Dwane Wall, president of Creative Labels of Vermont, a second-generation, family owned label printer located in Winooski, stated how important it was to align with a vertically integrated supplier. “When we made the decision to move from traditional solvent to thermal processing, it was a big step for us. Having a partnership with a supplier that could provide a total solution was key. We converted our entire workflow to a digitalized platform. Utilizing cloud-based software solutions allows us to better communicate with our customers in transferring artwork files and storing proofs. This workflow is designed from the ground up to work with our digital imager, thermal processor and plate materials. The result is a streamlined process that provides the highest-quality plate, faster and more efficiently.”
Press Platforms
The digital manufacturing journey continues throughout the pressroom. The flexographic press platforms of today offer a range of automation and clean-hand operations. All are designed to engage with a modern workforce and utilize the stream of IIOT communications both with inline features as well as production control.
Servo technology has taken a strong hold on managing the motion control of the presses and intelligent operations. These control systems are ideally suited to meet the web transportation requirements of the thinner materials and flexible packaging substrates requiring improved heat and tension management. They also provide the ability to preposition cylinders for inking and impression, preregister and auto-register functions, that greatly reduce makeready time and waste. These features allow us to manage the flexographic process as a predictable and repeatable science, rather than a craft.
All job parameters can be stored in a digitalized data base where every production run can be recalled by any operator at any time. As we continue to manage a workforce crisis, having a platform that can perform and produce on a consistent basis, regardless of operator experience, is key. Applying FIRST methodology allows us to apply the science of flexography to an automated platform for optimum results.
The press also has the ability to directly communicate with the OEM through IIOT for technical service, analytical information on performance history as well as training needs. This saves a tremendous amount of cost and time, utilizing a virtual service operation versus the associated downtime and expense of waiting for an onsite technician.
Many of the inline features installed on narrow web presses can also provide tremendous value and consistency in our operations. Inline color management control and 100 percent inspection systems continue to be one of the leading technologies in reducing makeready times and waste. Having the ability to measure more than 100 color patches per repeat, at speed, and provide instantaneous color data to the operator, is breaking new ground. This real-time data can also communicate with the press control systems to optimize inking and impression settings to predetermined, profiled expectations.
At the forefront of the digital manufacturing era in narrow web printing has been the evolution of the digital printing technologies. Both toner and UV inkjet solutions have provided endless opportunities for the narrow web converter to uncover never-heard-of efficiencies and speed to market. As a plateless printing solution, the need for conventional plate processing, mounting and hardware has been eliminated. The color management is all done through sophisticated software. Registration is no longer an issue.
The ability to RIP and print has brought a whole new workhorse to our industry. Converters have been able to easily adapt to the proliferation of SKUs and speed to market. Hybrid presses have provided an all-inline printing and converting solution, reducing waste and material movement. A new generation of consumers, regional markets and the explosion of e-commerce has driven brand owners to change the way they go to market.
Narrow web converters have capitalized on the digital process to provide quick turn, high-quality, variable data printing as a rewarding solution. I asked one very prominent converter, who chose to remain anonymous, “What would you do to future proof your operation?” and the answer simply was, “Go digital!”
Digital printing has been a very good complement to our traditional operations, offering all the outlined advantages, while opening up capacity on our conventional platforms. Combining the technologies into a full hybrid solution has turned out to be a triple threat.
Tom Staib, president of DWS Printing, a fourth-generation, family owned and operated label converter in Deer Park, NY, founded in 1865, has made the change to digital hybrid printing. “Our newest platform is an 8-color flexographic press with full converting that includes inline digital printing. It has proven to provide tremendous flexibility. If we need to run a flexographic job, at full speed, we can. If we need to run a quick-turn digital production job, we can. But if we need to run a very sophisticated label design, we can run flexographic, digital with full converting and embellishments all inline in one pass. This flexibility has allowed us to expand into new emerging markets.”
Opportunity Knocks
Endless opportunities to continue to streamline our operations, become more sustainable and improve our efficiencies are out there. Change brings new advancements. Innovations make it easier for customers to communicate and do business with us. Conversely, it will make it easier and more efficient for us to do business with them.
Current industry conditions have clearly shown us what the new normal will look like. We will offer more sustainable packaging solutions to be more responsible to the environment. Our operations will be a more virtual world, working with single-source suppliers managing supply chains through IIOT.
Automation will provide big data connectivity and analytics throughout our entire operation, from a digital storefront all the way through logistics and fulfillment. As part of the new normal, I look forward to learning a lot more about these innovations at FTA’s Virtual Fall Conference 2020.
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