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Recapping FTA’s FORUM & INFOFLEX 2023: Traditions, Reimagined

Assessments are in! All indications speak to the success of both FORUM and INFOFLEX 2023.

Collectively, some 80 percent of attendees who responded to FTA’s follow-up call for appraisals rated the combined FORUM & INFOFLEX experience as “good,” “very good,” or “excellent”; with the majority responding, “very good.”

At FORUM, the quality of presentations, topics addressed and time allotted for each session, all received positive endorsements. Once again, the most popular response was “very good.”

At INFOFLEX, 88 percent of attendees completing FTA’s satisfaction survey said they were able to both conduct business and network effectively. As a result, 96 percent assigned value to the event. Better than 60 percent identified new solutions that they planned to implement at their plant in the short-term future. Two-thirds of those polled indicated that they spent nearly every minute of exhibit time on the show floor. An additional 30 percent were there at least six of the nine hours.

What kept them engaged?

By all accounts, the multitudes of flexographers who came together in Columbus, OH April 16-19 challenged themselves to create a better future. Their focus was on production efficiencies, quality controls, evolving customer expectations, supply chain workflows, productivity, purpose, and of course, personnel. Calls to action were issued and embraced.

Agenda items touched on everything from sustainability to data analytics, standards to optimization of processes—from plateroom to pressroom. Fundamentals were emphasized. Automation, integration, artificial intelligence and machine learning were spotlighted. Color measurement, expanded gamut printing, multiprocess printing and the expanding footprint of hybrid presses were identified as critical concerns in reinventing and revolutionizing business models for the days ahead.

Planner’s Perspective

Laura Wright, FORUM chair, CSW Inc, reflected on what was accomplished and said, “I was very impressed with the work of our session co-chairs and speakers this year. They really embraced the topics and objectives, as well as the idea of clearly offering value to the audience. The presentations and discussions were professional, informative and engaging… Kudos to the FTA staff for pulling off another outstanding FORUM!”

Jason Cagle, co-chair, MacDermid Graphics Solutions, observed that choices of 20 years ago may not be most applicable today and added, “In the printing industry, clients often maintain age-old methods, stating, ‘We’ve always done it this way,’ so our conference theme, ‘Tradition Reimagined,’ directly addressed this notion. I was immensely impressed and proud of our session chairs, who developed insightful content that encapsulated the idea of reinventing customs. They presented fresh approaches through process control, employee recruitment and training, and new technology.”

Session Snapshots

“Sustainable Business, Sustainable Planet,” chaired by Julian Fernandez of Esko and Justin Green of Comexi, linked people, profit and planet. Elizabeth Rhue, Sonoco, acknowledged that, “We are challenging ourselves to create a better 2030,” then cited the need to address consumer product companies’ push toward net neutral/carbon zero. Tools to meet the demand: mono materials and biodegradable resins. Expectations: standard metrics will be developed.

Dan Collins, C-P Flexible Packaging, stressed renewable resources, reusable and compostable materials and suggested the market is going to continued size optimization, converting waste to energy, qualification protocols, color control and running to the numbers. Mike Ferrari of the Consortium for Waste Circularity briefed regenerative robust gasification (see FLEXO’s February 2023 issue).

“Off the Shelf and into Your Cart,” led by Jennye Scott of Berry Global and Kristen Olberding of Olberding Brand Family, showcased predictable, consistent production via a case study on the full packaging development campaign for Jergens Melanin Glow. Intent, engagement and control were profiled with comment offered by panelists and process owners Jon Arnold, Berry Global; Beth Baker, Kao USA; Jeff Brockman, Olberding Brand Family; Megan Burns, Berry Global and Paige Massa, Kao USA.

“The Great Tape Debate” saw Catherine Haynes of All Printing Resources and Scott Rickard of DuPont, engage panelists Alix Guyot, tesa tape, Mat Waddell, 3M, Alan Rogers, Polymount USA, Stan Riches, Lohmann Technologies and Jeff Randazzo, Controlled Displacement Technologies in a discussion on the composition and characteristics of mounting tapes, mounting sleeves and displacement cushioning tape, while reviewing results of a pre-event FLEXO Flash Poll and collecting live audience measurements that proved a near match to the poll. (See FLEXO’s March 2023 issue). The greatest challenge? Staying ahead of developing trends—automation, sustainability, high turnover.

“Find ‘Em, Train ‘Em, Keep ‘Em”—Bobby Congdon of Clemson University and Hank Welter of TC Transcontinental Packaging accepted the charge of delving into recruiting training and retaining, with the assist of three panelists. Claudia St John Affinity HR, noted everyone is hiring, then detailed employment trends vs. population trends for next decade with attention to Millennials and Gen Z. Her assessment: “The problem for print is to overcome the perception of gender-based—male, low pay, unskilled workforce and poor environmental footptints.” Her suggested solution: “Stress meaningful work, freedom and flexibility, plus adequate compensation.”

Sheri Hudachek-Lantz of TC Transcontinental indicated that “Employees expect their job to have a significant sense of purpose.” She suggested embracing a multi-factional approach involving rotational assignments, multi-location exposure, continuous coaching hybrid learning—all coupled with early financial recognition.

Shawn Oetjen of AWT Labels & Packaging targeted recruiting costs, onboarding costs, lost productivity, opportunity costs and cultural impact replacement costs that he estimated at 1-3 times annual salary. “That’s a real problem when a department of 12 goes through 27 people—225 percent annualized turnover.” Initial advice: “Look to increase pay, add headcount and provide additional training to improve processes.”

