THIMM bets on fully digital packaging and display production
The German group was the first European company to install, at its plant in the Czech Republic, a Highcon Beam 2C for digital corrugated die-cutting
To emphasize its mission to create innovative corrugated cardboard solutions for packaging and logistics, the German company THIMM has chosen the tagline “The Highpack Group”. At the heart of the company’s strategy are people, their ideas, and the most advanced production technologies to implement them.
With over 3,500 employees, 22 production sites in six European countries, and a turnover of 623 million euros (2019), the group serves customers in 18 European countries and is divided into four divisions. THIMM pack’n’display produces point-of-purchase materials; THIMM Packaging Systems, packaging for industry; and Christiansen Print, printed packaging. In addition to these, there is the online shop CARTONARA.
In recent years, the company has realized the centrality of printing in the development of packaging and POP materials capable of responding to the needs of brands and consumers. Therefore, in 2016, THIMM completed the acquisition of Christiansen Print, at which, in 2017, it installed an HP PageWide T1100S for the production of digitally printed corrugated cardboard (in preprint).
Last January, the group was the first in Europe to install a digital die-cutting machine, the Highcon Beam 2C, for corrugated cardboard at the THIMM pack’n’display plant in Všetaty, Czech Republic.
In order to better understand the technological evolution of the company, we interviewed Michael Weber, Corporate Strategy & Marketing Director of the group, together with Martin Hejl and Kamil Mašek, Managing Director and Production Manager, respectively, of the Všetaty production site.
Growth through acquisitions and a focus on people
Between 2009 and 2019, THIMM’s turnover increased by 122%, a result made possible by the expansion of its production sites and the acquisition of companies in several countries (especially in Central Europe).
“Every time we open a new location, we expand our presence, and we are closer to our customers,” explains Weber. “One example is the acquisition of United Packaging in Skarbimierz, Poland, which enables us to provide even better service to both Polish customers and those in neighboring countries.”
More than production facilities and sales networks, for THIMM the priority is people, who contribute to the unique positioning of the company.
“THIMM employees work on our solutions in order to make them the best possible, optimally combining expertise, innovation, and investment. In light of this, and after testing our products, customers trust us and are excited to work with us,” says Weber.
THIMM pack’n’display: a big company in the company
The pack’n’display division employs 2,134 people at 11 production sites and contributes 438 million euros to THIMM’s turnover. The site in Všetaty, north of Prague, which specializes in the production of packaging for consumer goods and e-commerce, is fully robotized and governed by an automated order management system. Here, 120 million square meters of corrugated cardboard is produced each year, and 25 million square meters of corrugated cardboard is converted using folder-gluers, flexo units, and flatbed and rotary die-cutting machines. THIMM has invested over 76 million euros in its Všetaty facility since its construction in 1994, making it one of the most modern sites of the group.
“The sooner customers realize the benefits of digital, the sooner they will use this technology to their advantage.”
— Martin Hejl, Managing Director of THIMM Všetaty
In addition to the ISO 9001:2015 and FSC certifications, in 2013 the facility obtained the BRC Global Standard grade AA certification for the production of packaging intended for direct contact with food.
The growing demand for small and medium quantities of customized displays and packaging has led the management to create a completely digital production department. Here, in 2018, a Durst Rho 1012 inkjet printer was installed, joined last January by the new Highcon Beam 2C.
“With a digital flow, we are able to react much more quickly, delivering packaging within a few days, making small and medium quantities and keeping zero stock in inventory,” Hejl explains. “Digital technologies create completely new scenarios for packaging and POP materials, allowing customization, limited editions, seasonal campaigns, AR applications, and the use of special codes capable of interacting with mobile apps.”
Automate and digitize to reduce variables
One of THIMM’s main challenges is finding adequately trained human resources to develop increasingly sophisticated packaging in design, performance, aesthetics, and functionality. Over the last decade, the company management has concluded that in the future it will be increasingly difficult to find staff capable of managing materials, machines, and processes.
“For a certain period of time, we trained a large number of newcomers, offering them two- or three-year learning paths, which many did not complete. This generated an exhausting turnover, and was not good for product quality,” explains Hejl. “So, we decided to focus on a few hyperspecialized technicians, who, once trained, are able to control all types of machinery, robots, and software infrastructure. Some of them become instructors and train newcomers.”
In parallel, THIMM invests in automation and robotics, and in the digitization of logistic and administrative flows, so as to have teams of “smart” specialists capable of governing even very different processes.
