Three days...10 sessions...eight hours of exhibit time...approximately 1,200 attendees—demographically speaking, Foundation of FTA's 2009 Annual Forum and INFO*FLEX Exhibition held up to its billing as North America's single largest gathering of the packaging industry's printers, converters, suppliers and buyers, set for 2009.
The event took place May 3-6 at The Disney Coronado Springs Resort in Lake Buena Vista, FL, where the focus was on "Navigating the Future of Flexo," Speaker after speaker (see roster) encouraged listeners to innovate, educate and communicate. The resounding message delivered: "The future is now!"
Forum Chair Colleen Larkin Twomey, MacDermid Printing Solutions; and Co-chair Jean Engelke, Alcan Packaging; built the agenda around succeeding in turbulent times. All presentations, including a poignant keynote address, honed in on efficiency, technological advancement, sustainability, and the debut of FIRST (Flexographic Image Reproduction Specifications and Tolerances) 4.0. Highlights follow.
Honors & Recognition
FTA's Awards Banquet saw an estimated 160 medals and prestigious honors given out to members of the flexographic printing industry. This included:
- Hall of Fame: Mark R. Mazur, DuPont Imaging Technologies
- Technical Innovation: Eastman Kodak Co.’s FLEXCEL NX Digital Flexographic System
- College Phoenix Challenge: California Polytechnic State University
- President’s Awards: Mark Coffman (Dixie Graphics), Paul Lancelle (Eastman Kodak) and Allan Marquardt (Kimberly-Clark).
- Environmental Excellence Awards: AllpakTrojan, Coating Excellence International LLC, Creative Labels and Lauterbach Group.
In addition, 145 Excellence in Flexography Award winners were named, including nine Best of Shows: Wide Web, Exopack; Mid Web, Label Technology Inc.; Narrow Web, Paragon Label; Folding Carton, Cascades Boxboard Inc.; Napkins, Paper and Design GmbH; Combined Corrugated, Lewisburg Container Co.; Preprinted Linerboard, Temple-Inland Inc.; Envelope, Encore Washington Ltd.; and Graphic Design, Coating Excellence International LLC.
World Tour
Renowned Emory University professor and Forum keynote speaker Jeff Rosensweig discussed the “good, the bad and the ugly” of today’s business environment, yet stressed:
- The U.S. economy, by far the world's largest, will stay that way.
- Developing countries are becoming world market competitors, and customers/business partners too.
- While the thought of the declining value of the U.S. dollar is chilling for some, it leads to increased exports.
- Housing markets will bounce back. The population will continue to steadily grow, translating to more buyers for housing and packaged goods.
AFTA Executive Secretary Tony Dalleore, talked about the flexographic printing market in Australia and New Zealand, saying the region represents the fourth largest employer of printing and graphic arts. The wide web market has contracted in recent years, Dalleore noted, which is creating opportunities for smaller printers, as print buyers look to increase their sources. Representing DFTA (Germany), Dr. Martin Dreher predicted that electron-beam inks will continue to advance and observed that wide web presses are capable of reaching 1,000 meters/minute. He also said that the shortening of run lengths will negate the need for such speeds. Dreher insisted that the price of ITR (in the round) plates will have to come down before it can see widespread adoption. Direct-laser engraving has some eight years, he claimed, before it can see greater acceptance.
Alfredo Domador, vice president of operations for B2B Portales, educated flexographers about the Latin American market and said a recent poll that his firm conducted indicated that 13 percent of the region's printers/converters foresaw greater economic growth in 2009 than in 2008. Another 57 percent estimated growth, albeit below 2008 levels. While 79 percent claimed to feel the impact of the global recession, five of the top 10 business responses have involved partnership and innovation. Domador’s poll revealed that 53 percent of respondents plan to buy new presses this year, 52 percent intend to purchase slitters/rewinders, and that 14.7 percent will likely buy them from the U.S., which was second only to Italy (18.9 percent) for exports to the region.
Prepress = Managing Color
Brand color management is fast becoming the newest buzz phrase in a flexographer’s lexicon. Shannon Steele, The Coca-Cola Co. and Mike Butler, Southern Graphic Systems; detailed how they’ve succeeded in translating the term into practice at the Prepress Session. Steele indicated that “Everyone has a stake in consistency.” In fact, she and Butler advised printers/converters to expect package buyers to insist on universal color standards and demand the utilization of both visual and instrumental color measurements. “Color evaluation is the backbone of any brand color management system. It is the common thread that must exist throughout the process of commercializing a brand.”
With a similar message to convey, Jim Breitung of Sara Lee, alongside session co-chair Dan Dietrich of Schawk, talked about managing color on multiple substrates. According to Breitung, Sara Lee owns 100 brands, manages more than 10,000 SKUs globally, and utilizes four print processes (flexo, offset, gravure and digital) across paper, plastic and metal substrates. Both men encouraged attendees to create printer profiles from fingerprinting on the final packaging substrate, compare the color space of the profiles, and create project-specific profiles to ensure all artwork is proofed within the lowest common denominator of all profiles.
