Neuenstein-based HEPACK druck+verpackung GmbH has invested around Euro 12 million in overhauling its entire production and logistics operations. The construction work created an additional 5,000 square meters of space and the flow of goods was completely redesigned based on the lean principle.

Production is now organized efficiently with two new large, format 6 presses from Heidelberg, a folding carton gluing machine, and three die cutters in a fully integrated Prinect workflow – a solution that is unique within the industry. In the first five months of the year, this resulted in a 10% increase in throughput despite the ongoing construction and installation work.

Around 80% of HEPACK’s production is accounted for by food and confectionery manufacturers with production sites in Germany and neighboring countries, and approximately a fifth of its contracts fall under the general packaging segment.

By working with Heidelberg to redesign and restructure its production operations, HEPACK has also done much to optimize the energy balance of its folding carton production. An idea proposed by Heidelberg made it possible to implement the concept of using waste heat from the presses and additional warm air from a wood-chip heating system and a cogeneration plant to preheat the process air for drying the print sheets.

Cardboard is delivered to HEPACK on single-use wooden pallets, with a throughput of around 28,000 metric tons annually. The pallets are now processed to make wood chips for burning, reducing energy consumption in the print area by approximately 30%. The additional gas cogeneration plant also heats the production hall in winter.

The technical outlay and installation of the wood-chip system pays dividends for the environment on a daily basis, with HEPACK saving around 100 kW per operating hour and press.