Automated Workflow
Paul from Nilpeter proclaims, “We live in the age of automation. We can do so much more with less. Everything we have now is a computer that performs a task. Unleashing the science of flexography can now take us to heights we have never seen!”
Anderson & Vreeland calls on flexographic printers/converters to adopt a six-point plan when seeking to use technology to their advantage. Point by point, it reads:
- Implement digital technologies in prepress and printing, wherever appropriate, to reduce labor costs and improve product quality
- Replace analog workflows with digital ones, whenever they can boost productivity without compromising quality
- Work smarter by adopting inventory management systems that reduce labor and automate ordering and delivery of consumable items
- Understand how using new technologies, such as augmented reality, can provide a competitive advantage
- Work with vendors and distributors to help ensure the optimal technologies are being used
- Partner with other print providers to expand and enhance existing capabilities
Todd from Bobst insists, “Optimized automated workflow and machine connectivity features deliver many benefits, such as less output defects—hence less recalls, thanks to immediate correction through preventive action or, in case of deviation, fast identification and adjustment in real time.” He also lauds, “reduction of the chances of errors and inconsistencies, due to manual settings; faster response to customers’ request for new or changed products; implementation of remote troubleshooting; and digital automation systems that manage all the press operations, including embellishments available with inline finishing.”
He stresses, “Advances in process control mean doing away with the fallacies or inconsistencies generated by manual settings that affect the consistency and repeatability of the process. This relates to both on-press makeready and the handling of tooling/sleeves, whereby the use of automated solutions further contributes to the improvement of the process.”
Craig from Martin Automatic cites core concepts. “With regard to automation technology in printing/package printing/web-fed processes, for 50 years we have followed—even trumpeted—the KIS (Keep It Simple) principle of getting a job done in the most efficient, least complicated way. This principle guides us in choosing when, where and how to employ the appropriate technology; so, for example, rather than throwing complex systems into an automatic roll-changing splicer, we look to understand how it will be used, by whom, and under what operating parameters—both present and future. If it makes sense—that is, if there is an advantage—then it’s a good use of that new technology; if the benefit is marginal, or even negative, that will steer our implementation.”
“When technology is combined with the adoption of standards and process control, the result is consistency like never seen before. Today, a printed product will look the same regardless if it is printed on one press, multiple presses in the same facility, or multiple facilities.”
He brings out other questions: “If automation is to replace a human operator, it will necessarily entail additional levels of safety. What are the safety-related consequences of additional automation? What are the initial, ongoing and future costs to install, maintain and upgrade the automation? And with technology comes the need for maintenance, so how will the printer or converter train, hire or outsource personnel for those functions?”
Steven at AMETEK Brookfield also speaks to specifics. “Automatic viscosity and pH control technologies and methods are extremely advanced and very affordable, offering excellent return on investment (ROI)—most times less than one year. Some large printing houses and large flexo press manufacturers are taking good advantage of this; but many other large, medium and small companies are missing this clear money-saving opportunity.”
He claims specialized chambers now control tough process conditions, like foaming. “This need applies for solvent and UV printing flexo, but more often for water-based inks/printing. Automatic viscosity control goes hand in hand with this need and is a top priority to address at many large printing plants.”
Art to Manufacturing
Richard of All Printing Resources argues, “New technology is only useful if it is used!” He maintains, “We cannot keep doing things the way we have always done them. Flexo is truly becoming a manufacturing industry, rather than the traditional graphic arts, where things work one day, but for some unknown reason will not work the next day.” Admittedly, he says, “We all know change is difficult. To get the most out of these new products/technologies requires a partnership with your supplier/manufacturer.”
According to Richard, “To continue to move our industry forward and improve print quality/consistency, flexo converters must employ new technologies that have come into the market in the last five years, such as:
- Workflow automation that reduces common errors and streamlines job processing
- New screening applications that virtually eliminate the fade to zero, as well as many other common print issues
- Flat top dot plates (commonly known as in-the-plate technology) adding consistency to both plate making and pressroom latitude
- Standardized ink sets, such as EG, providing the ability to gang product designs or SKUs
- Software specifically designed for the pressroom, systematically making press-side color matching easier and resulting in improved color consistency throughout the pressrun
Larry of Beta Industries adds, “Now that we’ve spent 30 years getting press operators to understand the value of using a densitometer, we must continue the process by teaching that ‘Density is not color!’” He advises printers to, “Use a colorimeter or a spectrophotometer.” Then urges, “Don’t stand over the computer screen with a pencil and clipboard. Take advantage of the automatic data recording, collection and analysis available in most every piece of QC equipment and software.”
He clearly states, “Your most successful and productive salespeople are the ones who best understand your process capabilities. Engage them in your standardization and process control discussions. Help the production staff understand the importance of a consistent process, versus an occasional prize-winning density or dot gain run. Any conceivable plate curve or color correction can be delivered by electronic prepress, when you give them a stable target. A constantly changing process thwarts their efforts to provide the required plate.”
“With ink being the largest spend after substrate in most plants, think what a 3 percent, 5 percent or 10 percent reduction in consumption would mean while increasing consistency and print fidelity.”
Kodak’s Gill decrees, “Flexo must continue its transition from an art driven/influenced process to a manufacturing process, using standard practices and controls straight through from the leading edge to the average printer worldwide. Flexo is slow in transition because of the complexity of change in the entire packaging lifecycle. Still, it must continue to advance with proven and robust solutions, driving the quality and productivity of the process globally.”
She portends, “The main focus is for the majority of the flexo market to move to the equipment and tools that have been proven over the last few years, to gain improvement without significant risk.”
Standards & Specifications
Richard states, “Deploying new products, technologies and services requires converters to establish targets or aim points. Many new ISO standards have been approved and published to help framework these targets, such as new colorimetric aim points, known as Characterized Reference Print Conditions (CRPCs).”
He testifies, “FTA’s Flexographic Image Reproduction Specifications & Tolerances (FIRST) 6.0 is the perfect source to explain how to implement and document the process control required to achieve these targets or aim points. Customer and brand owner are requesting statistical documentation of the pressrun, which can only be generated by running to predetermined requirements.”
Mike of Saint Clair Systems professes, “It seems like standardization and printing to the numbers must be judged at the outcome stage of the process, working backward to drive process control. This is because of the prevalence of legacy equipment and systems of wide diversity in both age and configuration. Many of these systems are capable of attaining state-of-the-art print quality, but require emphasis on different aspects of the process, in order to maintain adequate process control. It cannot be a one-size-fits-all proposal.”
AMETEK Brookfield’s Steven believes, “The impact of using standardized process controls for printing is a very cost-effective one. Taking out of the equation human error; dissimilarities in how process variables are addressed and adjusted; maintenance, labor and timing; spoilage; quality of end product and even piece of mind—all big contributors to lower operational costs—means a lights out, 24/7, 100 percent controlled process is in place. Of course, it’s keeping the customer satisfied, and in the end, obtaining higher revenues and profits.”
Gill says, “Printing by the numbers, and process control, rely on the standardization and preparation of the components used, and implementation on press. Flexo is one of the more complex print processes, with a large number of variables, so the limiting of changes in the process is a positive.” She then observes, “The plate is in the middle of one of the most complex processes, the multiple transfers of ink from the chamber to the anilox, plate and substrate, the drying demands of the ink film; plus the compressibility of the plate/tape/sleeve combination from the anilox and the impression cylinder. Reducing the number of variables, with fewer changes in plate, tape, anilox, ink, screening, etc., significantly helps to reduce the complexity, and is essential as part of process control.”