Bryan Backhouse, CTP Packaging’s general manager, is confident that the purchase of two new folder-gluers – a Bobst Expertfold 80 A1 and Visionfold 80 A2 – will help to continue to stabilise the company’s business and product quality, as well as assisting in attracting new clients and improving customer service. ‘With such an investment, we’re building customer confidence as well as a strong sense of ownership within the company,’ Bryan stresses. ‘We’re in a very competitive industry; our older technology was becoming too slow and cumbersome, reducing capacity and machine downtime was getting our operators stuck in a rut.’
Previously operating seven folder-gluers, CTP approached Beswick Machinery to conduct a detailed analysis of its jobs, including volumes, set-up times, running speeds, etc. With the help of Bobst, Switzerland, Beswick presented a replacement proposal and discussed various machine options with CTP’s management.
After careful analysis, the company decided to remove four of its existing machines and replace them with two specialised, modern units.
The first, a Bobst Expertfold 80 A1 high-speed folder-gluer for straight-line cartons, is fitted with a Baumer HHS code reader for checking conformance as well as print variation on each carton as it passes through the pre-breaker. It also sports the latest Bauer HHS glue line detector, which checks quantity and position of glue on each carton as it passes through the glue unit. Both quality control devices are included with the exclusive Bobst Flipper Ejector that ejects non-conforming cartons at full machine speed without operator intervention and regardless of carton style or shape.
Also installed is the latest Bobst Handypack GT semi-automatic carton packing machine to go inline with the Expertfold to maximise the machine’s
The second investment is a Bobst Visionfold 80 A2 Universal folder-gluer for straight-line, crash-lock and special cartons (eg fast food chip scoops). This machine, which can run at 400m/min, is equipped with a crash-lock bottom module that allows CTP to change over from one carton type to another in a very short time.
In addition, a host of special options make the machine flexible enough to handle most carton sizes, styles and types required by today’s market.
‘Most options are interchangeable between the Expertfold and Visionfold, giving CTP the flexibility to use either machine as production requires,’ explains Bruce Beswick, MD of Beswick Machinery.
‘Despite having seven folder-gluers, bottlenecks sometimes occurred in CTP’s operation,’ he continues. ‘Die-cutting had to be carefully managed to avoid flooding the factory with die-cut sheets awaiting gluing. Now, thanks to the new folder-gluers, CTP has created a pull-through effect and has actually increased shifts on the Bobst Autoplatens to feed the new gluers and keep them busy.’
The new computer-operated folder-gluers run an average of 70 000 sheets/hour, which has doubled CTP’s output. Both machines can handle from 76mm up to 800mm open blank sheets and can fold and glue materials from 150g/m2 to 600g/m2, and corrugated up to E flute. Both the Expertfold and the Visionfold are modular in design, facilitating future upgrades if required.
Apart from improved output, CTP also notes a reduction in production waste, and, importantly, consistently higher quality products delivered to customers.
Installation and training was carried out by Beswick Machinery; and CTP’s operators also received advanced operator training by a Bobst specialist instructor. The company now has its first female ‘apprentice’ operator and competition is now ‘hotting up’ among the tight-knit team!
‘We’ve had great support from the Beswick Machinery team,’ comments Bryan Backhouse. ‘They understand our business processes and have integrity and a good reputation.’
Focused sales strategy and support
According to Bryan, CTP now offers customers extended development options. We’re pleased to have secured a significant tender with an international pharmaceutical company to produce its toothpaste cartons,’ he continues. ’Having said that, however, we don’t want to lose focus on smaller customers. If we can run high-volume orders through the two new folder-gluers, it frees up our remaining equipment to carry value-added work. We’re definitely pushing for sales and creativity in design, while continually striving to improve business relationships by being more professional, personal and in touch with customer trends and needs. CTP Packaging has a strong Gauteng-based sales team all committed and focused on building business, especially in the pharmaceutical, personal care, home care and cosmetics industries.
‘Many of our smaller customers have huge growth potential, and we want to support them with good communication, quality products and great service,’ reiterates Bryan. ‘If we want to be a leading packaging supplier we need to be the best and be ever mindful of the manner in which we present ourselves.’
In Bryan’s view, the new-look CTP flexibles in Cape Town and its significant investments (PPM Jun10, p45), have resulted in an enhanced image for the entire CTP Packaging group.
With the new Bobst folder-gluer technology significantly increasing efficiencies at CTP Packaging, and group entities now working closely together, Bryan believes the company has the full potential to become a leader in the ultra-sophisticated packaging sector and attract the cream of the blue-chip FMCG manufacturers to its customer list.
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PHOTOGRAPHY: Clive Glover
Caption: CTP Packaging is pushing for creativity in design and can provide a variety of packaging solutions for all customers – big and small.
Caption: Bryan Backhouse, general manager of CTP Packaging, shows Susi Moore the latest Bobst Visionfold 80 A2 Universal folder- gluer for straight-line, crash-lock and special cartons.
Caption: The Bobst Expertfold 80 A1 high-speed folder-gluer for straight-line cartons, is fitted with a Baumer HHS code reader for checking conformance as well as print variation on each carton as it passes through the pre-breaker.
Caption: With the new investment in technology, CTP is building customer confidence as well as a strong sense of job ownership among staff.