Kevin Chop, Diageo North America and Greg LaFond, Matthews Brand Solutions, stressed the importance of consistently communicating color, and advocated that use of common viewing conditions, a universal color language and identical measuring devices.
Ready to Tip
“Great new products may not impact businesses,” said Mark Vanover, chair of the Emerging Trends Session. “But these technologies will impact the industry.” Vanover based his session and speakers on concepts from the book The Tipping Point – How Little Things Can Make a Big Difference by Malcolm Gladwell, who defined the tipping point as “that magic moment when an idea, trend or social behavior crosses a threshold, tips, and spreads like wildfire.”
Jeff O’Reilly of Hewlett-Packard, revealed that his firm perceives itself to be in the consumables business, namely for ink. However, with the decline of personal document printing, HP is looking to expand into labels and packaging. He noted that digital printing represents less than 5 percent of labels. But companies are looking to customize labels—score one for digital. In addition, most are not looking to beat flexo quality, but instead want the same quality at a better price.
Jay Dollries, president, Innovative Labeling Solutions, a flexo printer who has adopted digital, informed attendees that there are opportunities in adding digital printing to a flexo operation, and advised that printers educate brand owners on the difference and benefits of each.
Al Bowers of RR Donnelly discussed the tipping point of expanded gamut. He reminded flexographers of the 1970s when CMYK in flexo had not yet tipped. Expanded gamut, he explained, is in a similar state now. Bowers said it's not just about making reds redder—it's matching spots, increasing the intensity of process images, and enabling “impossible” images. EskoArtwork’s Mark Samworth followed to say that expanded gamut would tip when spot color accuracy and proofing improve. “We have to change the rules,” he proclaimed. The current rules of color approval focus only on color accuracy, and not visual appeal."
Larry Ahleman, Western Michigan University, reported 13.3 percent of the flexo workforce is more than 55 years of age, and an additional 22.9 percent is over 45. Without a young, well-trained workforce to take their place, this will create a large deficit in skilled employees within 15 to 20 years. Internships, he insisted, are an ideal way to cultivate such workers, while bringing numerous benefits to printing/converting operations.
Green Gauges
Printability, sustainability and the all-important link between the two, dominated discussion, with one focal point being substrates, a second inks, and a third stewardship. Environmental consciousness came into clear view for Forum delegates on hand.
Paul Kearns and Marc Edlein explained, "A good substrate is the building block to great printing." Elaborating on the point, they indicated that a package's function is fourfold: contain, protect, preserve and communicate. Advances in substrates, particularly the technical elements of the paper board and films, they argued will have a profound effect on printers/converters abilities to meet and exceed customer expectations. Most notable is the growing demand for green alternatives and the flexibility, innovation and dedication required to go green and establish much more earth-friendly printing plants.
"Environmental issues will drive printing's future," Jose Santiago, Comexi, declared. "Eco-friendly packaging is in demand." He further noted that both "green inks" and recyclable substrates are hot properties. Santiago dubbed present-day flexography as "the start of a new technological era." In doing so, he affixed the "easy but different," label to EB, and immediately noted that its application reduces dot gain, betters image resolution, and promotes in-line converting.
James Ford, Color Resolutions International, stressed the metrics of sustainability in a presentation entitled "Beyond the Binder." He pointed out that ink is composed of resins, solvents, colorants and additives, then noted that the greenest alternative in each component class is coming into higher and higher demand. Defining "green" as "tending to preserve environmental quality," Ford said that he sees sustainability as a growth business. Strategies that printers/converters can deploy or expect to see their peers implement entail simplification of the supply chain and Lean Manufacturing. Both measures are designed to improve pressroom productivity, reduce waste and to some degree promote environmental responsibility.
Ian Hole of EskoArtwork presented guidelines to strengthen flexo’s sustainability performance and stated that collaboration among package buyers, package designers and producers is key to find ways to “do things right the first time.” Environmental impact can be reduced by right-sizing, virtual prototyping, and online review and approval.
Richard Rosenberger of Solo Cup Co. spoke about how his company lowered costs and reduced its sustainability footprint. Solo Cup was using three different platemaking technologies to make 18,000 plates each year. The company evaluated the different systems on today’s market and retired 11 old flexographic platemaking systems for nine new, state-of-the-art thermal platemaking systems. By doing so, the company annually eliminated the purging 240,300 gallons of chemically-treated effluent and 89,000 dry pounds of chemicals. Bottom line: $384,918 will be saved each year moving forward.
FIRST Needs
Forum 2009 saw the debut of FIRST 4.0—FTA's signature resource/reference instrument—and with it, a special session—FIRST: Faster and Better—geared around information about and application of this bold new set of guidelines for flexographic printing. Designers, printers and professional educators stood and offered their unique assessment.
John McDonald of BrandImage-Degrippes & LAGA, spoke about FIRST from a designer’s perspective. He indicated that FIRST supported three main design strategies: stewardship of a brand, disciplined design, and advocacy for prepress and print. McDonald called design a visual solution for a business problem. “Our workflow begins and ends with the shopper.” Robb Frimming of Schawk Inc. spoke from the prepress side, noting that his firm uses FIRST as a guideline, but often goes above and beyond it.
