Precision rotogravure cylinders, repro/prepress and chrome-free plating for packaging printing
4Packaging GmbH
Dissen am Teutoburger WaldNew on Amplifa
About 4Packaging
4Packaging GmbH manufactures rotogravure cylinders in Dissen am Teutoburger Wald for packaging printers and branded goods manufacturers. Its service portfolio includes electromechanical engraving, direct laser engraving (Cellaxy), prepress with data preparation, separations and trapping, repro and colour management, and digital and physical proofs on the target substrate. With ChromeNEO, the company offers a chrome-free process for plating rotogravure cylinders; with 4P ReSleeve Pro™, aluminium embossing sleeves are reconditioned and reused within about five working days. For quality assurance, the Q-Trac defect detection system (K.Walter) is used, whose early development 4Packaging was involved in. Customers come from the tobacco, FMCG, labels and premium packaging industries; deliveries go to Europe and beyond.
- Site
- Dissen am Teutoburger Wald
- Processes
- Rotogravure cylinder engraving (electromechanical), Laser engraving of rotogravure cylinders (Cellaxy), ChromeNEO – chrome-free rotogravure plating, Recycling of embossing sleeves (4P ReSleeve Pro) – reuse of aluminium sleeve bodies, Packaging prepress (artwork/data preparation, separations, trapping), Repro and colour management (colorimetry across printers/substrates), Proofing (digital and physical proofs on the target substrate), Digital mockups / packaging visualisation
- Materials
- Aluminium (sleeve bodies), Chrome (plating of rotogravure cylinders), Copper, Chrome, Direct laser engraving, Electromechanical engraving, Chrome-free plating, 4P ReSleeve Pro™
- Certificates
- Q-Trac defect detection
- Founded
- 2000
- Industries
- Rotogravure packaging printers, Branded goods manufacturers, Tobacco packaging, FMCG packaging, Labels, Décor packaging
- 01
Artwork and data preparation (separations, trapping)
- 02
Repro and colour management
- 03
Proofing (digital/physical)
- 04
Cylinder preparation and machining
- 05
Engraving (electromechanical or Cellaxy laser)
- 06
Plating (conventional or ChromeNEO)
- 07
Cylinder defect detection (Q-Trac)
- 08
Delivery
Materials & Processes
Aluminium (sleeve bodies)
Aluminium sleeve bodies are used for embossing sleeves and reused via 4P ReSleeve Pro™.
Copper
Copper layer as the engraving substrate on rotogravure cylinders.
Chrome
Plating of the rotogravure cylinders for surface protection; chrome-free alternative via ChromeNEO.
Direct laser engraving
Precise engraving without a sawtooth effect, improved ink transfer for coatings, solids and white.
Electromechanical engraving
Consistent cell geometry for stable ink transfer on short and long runs.
Chrome-free plating
Environmentally friendly alternative to conventional plating to reduce the CO₂ footprint.
4P ReSleeve Pro™
Reconditioning of used embossing sleeve bodies made of aluminium in approx. five working days.
Locations
Dissen am Teutoburger Wald
DEHeadquarters, production (rotogravure cylinders, embossing department, repro/prepress)
- Materials
- Aluminium, Copper, Chrome
- Cellaxy direct laser engraving machines
- Electromechanical engraving machines
- Q-Trac cylinder defect detection system (K.Walter)
- Automated cylinder production line
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Rotogravure cylinder engraving (electromechanical)Engineering | – | – | – | – | Chrome, Copper |
| Laser engraving of rotogravure cylinders (Cellaxy)Engineering | – | – | – | – | – |
| ChromeNEO – chrome-free rotogravure platingSurface | – | – | – | – | – |
| Recycling of embossing sleeves (4P ReSleeve Pro) – reuse of aluminium sleeve bodiesSurface | – | – | – | – | Aluminium |
| Packaging prepress (artwork/data preparation, separations, trapping)Engineering | – | – | – | – | – |
| Repro and colour management (colorimetry across printers/substrates)Engineering | – | – | – | – | – |
| Proofing (digital and physical proofs on the target substrate)Testing | – | – | – | – | – |
| Digital mockups / packaging visualisationEngineering | – | – | – | – | – |
| Embossing (embossing technology, embossing department)Forming | – | – | – | – | – |
| Cylinder defect detection (quality inspection of rotogravure cylinders with Q-Trac)Testing | – | – | – | – | – |
| Cylinder machining and preparation for the production process (measuring, adjusting to specifiedMachining | – | – | – | – | Chrome, Copper |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Q-Trac cylinder defect detection system | K.Walter Q-Trac | – | – | – | Dissen am Teutoburger Wald |
| Direct laser engraving machines | Cellaxy | – | – | 2008 | Dissen am Teutoburger Wald |
| Automated line (cylinder production) | – | – | – | – | Dissen am Teutoburger Wald |
| Electromechanical engraving machines (rotogravure cylinders) | – | – | – | – | Dissen am Teutoburger Wald |
Additional services
Reference customers
Quality
Cylinders are inspected automatically with the Q-Trac defect detection system (K.Walter); 4Packaging was involved in the early development of this technology. In addition, the dimensions and quality of the cylinders are measured and checked throughout the manufacturing process.
| Evidence | Dissen am Teutoburger Wald |
|---|---|
| Q-Trac defect detection |
History
- 2000
Founded by Jürgen Möller, Gisbert Lumme and Manfred Beck in Dissen
- 2006
Relocation to a larger, modern production building
- 2008
Investment in direct laser engraving (Cellaxy)
- 2012
Relocation of the embossing department to Dissen