Poland’s Top-Pol commissions Rapida RDC 106 rotary die-cutter

The rotary die-cutter for printing IML in an offset process

Marcel Topolski (left) has raised the bar for IML production in Poland with the Rapida RDC 106. Photo - Koenig & Bauer

The Polish printing company, Top-Pol has commissioned Rapida RDC 106 rotary die-cutter from German firm Koenig & Bauer to boost its operations. The machine was purchased as part of a project to allow the printing of innovative IML labels in an offset process, which received funding support from the EU. The rotary die-cutter aims to guarantee production stability and high cutting speeds, alongside significantly reduced makeready times.

Top-Pol is a family-run company that has been active in the printing market since 1989 and has become a specialist for the production of labels using non-absorbent substrates – primarily plastics – since the end of the 1990s.

Top-Pol’s co-proprietor Marcel Topolski, said, “We were one of the pioneers in the use of UV offset technologies for substrates like this. IML labels soon became our flagship product and currently account for 70 to 80% of our production volume. Another key area is the production of lids and covers made from PE, PS or PP for plastic packaging, for example for yoghurt pots.”

Top-Pol exports 30 to 40% of its production output. It prints labels, which are primarily used by customers in the food and construction industries. “The systematic development we are pursuing means we are constantly modernising our production machinery, also with regard to finishing processes,” Topolski said.

High production speeds, fast makeready

According to Koenig & Bauer, the maximum mechanical output of the Rapida RDC 106 totals 15,000 sheets per hour. The press enables the die-cutting of substrates in thicknesses from 0.03 to 0.6 mm and is equipped with numerous solutions introduced with the Rapida 106 sheetfed offset printing presses. These include, among others, DriveTronic technology with dedicated drives, the sidelay-free infeed DriveTronic SIS, and a camera system to monitor sheet travel at the feeder and delivery.

Enhanced production and productivity

Topolski added, “As we had already been successful using rotary label die-cutting in the past, the purchase was an ideal opportunity to continue to enhance our productivity and production. After all, our products are quite difficult to produce. The IML labels are made of plastic and also feature indentations to make it easier for the end customer to separate them later on. This makes it a perfect opportunity to broaden our knowledge, both for our own and for the manufacturer’s benefit.”

“Our customers in the food industry, along with our customers in other sectors, expect labels of the highest quality. Accordingly, the solutions we use must also represent the highest standards and the best possible performance that the global market has to offer. The latest investment in the Rapida RDC 106 will more than satisfy these expectations, which are becoming more and more demanding due to changes to the market and to consumer tastes. These aspects are all the more important in the current global situation, which has, of course, also impacted our order volume,” Topolski concludes.

Jan Korenc, managing director of Koenig & Bauer (CEE), added, “This is a first-class solution which requires up to 40% less makeready to complete an entire job. This is why we are confident that it will contribute to the continued growth of Top-Pol as one of the leading print companies in Poland, and play a role in the successful implementation of the new technology project for which the Rapida RDC 106 rotary die-cutter was purchased.”

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