New Koenig & Bauer press yielding 30% business growth for El Paso Paper Box

Dallas, Texas - In 2016, El Paso Paper Box made a $15 million capital expenditure that included a new Koenig & Bauer 41-inch Rapida 106 full inline UV coating sheetfed perfector press. The result of its expansion of facilities and equipment has been dynamic growth in its printing and converting capabilities.

Sales for its paperboard packaging products have gained by 30% and new markets have emerged. El Paso’s management believes that total sales will continue to grow and double within five years. The company will possibly add a satellite location within five to 10 years, said Paul Malooly, El Paso president and CEO.

The strategic impact of the investment has not only been sales growth, but faster speeds and productivity, and the ability to meet new customer demands for higher quality levels. “Our 30% sales increase has come both organically and externally, via the addition of new customers,” says John Dowd, El Paso’s executive vice president. “Since the net speed of the Rapida 106 is averaging up to 18,000 sheets/hour for our longer runs, we are yielding up to 50% faster speeds. This has increased our productivity and become a prime driver of new business for us. We also have the confidence imparted by the Rapida’s excellent colour controls to seek out new business that we are now handling with ease.”

When asked why they chose Koenig & Bauer, Manny Corral, El Paso’s printing supervisor, said: “The uptime on our Rapida 106 is world-class. The reliability of the press gives us a solid footing to tackle the most demanding jobs and deliver on-time. Its’ high-speed production provides us with faster response to customer deadlines.”

Like the majority of printers today, one of its most demanding areas is colour control. El Paso’s operations team is mandated to insure that the printed product maintains superior colour consistency from the beginning of the production run to the end. “The colour of the packaging we produce must be consistent, both within the run itself and from one run to another,” explains Dowd. “Our clients value consistency and repeatability, and the tools for providing both are state-of-the-art with our Koenig & Bauer Rapida 106.” To that end, El Paso invested in the unique Koenig & Bauer LogoTronic software that delivers accurate presetting data from its prepress department.

After initial start-up, where 20% less waste was realized than the previous press, both the Koenig & Bauer ErgoTronic and QualiTronic software step up its game with solid colour controls, ink densities and colour measurement reports. The ability of the ErgoTronic camera to constantly measure registration, along with the QualiTronic measurement of colour - for every single sheet – ensures El Paso can deliver 100% colour control for all of its customers, says Dowd.

Another management decision by El Paso was to configure its new Koenig & Bauer Rapida press in the perfecting mode. Since the installation, El Paso has been able to offer a variety of solutions such as six-over-one positions to its customers. “The perfecting capability of the Rapida106 has been a real plus for our business,” says Dowd. “A lot of formerly two-pass work can now be run in one pass since we can simultaneously print the front and reverse sides of the package. This gives us a “leg up” on our competition, as the costs to perfect are minimal compared to a two-pass run.”

Koenig & Bauer (US) is located in Dallas, Texas and a member of the Koenig & Bauer Group, which was established over 200 years ago in Würzburg, Germany.

Koenig & Bauer

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