Running Lean, Mean and Green

While Deer Park, N.Y.-based DWS Printing Associates Inc. proudly traces its roots back to 1865, it can also boast that it is a trendsetter when it comes to investing in the most up-to-date printing technologies, while focusing on modern-day sustainable business practices.

David Weil’s Sons Lithographic Company—the original name of the company—was established in New York City shortly after the Civil War ended, printing labels and packaging for the food, beverage, and textile industries. The Staib family got involved with the company in 1888, when Charles Staib joined the company as a salesman. He eventually became a partner in the early 1900s. His son, Arthur, entered the business in 1920.

During World War II, the company contributed to the war efforts by printing maps for the government. Arthur Staib’s two sons, Arthur Jr. and Allen, joined the company in the 1950s and 1960s. Today, brothers Tom and Andy Staib, sons of Allen Staib, lead the company.

Operating for growth

DWS Printing specializes in printing cut-and-stack paper, film, and pressure-sensitive labels for the food, beverage and household industries. In 2012, it moved to a custom-renovated facility, more than doubling its space and suiting the needs of the company for future growth.

“We have a complete in-house prep and art department that services all forms of graphic design,” Vice President Andy Staib notes. “We also offer inventory management programs for some of our highest-volume, top-tiered clients. The market that DWS serves is extremely broad and includes the beverage, craft beer, food, and household product categories.”

During drupa 2012, the company announced it purchased a new Heidelberg Peak Performance Speedmaster XL 106-8+L. The new press is the first in the United States to be configured with the combination of a CutStar inline sheeting system, Hybrid UV technology, and both Prinect Inpress and Axis Control color measurement and control systems.

The CutStar sheeting system will allow the company to buy substrates more economically, President Tom Staib points out. “It will pay off for our customers because ultimately, we will be able to give them superior quality with even more competitive pricing,” he says.

With the new press installation, DWS will take advantage of lower makeready times, expand the company’s product portfolio with advanced UV technology, and will be able to a significantly reduce its waste. This all fits with the company’s Green Initiatives program.

Aggressive sustainability efforts

When DWS moved to its current location, it installed eco-friendly fluorescent lighting throughout the entire production and office space. Heating, cooling, and electrical systems were also replaced and modernized. DWS qualified for substantial rebates through its local power authority as a result of these initiatives.

“We follow an aggressive program to recycle virtually all paper stock used in our print production,” Andy says. “We also recycle all the metal plates, the wood pallets and pallet tops, cardboard packing materials, [and] plastic packing materials.” The end result of the company’s efforts is that it recycles 92 percent of all materials used in the production process.

Customers can visit the company Website (www.dwsprinting.com) to see a running total of the number of tons of waste the company has recycled, number of barrels of oil conserved, number of cubic feet of landfill kept clear of waste, and number of trees saved. “It gives a good visual of what our recycling efforts really mean to the environment,” Tom contends.

“The measurements that we can give to our customers as far as the positive impact we are having on the environment is helpful,” says Andy, who leads the company’s sales efforts. “It is especially helpful to new prospects, that have business models concerned with sustainability.”

In 2011, DWS Printing introduced Legacy Label, its exclusive 100 percent post-consumer recycled, 51-lb. wet-strength paper. Legacy Label is an eco-friendly paper, suited for high-speed craft beer, beverage, and food labeling environments.

“The craft beer segment in particular is growing faster than the broader beverage and food markets, and DWS is poised to capitalize on this trend through Legacy Label,” Andy says. “Legacy Label is manufactured carbon neutral, process chlorine-free, and low-impact hydro. Reception to the product has been excellent to date and we expect this positive momentum to continue to grow in the future.”

In addition, DWS currently uses only low-VOC, soy-based inks. However, when the new Heidelberg press is installed in late 2012 , the company will reduce VOCs to zero with advanced UV technology.

Front-end flexibility

On the front end, the DWS prepress department has been designed to accommodate clients’ needs for immediate turnaround times and flexibility, the company execs note.

“We provide more than just label output for our clients,” Andy says. “Whether it’s processing labels, 3D rendering, providing access to all their digital art assets using our S.T.A.R program (System For Tracking, Archiving, and Retrieval), creating designs from our award-winning design team, Web site development, or commercial and packaging printing, we have all the tools necessary to help them exceed their goals.”

DWS is currently using all major design suites from Adobe and Quark. The company is able to set up custom workflows for its clients with the latest technologies from EskoArtworks, Epson, GMG, Xinet, and AGFA, the Staibs note.

“We have recently moved all our color technologies over to G7 specifications to ensure consistent color throughout the entire prepress process to the final printed material,” Andy reveals. “Our prepress department also offers remote support and training on all software applications for our clients.”

Being a relatively smaller operation than the larger label houses enables DWS to be flexible and provide exceptional customer service, the Staibs maintain. Customers are rewarded with unparalleled lead-time from order to delivery, they say.

“More importantly, our size also allows us to build relationships on a more personal level with our clients,” Andy points out. “We build our business based on long-term partnerships with our clients, not just processing their orders. Our customers are treated with the utmost respect and dignity and they return that gesture with continued loyalty. Many of our customers have been with us for decades. They get the service and quality that they deserve, which is why they continue to align themselves with DWS.”

Looking forward

The Staibs add that unlike the commercial market that depends on print media or printed advertising, which can be vulnerable to the volatility of the economy, DWS specializes in the beverage and food supply chain that is generally more protected against a slowing economy. “People still do need to eat and drink, regardless of the current economic condition, and those food and beverage products need a label,” Andy says. “DWS has a niche in this industry.”

Continuous improvement initiatives and advancements in technology are constantly in motion at DWS. The Staib brothers are now looking beyond the arrival of their new Heidelberg offset press due in late 2012 and already have their next major capital investment in the planning stages for 2013. pP