Russia’s Lux Upak benefits from Koenig & Bauer’s sheet offset technology

Sharp rise in print volumes

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At the press (left to right): Fjodor Smirnow, general director, Koenig & Bauer (RU); Alexander Leonov, general director, Lux Upak; Sven Strzelczyk, sales director, Koenig & Bauer; Maxim Kruglow, sales director, Koenig & Bauer

Lux Upak, a packaging printer with headquarters in the Russian city of Tver, is a relatively young company. It has been using a Rapida 105 in 3b format since 2014. The five-color press with inline coating facilities is being used for UV production. In 2017, the company moved to new premises, where a Rapida 105 PRO – this time with six printing units and inline coater – was installed last year.

With the commissioning of the press, the production volume handled by the company started growing steadily. 2019’s figure of 180 million packaging units had already increased to 300 million last year. Lux Upak primarily focuses on the production of folding cartons and other board packaging for the food and beverages industry and the pharmaceuticals and mechanical engineering sectors. The company today employs a workforce of 130 production and office staff.

Outstanding print quality

There is at least one unique feature that the new Rapida 105 PRO exhibits, making it unique on the Russian market: It is the first press in this series to be equipped with QualiTronic PDFCheck. In other words, the inline inking control system QualiTronic ColorControl has been supplemented with functionalities for sheet inspection and comparison of the printed sheets with a pre-press PDF – all of which is done using a single camera system.

Even before job production commences, QualiTronic PDFCheck can detect any potential errors and imperfections on the sheet. At the same time, it also ensures a high level of consistency over the entire length of a production run. If deviations are detected on the printed sheet, the operator is prompted to intervene.

The press was explicitly configured for packaging printing, with its foundations having been raised by 450 mm to accommodate higher piles. A long list of automation features guarantees production speeds of up to 17,000 sheets per hour on the Rapida 105 PRO, including FAPC automatic plate changers, multi-function CleanTronic washing systems for the blankets, impression cylinders, and ink rollers, and a lower non-stop roller rack in the delivery. VariDryBlue IR/hot-air dryers optimize energy consumption during the drying process.

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With production speeds up to 17,000 sheets per hour and comprehensive quality control features, the Rapida 105 PRO at Lux Upak sets new standards in packaging printing

Fully integrated production

Like the press hall, the areas used for post-press, packaging design, and dispatch at Lux Upak are all equipped with the latest technologies. The production facilities are constantly being adapted to cater to new trends in the packaging industry. One of the company’s guiding principles is to promise customers reliability, individual support, short production times, and end-to-end quality assurance at the highest level.

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QualiTronic PDFCheck informs the printers at the console when quality deviations occur, thereby enabling immediate intervention

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