Hood Packaging’s Joe Aker completed the trifecta by addressing the printer’s perspective. The good news: “FIRST offers tools for cutting down cost.” He advised attendees to “commit to what you can do” as “you, the printer, determine the optimum conditions.” When it comes to press characterizations, it is crucial that the substrate match the one used for the job. Another key to success: “Reference FIRST at every possible moment.”
FTA’s Joe Tuccitto proclaimed that TEST (Technical Education Services Team) is using FIRST to change flexo education. “We outlined learning outcomes from each section, identified skills that could be certified, and aligned those to the outcomes.” This has been carried through FTA’s Level I and II skills certification, the soon-to-be released Level III certification, and the plant-level FIRST certification, which, he claimed “CPCs are crying for.”
Getting Ahead, Staying Ahead
Networking and maintaining business relationships—that was the call at the INFO*FLEX Exhibition, May 4-5. Students, printer/converters, prepress providers and suppliers alike—as well as several CPCs—walked the eight aisles and manned 200+ booths on the sold-out showfloor. They navigated the future toward the first-ever Education Pavilion, which touted the wares of major flexo printing/converting colleges. And they continued their education at the Presentation Theater, which featured eight technical briefings daily.
Next Year's Forum
FFTA's 2010 Annual Forum is set for May 2-5 at Paris Las Vegas, Las Vegas, NV. Jean Engelke will serve as chair, with Mark Coffman holding the co-chair role. Presenters' abstracts are now being accepted. Deadline for submission is July 17. Materials can be submitted online.
Roster of Players
Sessions and speakers associated with Forum 2009 follow in concise summary.
Flexo "Round the World
Mark Cisternino, FTA; Tony Dalleore, AFTA; Michael Ferrari, Procter & Gamble; Dr. Martin Dreher, DFTA; Alfredo Domador, B2B Portales; Felice Rossini, Rossini s.p.a.
Prepress
Mark Coffman, Dixie Graphics; Randy Butler, Printpack; Shannon Steele, Coca Cola; Mike Butler, Southern Graphic Systems; Jim Breitung, Sara Lee; Dan Dietrich, Schawk; Kevin Chop, Diageo; Greg LaFonde, Matthews Brand Solutions
Emerging Trends
Mark Vanover, Jeff O'Reilly. Hewlett-Packard; Jay Dollries, Innovative Labeling Solutions; Mark Samworth, EskoArtwork; Al Bowers, RR Donnelly; Larry Ahleman, Western Michigan University.
Flexo 101
Ruth Buckley, Bancroft Bag; Richard Black, All Printing Resources; Dominic Ibarra, Anderson & Vreeland; David Lanska, Stork Cellramic; Catherine Haynes, All Printing Resources; Brad Taylor, DuPont Imaging Technologies.
FQC
Paul Lodewyck, Flint Group; Jean Jackson, Praxair Surface Technologies; Mark Mazur, DuPont Imaging Technologies; Timothy Gostick, MacDermid Printing Solutions; Rich Emmerling, Flint Group.
Substrates
Paul Kearns, Exopack; Mark Edlein, Sealed Air Corp.—Cryovac; Malcolm Keif, California Polytechnic University; Nilesh Savargaonka, Dow Chemical; Marie Dumontier, Fraser Papers; Jay Sperry, Clemson University.
FIRST: Faster & Better
David Nunez, International Paper; Dan Dietrich, Schawk; Michelle Beuscher; John McDonald, Brandimage-Degrippes & LAGA; Robb Frimming, Schawk; Joe Aker, Hood Packaging; Joe Tuccitto, FTA.
Inks
John Daugherty, NAPIM; Joseph Schlinkert, Color Resolutions International; Jose Santiago, Comexi; Malcolm Keif, California Polytechnic University; Andrea Ho, California Polytechnic University; James Ford, Color Resolutions International; Stephen Postle, Sun Chemical.
Sustainability
Allen Marquardt, Kimberly-Clark; Doreen Monteleone, FTA; Ian Hole, EskoArtwork; John Serafano, BASF; Paul Zeinert, Anderson & Vreeland; David Roey, Max Daetwyler; Chris Worachek, MEGTEC; Richard Rosenberger, Solo Cup.
Sponsors:
FFTA's 2009 Annual Forum & INFO*FLEX Exhibition was sponsored by the following companies: ARC International, 3M Company, All Printing Resources, Inc., DuPont Imaging Technologies, Lohmann Technologies Corporation, Mekrom-Degraf, Anderson & Vreeland, Inc., Eastman Kodak Company, and Sun Chemical Corporation, MacDermid Printing Solutions, Max Daetwyler Corporation, and Rogers Corporation, BTG Americas, Inc., Esterlam International Ltd., Flint Group, Harper Corporation of America, and Praxair Surface Technologies, Canflexographics Ltd., Color Resolutions International, Flexo Wash, LLC, Sentry Insurance, and Water Ink Technologies.