“The Value of Color Measurement”—Jason Campbell of X-Rite and Dan Uress of MeasureColor, assisted by panelists Ben Abray of Autumn Graphics; Bob Coomes of PPC Flexible Packaging; Michael John of 3M; and Robert Ciezczak of INX International Ink Co delivered the resounding message that resonated throughout FORUM: “Quality earned is dollars saved!” They proclaimed, “Digitizing color provides single sources of truth, achievable targets and opportunities for quality and process improvements.”

In “Color Throughout the Workflow,” Jessica Harrell of SGS & Co and Kevin Bourquin of Cyber Graphics expanded the examination of color and its impact. The session saw International Consultant Dr. Kai Lankinen discuss the potential to migrate legacy jobs to expanded gamut print, with the expectation that, “OEE improves. Setup time and waste is reduced. Cost savings is achieved and carbon emissions drop.” Aileen Chiu of Sun Chemical then spoke of the relevance of color management in white ink and offered specific advantages—increases in gamut size and increases in opacity.

James Summers of Just Normlicht talked to LED lighting’s impact on color. Noting, “Light impacts the entire supply chain workflow from concept to delivery,” he recommended, “Optimize integration of light into workflows.” He foresees broader use of more universal light communication standards. In closing the session, Charles Spontelli and Bill Birkett offered an encore performance of their Fall Conference presentation “The Optimal Method for EG Printing Applications.” (See FLEXO’s September 2022 issue).

“FQC: Respecting the Past While Focusing on the Future” featured Jean Engelke, FQC Committee Chair and Joe Riccardella, ABX Packaging, as they singled out numerous research initiatives in the session they put together. Specifically, the FQC Plate Life Project was briefed by Kevin Schilling, Miraclon and PJ Fronczkiewicz, DuPont. They stressed, “Plate thinning and hardening are not reliable enough to use as indicators for plate replacement,” then reported, “We are attempting to create industry-wide thresholds for plate thinning and hardening that could have ill, unintended effects, causing printers to discard plates too early.” Their recommendation to date: “Individual facilities who have issues with mottle or TEV may find benefit in determining an in-house specification. Proper plate care can be your best advocate.” (Full report in July’s FLEXO).

Congdon briefed the Measurable Slur Target project and said, “We learned anilox volume makes a difference.” Outlining next steps, he decreed, “We plan to evaluate targets for sensitivity among process variables, like anilox, substrate, ink and press type.”

Students played a large role in the session program, with Jose Canas of Central Piedmont Community College in Charlotte, NC presenting his 2022 Gary Hilliard FQC Scholarship-winning research into “The Impact of Various Cleaning Methods for Anilox Rollers on Cell Volume and Print Density.”

The 2023 Appalachian State University Phoenix Challenge team—Dylan Connell (team leader), Mattie Felker, Heather Byron, Rebecca Hartung, McNeil Johnston and Sean Byron, with Tom Reeves as the faculty leader—briefed their project from concept and development, through client approval and actual production.

“Flexographic Essentials”—Dr. John Anderson of Miraclon and Brad Gasque of DuPont—walked presenters through fundamental processes and encouraged comment on potential for optimization. Here, Zachery Blackburn of CPCC addressed plates, their parts and the plate making and mounting processes, by offering advice on optimizing processes and adhering to Flexographic Image Reproduction Specifications & Tolerances (FIRST) methodologies, stressing “Documentation is critical for repetition.”

Kenny Tucker of Clemson University tackled ink and ink delivery systems, which launched a discussion into all components of the ink metering process—from ink to anilox roll, to ink pump, doctor blade and substrate. His message with so many options, “Optimization is key.”

Becky Bunch, MacDermid Graphics Solutions, offered an assessment and fundamental format highlights for central impression, stack, inline narrow web and inline corrugated presses. In the process, she launched into a primer on impression and registration controls.

“Flexography: Yesterday Today and Tomorrow,” a session chaired by Rory Marsoun of Esko and Marek Skrzynski of CSW Inc, honed in on FORUM’s theme, Tradition Reimagined.

Panelist Jill Tapia of Cornerstone Strategic Brands addressed the design aspects of packaging, pointing to challenges she envisioned in the future. Heath Lukens of HYBRID Software talked to technology necessary to support virtual retail and 3D graphics of the future. Birgit Plautz of GMG Color addressed color management, AI’s impact on color profiling and the near-term outlook.

Brian Cook of MacDermid Graphics Solutions noted applying data analytics and machine learning could transform flexography as a whole and affect prepress deliverables, as well as tooling used in the pressroom. “AI is likely to deliver big benefits, but not without initial challenges.”

Nathan Rank of AV Flexologic tackled automation and all it entails, including how it will expand its influence forever more. Garrett Taylor of SOMA pointed to the drive toward efficiency, offering a look at how past developments became commonplace and imagining what the future might bring. Chuck Slingerland of Durst looked at the future of digital printing and how flexographic printers can benefit from it, stressing, of course, multiple platforms positioned in the same plant and increased reliance on hybrid options.

All in all, FORUM’s purpose came into clear sight over four days in Columbus: maintain flexography’s vitality and viability through action-oriented plans, designed to carry package printing practitioners forward, guaranteeing delivery of top-quality print at maximum profit and minimum stress.

Industry Accolades

The honorees announced at FTA’s Awards Banquet, held Sunday, April 16:

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