SPRINGFIELD, MA—Utilize technology and increase your profits! That, in a nutshell, was the message put out by MPS Systems North America and a host of printing partners that included ACTEGA, Advanced Vision Technologies (AVT), Apex, Avery Dennison, CC1, Dion Label, Graphbury Machines, Kocher + Beck and Kodak. These forces came together to offer a morning long seminar delving into the intricacies of flexographic package print and production.
Held June 22 at the Sheraton Springfield Monarch Hotel in Springfield, MA, it attracted 45 individuals. Representatives from 15 different printers and converters came poised to listen and learn. Serving as master of ceremonies was MPS Systems’ Michael Weyermann.
A key theme of the day came into focus quickly: Minimization—doing more with less. It was described as a top challenge currently presented to flexographers. Among potential strategies unveiled was transitioning complex, 8-color process work to 4-color. That, of course entails, elimination of spot colors.
The issue was discussed at length as six speakers took to the podium. Later in the day, with a site visit to Dion Label in nearby Westfield, MA, the concept was illustrated with the running of a label job designed with that purpose in mind.
Keith Nagle, ACTEGA, told listeners pH meters are essential when running water based inks, though he admitted relatively few printers utilize the simple device. Another point made was that pigment should be seen as a significant portion of final ink cost and, as such, should weigh into all ink selection decisions. Returning to the day’s theme, Nagle said, “CMYK for spot color reduces plate cost, setup time and spot inventory. It also frees up print stations for other uses.
Doug Weiss of Kodak had similar advice. “Today, flexo is printing better text than gravure and holding better color than offset,” he explained. “Flexo technology is booming and evolving.” On the plate side, he explained, “Good plates can speed up the press, speed lamination, save money, save tape, allow for smaller anilox roll inventories and cut substrate costs attributable to waste.” He advocated examining pixel for pixel imaging, strong and supported dot structures and complex patterning to carry the ink. “Look at plate spend, not plate price,” he cautioned. The implication—Savings can accrue.
Aaron Lessing of Apex spoke to intelligent ink metering and encouraged application of ceramic and lasers in perfect combination. The result: stronger, more consistent, precise dots. Among the insights he offered, “Technology with good potential offers possibilities.” He said work is currently being done to ensure consistent density is delivered at all speeds.
Kees Nijenhuis, MPS, suggested printers and converters follow the same strategy as his firm. “Focus on your operators. Improve your results.” In demand today: complex machines that are simple to operate. Nijenhuis said the industry is working to take automation from an art to a science. “It’s separating printing from converting.” Describing the EF press as indicative of the trend, he noted the model is available in 13-in., 17-in. or 20-in. web widths and keeps evolving with the advent of new technological developments. He listed it as MPS’ flagship press.
John Dion, of Dion Label, spoke to his firm’s history, vision and press positioning strategy before inviting all to the plant for a look at those words put to action. Dion Label was born in the 1960s, has roots in offset and later turned to flexo. Innovation and ingenuity have long been a core competency of the business, according to Dion. “That’s by necessity.” Listing out longstanding challenges, he pointed to variety, size and geographic diversity, and said that as industry customers left the area, the firm evolved into new applications and product classifications, moving from emphasizing food products to medical.
Dion said the environment requires versatile equipment that is capable of multiple things. “Modularity is key. We can laminate inline, position inserts, register the web and add auxiliary equipment. It is essential that we be able to changeover from one process to another with relative ease. Modern equipment addresses essentials like registration, pressure, control and speed with little to no intervention.”