes – more than ten times. The other device – flexographic printing forms washing device – not only completely washes and dries clichés in a few minutes, but is also environmentally friendly – it has a closed water and detergent circulation system.
“The range of equipment we purchased within the framework of the project is really wide. Indeed, this project has helped to update our existing machine park and significantly expand the range and ensure higher product quality. Our production capacity is increasing, we can fulfill more complex orders: print labels with a wider color range and more sophisticated configurations. In addition, modern equipment reduces the need for raw materials and their waste, so the activity of PakMarkas will be not only more efficient, but also more sustainable”, emphasizes I. Pociūnienė.
Extraordinary project
According to I. Pociūnienė, the implementation of the project was difficult, but thanks to teamwork, all requirements were successfully met on time. The project is supposed to end on April 30th. The equipment is purchased and in PakMarkas premises.
“The project was characterized by specific requirements, strict procurement criteria – the procurement process was regulated by the Innovation Agency, it has a very short deadline – the implementation period was less than a year. It’s no secret that the production of the equipment itself often takes more than half a year, not to mention the fact that it must first be designed and the manufactured equipment must be delivered, installed, employees must be trained. It is a process that takes time, work and knowledge. We are very happy that we managed to successfully implement this project on time”, says PakMarkas Project Manager.