Die-cutting becomes digital
If digital printing is a path already traveled by some corrugated operators, die-cutting represents a bottleneck for everyone, especially in high volumes, where cutting tables are unsuitable. To overcome this limitation, THIMM has bet on Highcon’s laser die-cutting technology.
“Our goal is always to provide the best solution to the customer, and the digital finishing of corrugated board is a logical extension of our capabilities,” explains Hejl. “We believe that laser-cut packaging and displays are applicable to many industries, and we work closely with customers to create new products that give them a competitive advantage.”
The Highcon Beam 2C can handle sheets between 500x700 and 760x1060 mm, combining laser technology for through cuts and perforations, and the patented DART (Digital Adhesive Rule Technology) for creasing. The latter involves the creation of the creasing matrix directly in the machine, using a UV-curable polymer dispensed by a digital writing head. With a maximum productivity of 4,000 B1 sheets per hour, the system is able to die-cut different types of single- and double-wall cardboard (N, F, G, B, C, EF, EE) with thicknesses between 1 and 4 mm.
“Digital die-cutting is a logical consequence of market development and is ideal to meet the needs of different types of packaging, in several customized variants,” explains Hejl. “The elimination of dies, and an almost zero preparation time, make it possible to respond lightning-fast to any request. The laser can then make high-precision cuts that are impossible with a conventional die cutter.”
Towards on-demand production of boxes and displays
Kamil Mašek, Production Manager of THIMM Czech Republic, talks about the introduction of the Highcon Beam 2C on the Všetaty website: “We have performed several tests in Highcon’s laboratories, using our materials and files. This gave us a clear idea of the machine’s potential and performance, and how to exploit this technology,” explains Mašek. “Together with the Highcon team, we analyzed numerous types of packaging that we believe are suitable for this technology. It has been an intense month, but very interesting.”
Today, the company uses the Highcon to make orders of a few dozen or a few hundred boxes and displays, as well as to more effectively manage the frequent reorders, thus eliminating inventory.
“We are full of optimism, and we believe that investing in digital packaging production is the right decision.”
— Kamil Mašek, Production Manager of THIMM Czech Republic
“In the field of displays, the potential is enormous. Our designers are enthusiastic about the possibilities offered by Highcon, which allow them to look at the product from a new perspective and be more creative,” continues Mašek. “This technology can be used both for special projects, thanks to its high cutting precision, and for small conventional products.”
Scalability of technology, automation, and development
With the introduction of the Highcon Beam 2C, THIMM has implemented a fully digital production process, from data design and preparation to corrugated board printing and finishing, which can be extended to the group’s other production sites in the future.
“We are full of optimism, and we believe that investing in digital packaging production is the right decision,” concludes Mašek. “For the future, we intend to focus on digital technologies, and we want to become a leader in this field, in our sector.”
Faith in digitizing processes to create the packaging of the future
Together with the other players in the packaging supply chain, THIMM is preparing to face the changes induced by brands and consumers, and plans its investments in technology accordingly.
“In the near future, we will make every effort to meet the needs of a market that is increasingly influenced by changes in consumer purchasing behavior and the demand for sustainability,” Hejl points out. “Today the consumer wants it all, and he wants it now; he has more physical and online purchasing options; he is focused on quality, sustainability, and a premium experience. Brands must simultaneously meet the needs of both young, digital-native consumers and previous generations of digitized consumers. That’s why our goal is to become a Digital Factory 4.0.”
This spirit inspired THIMM in its collaboration with Highcon for the development of the Beam 2C and is leading the German group in a broader strategy of investment and promotion of digital technology.
“We want to quickly transfer to our customers our enthusiasm and the skills that we are acquiring. The sooner they realize the advantages of digital, the sooner they will use this technology to their advantage. And their success is ours too,” Hejl concludes. “However, we will also continue to make extensive use of analog technology. At least until the advantages and values of digital are fully understood and assimilated by the market.”
The ambition to play the role of pioneer and innovator in the packaging industry is reflected in THIMM’s investments and strategic moves, including the installation of the HP PageWide T1100S digital press at Christiansen Print and the introduction of the Highcon Beam 2C at Všetaty.
In an era where data exchange is a crucial issue, and customization an essential requirement, THIMM has laid the foundations for the packaging of the future by investing, experimenting, and embodying an authentic faith in digitizing processes.
