Mex, Switzerland - The strategic deployment of BOBST gravure technology has laid a solid foundation for growth for the Turkish packaging manufacturer. Since the installation of two highly efficient RS 6003 presses, Çevikbaş Packaging has enjoyed the benefits of higher speed, exceptional quality and format flexibility, supporting the company in meeting its customers’ demands.

Founded in 1988, Çevikbaş Packaging in Turkey has a long history in gravure printing, lamination and converting, manufacturing a range of flexible food packaging applications, such as Doy packs, flat bottom and Quadro bags, single and double twists, flow packs, and recyclable, blister, and peelable packaging. To support growth and meet customer requirements, the company needed to substantially expand printing capacity and upgrade production speed.

After reviewing the market carefully, CEO Mehmet Çevikbaş and CFO Ahmet Çevikbaş made the decision to partner with BOBST and signed a contract for two RS 6003 gravure presses. Representing a large uptick in output, both 8-color machines were installed in 2021, immediately extending capacity at Çevikbaş by 40% to a total of 18.000 tons annually.

Impressed with BOBST gravure

Located in Konya industrial zone, in the central part of Turkey, Çevikbaş operates from a 32,000 sqm modern facility where 150 staff are employed. The packaging specialist runs two production shifts utilizing six gravure lines, including the two latest machines from BOBST, and a digital press, along with a swathe of advanced converting equipment. Around 40% of its production is exported to customers across Africa, Central Asia, and Europe.

Incorporating BOBST’s industry-leading expertise in gravure printing, the two BOBST RS 6003 gravure lines offer a maximum running speed of 500 m/min (1640 ft/min). Capable of working with water and solvent-based inks, the presses can print on a wide variety of filmic substrates, laminates and paper. The high level of automation and connectivity capabilities ensure high process reliability and exceptional productivity, allowing Çevikbaş to supply its customers with the best quality flexible packaging at short notice.

“BOBST’s gravure technology really impressed us, in particular the high speed and the format flexibility,” said Mehmet Çevikbaş. “Our customers are looking for high quality and increasingly quicker turnaround times, so we must live up to those expectations by bolstering our offering with state-of-the-art equipment.”

Sustainable packaging production

In addition to its continued growth plan, Çevikbaş is also concerned with minimizing its environmental impact and is a member of SEDEX, the Supplier Ethical Data Exchange established to empower sustainable supply chains. Among its products, it offers mono-material packaging constructions, designed for recycling. In 2022, a new recovery facility was commissioned to ensure solvents in air emissions were captured and recycled. A solar system has also been put in place to supply renewable energy to the factory.

The short web path and accurate register control system on the BOBST RS 6003 press are among the features that align with Çevikbaş’ sustainability vision, helping the company to cut down on waste and costs. The compact press design ensures that 30% less waste is produced at start-up and changeovers, compared to a conventionally designed machine. The unique twin flow drying technology, as well as the heat recovery system on the printing units, deliver higher efficiency, further adding to the environmental benefits.

Benefits of twin strategy

Since the initial investment, the partnership with BOBST has delivered outstanding results, fueling growth and positioning Çevikbaş as a stronger competitor in the market. Delivering strong savings in terms of the overall investment, the dual installation has significantly increased output, while enabling the company to confidently expand into new, profitable market segments.

The strategy to buy two identical BOBST RS 6003 gravure presses, which provide identical printing quality, also offers increased flexibility in planning and guaranteed job repeatability. A major benefit is the ability to share machine parts, printing cylinders and ink trolley, bringing even more efficiency in production and additional cost savings. Meanwhile, the operators find it easy and simple to move from one machine’s SPHERE Human Machine Interface (HMI) to the other, speeding up operations and maintenance.

The two machines also benefit from a shared service plan and the team is highly satisfied with the support received from BOBST. Mehmet Çevikbaş highlighted the fast respond times: “Thanks to the 24/7 service connection agreement that covers both machines any problems we have are solved very quickly. This is vital for us because it means we can keep both machines running and our customers satisfied.”

“We were very honored when Çevikbaş, one of Turkey’s premier packaging producers, chose BOBST gravure technology as its next strategic move. The growth the company has experienced on the back of this investment is a major point of pride for us. We look forward to continuing the collaboration for many more years,” said Angelo Cavallo, Technology Sales Manager, Gravure & Laminating.