Perfectly packaged
Bischof+Klein manufactures high-quality packaging with metering technology from DOPAG
Food, cleaning agents, building materials or even animal feed – all this is packaged in bags that we are using in our everyday lives. It is not noticeable at first, but there is a complex manufacturing process behind it. During this process, packaging manufacturer Bischof+Klein relies on metering and mixing technology from DOPAG.
Bischof+Klein focuses great importance to quality in its production. At its headquarters in Lengerich near Osnabrück (Germany), it produces premium films and packaging that are used in the consumer sector, for example for baby food, hygiene products, food and animal feed. Each type of packaging is individually tailored to the product. Coffee, for example, is packaged in a vacuum. The pouch consists of three glued foils that are specially matched to each other. This is the only way to achieve all the properties that protect the quality and flavour of the coffee.
They are produced using a duplex laminating machine. Here, two films, a thin, printed outer film and a slightly thicker film, are glued together. Later, they are processed to make pouches. The company manufactures most of the base films itself and also prints them. The laminating machine works with a solvent-free, two-component adhesive. Using several rollers, the adhesive is rolled down to the respective thickness level and then applied to the film material. After a few metres, the first film is glued to a second film, which runs upwards from the other side of the machine. The machine can process 100 to 400 metres of film per minute. The two-component adhesive is prepared by the DOPAG metering and mixing system eldomix 600 and dosed into the roller gap.
The metering and mixing system is used at Bischof+Klein whenever there are special requirements for adhesives, films and the final packaging. Over the course of the project, Bischof+Klein and DOPAG designed the system accordingly. Two requirements were paramount in this respect: it should be mobile and work flexibly on different laminating machines. The change of material should be quick and easy to handle, as it is necessary to switch between specific adhesive systems. This can be, for example, a UV-resistant adhesive or a material with a particularly high bond strength.
The eldomix constantly dispenses the adhesive into the roller gap of the laminating system.
So that it is possible to switch quickly between the different adhesive systems, the adhesive is pumped directly from 200-litre drums. These stand with the system on a chassis that is mounted on rollers. This means that the system and the material in the production hall can be flexibly moved to different laminating machines. Continuous heating and temperature control ensure the correct processing temperature of the material. Special seals prevent the ingress of humidity. Changing materials takes very little time. The bunghole pump is moved out of the drum. Then the drum is changed and the pump retracted again. With a pre-run the material contained in the system is exchanged, the system is metered out and the respective mixing program is entered. All important process parameters such as the mixing ratio for the different adhesive systems used are stored on the system.
The containers can be changed quickly and easily, allowing the company to remain flexible and use different adhesive systems on one system.
Precise metering
An ultrasonic sensor is installed in the coating unit, which ensures that the material is dispensed at a constant rate. In addition, the machine is able to automatically adjust the flow rate to the speed of the laminating machine. Depending on whether the machine is running fast or slow, a lot of or a little adhesive is applied to the gap. The aim for the system is to deliver constant and continuous metering, as the adhesives have a short pot life. Only if the filling level in the roller gap is always kept the same an increase in viscosity can be avoided and the adhesive applied in a consistently high quality. This ensures high quality and durability of the packaging and the product packaged in it. At the end of the laminating process, the bonded film is rolled up. The adhesive hardens completely before the film leaves the warehouse on rolls or is further processed into packaging at Bischof+Klein.
“With a DOPAG system, we can ensure high quality”
Interview with Daniel Webers
Daniel Webers is Deputy Operations Manager and responsible for process optimisation. The trained industrial foreman has been working at the company for 26 years since his apprenticeship. Bischof+Klein has been using a ladomix metering and mixing system from DOPAG for several years, primarily for processing standard adhesives. For this reason, Daniel Webers also enquired at DOPAG about the new system.
Mr Webers, DOPAG designed the eldomix 600 metering and mixing system individually for Bischof+Klein. What were the most important requirements for the dispensing system for you?
Daniel Webers: When processing the adhesive, it is important to us that we can quickly switch back and forth between different adhesive systems in order to be able to respond individually to the respective requirements in day-to-day production. We have to be able to change adhesives and containers relatively quickly and also to move the system quickly, as it is used on different laminating machines. And everything has to run reliably.
Why are the reliability of the system and the processing quality particularly important to you?
Daniel Webers: In terms of the mixing ratio, we have a relatively small window during which the system has to put the two components together. This is extremely important so that the bonding works perfectly afterwards. If one component is metered more than the other, this can lead to the adhesive not being able to properly react. Therefore, it is essential that the system works very precisely. With the DOPAG system, we can ensure high quality packaging. This is important because the filling systems also place high demands on the packaging and films while everything has to run smoothly in the downstream filling process.
Why did you choose DOPAG?
Daniel Webers: We use various other DOPAG systems in our production. Ultimately, we always like to have DOPAG as a strategic partner because the support level is high and the system runs reliably. The technicians are experienced and support us quickly if there are any problems. But even if we have to find our own solutions to problems in order to get the system up and running again quickly, DOPAG can be easily reached for relevant information or to provide spare parts. Further, we have been impressed by the reliability of the system and the quality of the processing.
About Bischof+Klein
In 1892, Bischof+Klein was founded as a paper factory and mint. The first packaging was produced in 1922: handmade paper bags. Today, the family-owned company is one of the leading providers of flexible industrial and consumer packaging made of plastic as well as technical films. Around 2,100 employees work at the Lengerich and Konzell sites. Other production sites are located in France, Poland and the United Kingdom.
Your partnership with DOPAG
- One contact for the entire system solution
- All applications from one provider
- Implementation of specific requirements and automation
- Competent support from DOPAG experts
- A dedicated technical centre for testing and customer training
- Close collaboration with material manufacturers
- Decades of experience in metering and mixing technology
- Global distribution and service in over 40 countries
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