F R E E I S S U E

M A D E R N J O U R N A L WELCOME TO THE MADERN WORLD OF ROTARY TOOLING AND CONVERTING SOLUTIONS

R E V O - L I N E P R ON E W !

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M A D E R N J O U R N A L

E D I T O R I A LJ.H.R. MADERN

H I S T O R YSIX DECADES OF INNOVATION

VA L U E S E R I E SLOW COST COMPETITIVE TOOLING

R E V O - L I N ENEW ROTARY DIE-CUTTER

E M B O S S I N GS Y S T E MNEW LOW COST DESIGN

A D A P T I O NPA R T SRE-DESIGN

C U S T O M E R S E R V I C ED E PA R T M E N TUPGRADE SERVICES

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This years Madern Journal is dedicated to Revolution in the broadest sense of the word. We will inform you about the latest improvements of the Madern Group and our new products that have been developed based on our decades of experience and know-how.

Historically, Madern was established as a small engraving company for nameplates and stamps by my parents in 1954. The company evolved over the past six decades, from manufacturing small label dies and soap forming dies to injection moulds for the plastic industry. Our commitment to con-stantly innovate and improve existing technology combined with our passion for the paperboard packaging industry resulted into high quality rotary dies for folding cartons. Today, Madern has become an established world leading supplier of rotary dies and converting solutions for the folding carton indus-try, setting the standards over the past two decades.

Since Drupa 2008 there have been a lot of changes worldwide. The global economic crisis has left its traces in the packaging industry, resulting in a global consolidation of printing and converting capacity and many ac-quisitions and mergers have been realized. Presently we notice a slow recovery in the developed countries, but a powerful upswing of the con-verting industry in Asia, South-America, India, Eastern Europe and the Middle East. Madern actively invests in these new markets with a new pro-duction facility in China and an increased network of representatives in stra-tegic markets, such as Mexico. A major part of the world wide packaging products are still manufactured out of paperboard. The variety in packaging types is growing rapidly and is becoming more important as a way of communicating to the consumers. We also see growing trends like environmental awareness. Recycling, flexibility, shorter production runs and time to market are getting more important. The industry is currently concentrating on these new trends and we at Madern are working hard to adapt our rotary tooling and converting solutions to meet these changing market conditions.

Our latest innovation in the field of converting solutions is the Revo-Line. A highly competitive and cost efficient rotary die-cutter made out of special stone cast material and compatible with various different tool executions. It will lead us to a new era of possibilities and opportunities for the rotary converting technology.Also on the rotary tooling side we have new and interesting innovations. We introduce a new range of solid tools called Value Series, and a new type of bearing blocks suitable for Bobst presses. Another development is our low cost segmented embossing systems for short and medium run lengths.

Inside our organization we have made important steps during the last years. Our worldwide sales and service departments have been upgraded and pro-fessionalized and with an improved corporate identity we hope to increase the communication and interaction with our customers and markets. Madern will continue working on new innovative developments and increas-ing our overall performance. New technologies, such as close loop gap con-trol systems and further developing the sleeve concept shown at Drupa 2008 will be a constant drive to offer the market the best solutions for the rotary converting packaging industry. We look forward to meet and exceed the con-tinuous challenges and expectations of today’s packaging industry.

I would like to welcome you to — The Madern World — of rotary tooling and converting solutions. Be sure to take full advantage of the opportunities and benefits offered by Madern and discuss your rotary converting challenges and needs today or visit us at www.madern.com.

J E A N M A D E R N

C E O O F T H E M A D E R N G R O U P

E D I T O R I A LJ.H.R. MADERN

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In today’s short/no contract, on-demand paperboard packaging market, produc-tion runs are getting shorter and budgets are tighter from top to bottom.

Madern is proud to offer you the single source solution for all your short run rotary packaging requirements. Our manufacturing capabilities have extend-ed to a very competitive range of alternatives to meet short run demands, while maintaining the outstanding Madern quality craftsmanship and mate-rial integrity our customers depend on.

Our solid and partially segmented Value Series rotary tools have this premier Madern quality at less cost than our traditional fully segmented tools. These price competitive tools are a stripped down design, allowing us to pass on the cost savings to you.

Value Series rotary tools are solid hardened cylinders that are manufactured for high quality cuts at the highest speeds and for countless products. They can be made based on the crush cut or scissor cut (MP) cutting principles, depending on the carton shape and type of paperboard to be used. We also have the capability to combine cutting and creasing in the same station, de-pending on carton intricacy and die-station availability.

VA L U E S E R I E SLOW COST TOOLING

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At this year’s Drupa we will introduce our most recent product, the Madern Revo-Line rotary die-cutter. This Revo-lutionary die-cutter is a very versatile, operator-friendly rotary die-cutting concept. It’s one of our most important de-velopments of the past 4 years. The Revo-Line derives from the previous series of successful Madern rotary die-cutters and customers input. Therefore we are convinced this die-cutter will become ‘the one all converters are talking about’.

The modular design of the Revo-Line allows the converter to choose from a wide range of options to customize the unit to its own needs, specifications and budget. The Revo-Line is available as a single converting station using combined rotary cutting and creasing converting tools and can be extended up to 4 stations for separate cutting, creasing, embossing, punching and per-forating operations.

M AT E R I A L U S EThe Revo-Line distinguishes itself in the choice of material. The base frame is manufactured from a special stone cast material, which is less sensitive to temperature changes, compared to cast steel or iron. The special stone cast material will reduce vibrations drastically, because of its damping and absorbing characteristics. The base frame can be mounted on special high- precision linear guide rails allowing motorized lateral settings of each indi-vidual converting station. The base plate of the top frame is also made from the same stone cast material. The removal of the top frame from the base frame can be fully manually or optionally motorized and can be fixed in place with bolts to the base frame or optionally automatically locked by means of heavy duty magnets which are incorporated in the base frame.

