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In-House Level: PRO. Rawlplug Wrocław printing house just like Formula 1

4 min
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New machines, different printing technology, and acceleration worthy of a leader. A label printing shop has just been commissioned next to Rawlplug’s HQ, taking us to the next level in terms of self-sufficiency.

Preparations for the launch of the new printing house took us almost six months.

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We used all this time to the fullest. We learned a great deal and gained the know-how necessary to manage the entire printing process self-sufficiently, using our new machines. This is yet another milestone in the Wrocław master plan. We have become completely independent of label producers and suppliers, while losing nothing in terms of quality.

Dominik Graba

Logistics Manager at Rawlplug

Printing labels with a new technology – three times faster

The new investment entailed replacement of the entire machinery previously in operation and required us to find more efficient alternatives. Following a detailed reconnaissance, Rawlplug opted for the equipment from the European company. It is based on a completely different technology – ink jet printing, instead of the electro ink used before.

The labels printed by the machine are of excellent quality; they are also highly resistant to external factors, so there is no need to varnish them, which translates into measurable savings – PLN 140 thousand a year – and environmental benefits. We experienced the improved efficiency of the new equipment virtually instantly. With the performance almost three times higher than that of its predecessor, it is like a Formula 1 vehicle. We were once capable of printing 16 metres of web per minute, and now – as much as 52.

Patryk Żebryk (pictured above)

Head of Rawlplug’s Label Design and Production Division

Finishing equipment allows printing on any substrate and semi-rotary die-cutting in any shape.
Finishing equipment allows printing on any substrate and semi-rotary die-cutting in any shape.

Ink jet printing – more efficient; printing costs – lower 

The new printing house, comprising a printing machine and multi-module (extension-ready) finishing equipment, enables us to print on any chosen substrate and to use semi-rotary die-cutting to any chosen shape at a much higher speed, namely 100 m per minute, as compared with 38 m which the previous setup provided. Thanks to a special camera, it is possible to monitor the printing quality and colour compatibility at any time, adapting the ink amount and saturation accordingly, if necessary.

Apart of ink and paper, we no longer need to purchase anything from external vendors. Consequently, our costs have dropped by as much as three times. This is very important not only to us, but also to our customers, because the printing cost is a fraction of the product cost, after all. If we can produce an excellent quality label cheaper and faster, the price does not go up, which matters, for instance, in the context of inflation. That is precisely why this investment was so important to us.

Dominik Graba

Logistics Manager at Rawlplug

Bonded anchors. Flagship product, and top-quality labels as well 

One of the main tasks of the new printing house will be the production of what is commonly known as peel-offs, i.e. double-sided peel-off labels, applied primarily to the containers of Rawlplug’s popular bonded anchors. 

We had to order them from external suppliers before, since older machines did not allow us to produce them on an in-house basis. We are currently implementing this process at our plant. The suitable polymers, necessary for label printing on the adhesive side, have already arrived at the Wrocław headquarters.

Patryk Żebryk

Head of Rawlplug’s Label Design and Production Division

One of the main tasks of the new printer will be to print so-called peel-off labels, i.e. double-sided labels that can be removed.
One of the main tasks of the new printer will be to print so-called peel-off labels, i.e. double-sided labels that can be removed.

What about the limitations of the new printing house?

Given our current needs – none whatsoever. We could theoretically even print a book using our new machinery.

Dominik Graba

Logistics Manager at Rawlplug

Thanks to a special camera, the quality of the print can be monitored at any time.
Thanks to a special camera, the quality of the print can be monitored at any time.

With a budget of more than PLN 3 million (printing and finishing equipment), the recent HQ investment does not mean that the older equipment – still perfectly operational – is dusting in some corner on the premises of the refurbished printing house in Wrocław. Having made the purchase, Rawlplug is now in disposal of as many as three professional printing machines. Two of them will manage just fine at facilities with a lower demand for label printing, which is why one went to a manufacturing plant in Vietnam, and the other will soon be put into service at Rawlplug’s new logistics centre in Kożuchów. 

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