Gmund Paper: Precision in Finishing and Processing
Every day, a wide range of processes come together in Gmund’s finishing and processing department to cut, emboss, coat or satin finish paper – with the utmost precision and passion. We spoke to Hans Wild, who has been managing this department for 15 years, about machine diversity, craftsmanship and daily routines. The department is at the heart of production: precise, versatile and indispensable for what makes Gmund paper so special.
Dear Hans, would you like to tell us a little bit about yourself and your career at Gmund?
‘I have been working at Gmund since 1997 – so for almost 28 years. Before that, I worked in the paper industry for around 15 years. I started here in processing as a machine operator for embossing calenders and cutting machines, and then gradually worked my way through all the machines. I have now been managing processing and finishing for 15 years.‘
What exactly happens in finishing and processing?
’We have a very large machine park that enables us to meet all customer requirements. In finishing, we work with seven embossing calenders and around 130 embossing cylinders. In addition, there are various cutting machines, such as the state-of-the-art Milltex and Jagenberg – both with camera systems and very fast running times. This enables us to process everything – from heavily embossed to the finest papers. Our daily routine is geared towards fulfilling customer requirements on time and as requested.‘
What standards and processes must be adhered to?
‘We work according to fixed standards and there are precise regulations governing possible deviations. When cross-cutting, millimetre precision is essential – both in terms of format and angle. The edges must be precise and clean. It’s always about achieving the perfect cut. This ensures that the paper formats are adhered to exactly.’
Has the technology changed in recent years?
‘The technology has modernised, of course – for example, the Milltex cutting machine, which makes it much quicker and easier to change formats. The speed has also increased in the coating hall. But certain things remain the same, such as the embossing calenders. There are fixed specifications in the collections for how fast you can go, with or without steam, embossed once or twice. If you change too much, the embossing no longer fits.‘
“Anything that is not part of the standard programme is individually tested by us until the customer is satisfied. At Gmund, we are naturally well equipped in terms of all machines, embossing and finishing options.”
Were there any special projects last year that were challenging or particularly exciting?
‘Actually, every day is a challenge. When our sales team comes in with customer samples, it’s all about translating these very specific ideas into reality using our capabilities and materials – sustainably and precisely. When it comes to embossing in gold, for example, we take a step-by-step approach. Anything that is not part of our standard programme is tested individually until the customer is happy. At Gmund, we are of course well equipped in terms of all the necessary machinery, embossing techniques and finishing processes.‘
How do such tests with embossing or varnishes work in practice?
’We mainly create certain surfaces on the embossing calenders, while finishing is carried out in the coating hall. The basis is always the paper colour, which is first defined on the paper machine. All further steps are then based on this until the desired look and feel is achieved. If, for example, a customer wants a special colour, we test different coating variants on it. Special materials, such as natural pigments, are also used. The selected variant is documented, the recipe is stored and a unique paper type is created according to the customer’s individual requirements.
Close coordination between the customer, sales colleagues, technical management, paper production and processing is important in advance for each project. This is because not everything is technically possible, e.g. white coating on black paper. However, with our experience, we can set the right course in advance.‘
Gmund stands for fast and flexible implementation. How does that work in practice?
‘Every sheet of paper passes through our processing department. Everything is planned in advance: How many orders are scheduled for coating, for example? How many layers do we need? The qualification and shift schedule helps us to react flexibly. If there are a lot of delivery deadlines, we also work in two or three shifts. We coordinate everything on a weekly basis. There are daily shipping meetings where we determine exactly what goes out and when. We coordinate deliveries and custom-made products closely with Customer Service. My experience from almost 30 years at Gmund plays an important role here.‘
How does the team work together to ensure that everything runs smoothly?
‘We have 20 people working in production, spread across the entire production process: from embossing and cutting to printing, finishing in the paint shop and loading. We have 25 machines and ideally need people who can operate four or five of them. The qualification plan helps us to organise this precisely. New employees need two to three years before they can work independently on certain machines. Experienced colleagues take care of the training. Only when someone has really mastered a machine do they move on to others. This is how we build up the plan individually for each person.‘
Why should someone join the processing department?
’Because it’s very diverse and varied and interesting work. It’s a challenge. It’s not monotonous work where you always do the same thing; instead, you work on different systems and you can always learn something new.‘
What motivates you personally in your work?
’Yes, Gmund, of course. I belong to Gmund. Otherwise, you wouldn’t stay there for so long. It’s always about looking ahead. And there are always new things to learn.‘