Heidelberg unveils Push-to-Stop, which it says will solve the widespread problem of skills shortages and inefficient processes
As Heidelberg Middle East reports a more-than 10% year-on-year growth, it is understandably enthused about its prospects, and in particular with the introduction of its new Push-to-Stop technology.
Packaging MEA caught up with three key Heidelberg figures at the SPPPP (Saudi Print, Pack, Polymers, Plastics) 2020 exhibition in Riyadh to find out more.
“Our Push-to-Stop concept is an amalgamation of software and hardware,” says Zeid Al Jehni, General Manager, Heidelberg ME. “The whole concept is driven by workflow automation across the entire process. “The workflow is intelligent enough to understand the steps needed to be taken. The machine will run itself unless you ‘push to stop’. That is the whole idea. The overall effect is higher utilisation of the equipment. You are getting more throughput, more printed sheets, which means more revenue per machine. Instead of having three machines, you can cut down to two, reducing investment, operations, and manpower.”
Upgrading to the Push-to-Stop system will, of course, require an initial outlay, and Mr. Al Jehni says some customers baulk at this. However, he reminds them that it will prove more cost-effective in the long run. “Many packaging printers are evaluating the initial capital investment in terms of cost in comparison to other models, and some of them start negotiating on the price before they understand the concept,” he says.
“But though the capital investment is higher, the cost per sheet is less thana conventional machine, and operating it is more economical. “For example, if you pay 10% more for a particular machine which is highly automated and better equipped, what you get eventually is 25% or 30% more throughput by just investing 10% extra. So, at the end of the day, it is actually cheaper to buy such a machine.”
Push-to-Stop certainly appears to fit in well with Heidelberg’s modern presses, but there are many of the company’s older models still in operation. While the company says the new concept can be integrated with older models if capable staff is involved, nevertheless it is recommended that companies upgrade. “Even if you don’t have good machines, you can still get good output if you have qualified operators and good materials,” says Mr. Al Jehni. “But in any case (the printer) should reinvest in new machines every five years”.
Dr Ali Makari, Area Sales Manager, Heidelberg Druckmaschinen AG, concurs: “The ongoing costs of older machines are prohibitive. You become non-competitive. You cannot deliver on time. You cannot achieve the quality expected with a machine that is 15 years old. The automation level of the older machines creates a lot of waste before you get to zero-defect sheet. It is cheaper to get rid of all the older ones and, with a smaller number of new machines, you can achieve good quality and cost-effective production.”
He adds: “You can get better net margins with different machines, education, and material. According to research, 55% of the productivity of the machine is lost before you start printing. Our machine vastly improves workflow.” Finally, Heidelberg has identified a shortage of skilled staff in packaging printing and says Push-to-Stop addresses this by making the process that much easier.
“It supports press operators,” says Florian Franken, Head of Project Management, Standard Machines, Heidelberger Druckmaschinen AG. “For instance, the Drupa board says skill (shortage) is an issue not just in the Middle East, but in America and in Asia. In Australia, it is very hard to get educated operators. This is where Heidelberg comes in and says how can we guide the operator as best as possible to improve business. If the machine guides the operator, especially if he is new, it leads to faster speeds.”
With these innovations, Heidelberg aims to maintain its position as one of the industry leaders and to build on a solid performance last year. “For Heidelberg Middle East, 2019 was above 2018, definitely,” says Mr. Al Jehni. “Our performance was more than 10% better. We have very interesting projects coming from the Emirates that will add to our volumes. Overall we have done excellently.”
Dr. Makari is similarly enthused: “We have some very good customers who have invested in machines from us. We have been selling some very good machines to big customers, from Asia to North Africa and also in UAE. But we will have to improve our business more. We are waiting to see what we can do in Drupa.”
And Mr. Al Jehni issues a promise: “Any machine we sign from today will be Drupa-delivered. April is the new fiscal year and we will come up with some new generation machines. We are optimistic about 2020. There is no need for people to wait till Drupa.”