WEATHERFORD, OK—Kodak took a major step toward doubling worldwide production capacity for FLEXCEL NX plates in April. At the same time, it promoted America’s skilled labor, talent and Oklahoma’s work ethic as it broke ground on a $15 million expansion project at its 50-year-old plant.
The 22,500 sq. ft. facility, situated on a 35 acre tract of land, was originally built for 3M in 1967. It later served Imation and Kodak Polychrome Graphics. Today, the 60 member Kodak staff manufacture the thermal imaging layer (TIL) for FLEXCEL NX plates, as well as commercial print products.
Official ceremonies, staged April 20, featured a ribbon cutting by Kodak Chief Executive Officer Jeff Clarke and Oklahoma Governor Mary Fallin. Other dignitaries on hand included Weatherford Mayor Mike Brown; Rep. Harold Wright Jr., speaker pro tempore, Oklahoma State Legislature; Deby Snodgrass, Oklahoma secretary of commerce and tourism; several pioneers who have worked at the Weatherford plant since its opening; and, of course, Gene Meier, the plant manager.
“Today’s celebration brings a focus on the new face of flexo,” stated Clarke. “Differential flexo technology is helping our customers to drive growth, break new ground and transform flexographic printing and the packaging industry as a whole.”
Clarke continued, “Growth and acceptance of FLEXCEL NX plate technology speaks to the strength and opportunity of the flexographic packaging market. We’re looking forward to using the expanded facility, here in Weatherford, to continue helping our customers realize what its unique capabilities can do for their business.”
The soon to be built flexo plate line will be a mirror image and sister operation to Kodak’s existing plate manufacturing facility in Yamanashi, Japan. Capital investment expenditures associated with bringing it online represent one of Kodak’s largest investments since 2000. Points of note associated with the project, as listed by Kodak, include:
- Execution of the plan underscores the ongoing growth and adoption of FLEXCEL NX plates
- Consumption increased 16 percent from 2015 to 2016, exceeding growth reported for the flexible packaging market itself by four times
- The new flexo plate line is expected to be in full production by early 2019
- It will initially concentrate on supplying FLEXCEL NX plates to customers throughout the U.S., Canada and Latin America
One day prior to the public festivities, Kodak conducted an invite only customer and trade media briefing at Oklahoma City’s Colcord Hotel. There, the firm openly encouraged all printers and prepress providers present to “‘Elevate.’ ‘Innovate.’ ‘Celebrate.’ Do more. Look beyond traditional. See the change. Be the change. Become the new face of flexo!”
Chris Payne, president, Flexographic Packaging Solutions Division, opened proceedings by declaring, “Flexo is the future of packaging!” He then reported, “Printed packaging is estimated to be a $286 billion market by 2020. It is currently experiencing a 4 percent to 6 percent compound annual growth rate (CAGR). Flexo represents 39 percent of process print, offset 24 percent, gravure 14 percent, digital 2 percent, screen 2 percent and others 19 percent.”
Payne cited similar results on packaging market share by application, listing corrugated at 36 percent, flexible packaging at 25 percent, label and tag at 12 percent, folding carton at 20 percent and other at 7 percent.
“For cost effective production, flexo is key,” he said. “It’s a game changer for the printing industry. Print capabilities surpass brand needs. Plates surpass printer needs. Progress has enabled it to do high quality reproduction consistently. It’s moved from a craft industry to highly automated manufacturing process.”
Payne’s resounding message held that, “Developments drive evolution.” He stressed considerable contributions made by automated intelligent presses, better drying inks, better anilox technology, high definition plates, digital workflow and the drive to standardize. He also mentioned high definition flexo plates now accommodate both 4-color process and expanded gamut (EG) work, with results on par with gravure. The same opinion was expressed by two customers, one printer and one prepress professional.
Gabriel Jaramillo, Plastilene, S.A., commented on the ongoing capital expenditure program that has transitioned operations in its Latin American plants to high speed and complex production lines which support fast turnaround, quick setup, automated workflow and several other production efficiencies.
Ben Abray, Autumn Graphics, maintained, “Brand owners no longer categorize suppliers by print process. Instead, they look to optimized production recipes and ask, ‘Can you improve fidelity, efficiency, consistency and profitability?’ Today, we see a bright and profitable future for flexo. All of our flexo customers have invested in major capital equipment in the last three years. Flexo has migrated from low value commodity work to higher end customer based packaging.”
Abray concluded with a few more observations. “Printers now complement and enhance their flexo offering with digital capabilities. Key to continued success is meeting higher expectations. Process control is a critical factor moving forward. We must sustain improvements and keep moving. Comprehensive color management workflow is imperative.”