T E C H N I Q U EThe upper and lower converting tools that are used in the Revo-Line are me-chanically coupled and can be completely adjusted or set off-line with a spe-cial make ready set. With the economical basic execution of the Revo-Line, the complete tool set can be loaded from the top with a dedicated installed overhead crane. The Revo-Line Pro is executed with an additional top frame quick change-over feature. This makes it possible to either change the tool set from the top or completely with the top frame module. Either way en-sures the shortest change-over time and gives maximum flexibility.

Each converting station of the Revo-Line rotary die-cutter is provided with the latest servo drive technology. The converting tools are directly driven by means of a fixed position motor gear and are engaged with the drive tool-free.

All movements and operations for changing tools or top frames are manual or motorized without the use of any hydraulic components.

The Revo-Line rotary die-cutter is fully enclosed, reducing noise and dust coming into the pressroom and optimizing safety for the operators. The wide doors on operator and drive side allow convenient and easy access for change-overs and maintenance. The sliding roof doors can be fully opened to load the converting tools from the top.

The Revo-Line is the ideal and most competitive rotary die-cutting solution for all your folding carton converting needs.

G E N E R A L S P E C I F I C AT I O N S

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R E V O - L I N ENEW COMPETITIVE ROTARY DIE-CUTTER

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N E W E M B O S S I N G S Y S T E MLOW COST & QUICK CHANGE-OVER TOOLS

Packaging has a variety of tasks to fulfill. Not only does packaging store and protect products, it also has to get the consumers attention and convince them to purchase the product. There is a constant pressure on brand owners to bet-ter position and promote their products on the store shelves. Our world drives on aesthetics and customers purchasing decisions are influenced by appealing packaging with special finishing, like embossing.

Unfortunately, special finishing results in higher production and carton costs and cannot be used for all type of products. Currently, special finishing is confined to mostly luxury goods, such as tobacco and cosmetic products. Increased demands for lower cost enhancing processes for folding cartons inspired us to develop a new affordable embossing system with the premi-um quality customers expect of Madern rotary tooling. This new embossing system is our latest innovation, besides our traditional solid and segmented embossing solutions and will be presented at the Drupa 2012.

The new embossing technology is composed of molded synthetic female segments. These segments can be slid into a special body cylinder. This ‘fe-male’ cylinder will run against the anvil cylinder, which consists out of blank rubber coated segments, or can be foreseen with embossed male segments if very small embossing details are implicated.

The advantages of this new embossing system are in lower costs, less stor-age space, quick modifications into different kinds of embossing designs and short delivery times compared to the traditional embossing systems. We are convinced we will be able to amaze the market with this new technology and increase the quality and enhancement of packaging around the world.

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N E W A D A P T I O N PA R T S DESIGNED FOR MADERN ROTARY TOOLING

Besides our dedication to converting solutions, our core business and interests are still in rotary tooling. Over the last three decades, research and experiments by the Madern Group have resulted into the development of multiple innovations in the field of rotary tooling.

This year we will introduce our redesigned adaption parts, especially devel-oped for Bobst rotary die-cutters (DR55-S, DR67-HS and the DRive series).

Our goal with the new design is to simplify settings and make the complete tool set more rigid. To achieve these objectives, Madern designed the upper and lower bearing block set as one piece with an integrated spring system. This overcomes the possible skewing and off-setting problems that can oc-cur with separate upper and lower bearing blocks. Due to an ingenious in-tegrated spring system and an eccentric movement, the upper and lower cylinder can still be opened and closed and the optimum gap setting can be achieved by a combination of hard shims and tie-rods.

With this increased rigidity, the expectation is that vibration will be reduced in the rotary die-cutter. This high level integration of Madern Tooling will increase the overall productivity and therefore the profitability of our cus-tomers.

Little changes can make a BIG difference. It’s all in the details.

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C U S T O M E R S E R V I C E D E PA R T M E N T JUST ONE PHONE CALL AWAY

Growing trends in technology, transport, communication and logistics enhanced the need for a new customized service department at Madern. The expansion of the Madern Group allowed us to improve our position in service and support for our existing and new cus-tomers around the globe. Now we are able to handle all our customer service require-ments with great care and accuracy to find the right solutions.

S E R V I C EThe new organization is managed from our head office in the Netherlands in co-operation with local market organizations in several major time zones (America’s, Europe and Asia) . In this way we have the possibility to act fast in case of emergency situations, because our qualified and experienced service personnel are available for 24/7 technical support. Madern has created the possibility to simulate occurred problems in-house examined by specialists to generate the best and quickest solu-tions possible.

Madern will give professional support during installation, start-up and commission-ing of new tools and equipment.

Furthermore, Madern offers preventive maintenance programs to keep your equip-ment updated throughout the whole year. Preventive maintenance is conducted to keep equipment working and/or extend the life of the equipment.

T R A I N I N GAs a word leading single source supplier of rotary tooling and converting solutions, we also have to supply our customer’s personnel with the best know-how and ser-vice. That’s why Madern offers professional group or individual training courses on site when needed. Our training material is based upon our knowledge, product spe-cific parts and the practical field experience of our technicians.

With Madern services you’ll get the technical expertise and services you need.

S E R V I C E S I N C LU D E :

T E C H N I C A L F I E L D S E R V I C E

T R A I N I N G A N D E D U C AT I O N

P R E V E N T I V E M A I N T E N A N C E

S PA R E PA R T S A N D R E PA I R S

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