The Long Haul

Offset printing is a standard bearer for quality in package printing and has a long history of successful use in the folding carton arena. As much headway as flexographic printing has made during the last decade, its quality is still measured against that of offset.

It is not surprising that offset printing is still the process of choice for many folding carton converters in the packaging market. Many suppliers with a long history of providing high-quality printed products to their customers hold firm to their successful roots.

Carded Graphics, located in Staunton, Va., is one such folding carton converter that focuses entirely on offset printing—sheetfed offset, specifically. It uses the standard-setting, high-quality capabilities of offset to provide printed products for its customers in such markets as food, medical, consumer goods, tobacco, hardware, pharmaceuticals, and specialty products and applications.

Carded Graphics has been in business for 25 years, according to Murry Pitts, company president. He bought the company in April of 2006 from Manchester Industries of Richmond, Va. “At the time, Carded Graphics was a small regional folding carton producer located in Staunton,” he relates. “Prior to 2006 I owned a company called Pell Paper Company headquartered in Elizabeth City, N.C., which was founded in 1928. I merged the two companies together in May of 2006 in our present highly modern facility in Staunton.”

The company is in business for the long haul. “Our number one operating philosophy is doing what the customer wants and needs,” says Pitts. “This feeds into our goal of having long-term customers as partners for long-term growth.” To accomplish this, the company focuses on technology, speed to market, service, and quality to set itself apart from the crowd.

Enhanced operations

Carded Graphics recently expanded its existing building by 60,000 sq. ft. to accommodate its acquisition of a Heidelberg Speedmaster XL 105 press and future press growth. The expansion effectively doubled the size of the company’s facility to 120,000 sq. ft. With the installation of this new press, the company was able to replace two older presses. It now operates a 6-color plus coater Roland 700 press, along with the Speedmaster XL 105, which includes an aqueous coater and provides hybrid UV capability. According to Heidelberg, this press is one of the first XL 105 presses with hybrid UV capability to be installed in the U.S.

The new press allows Carded -Graphics to handle an expanded range of materials. “We can print on just about any substrate possible—CCNB, SUS, SBS, poly 1-side and 2-side, chip, N-flute, plastics, and 70-80 lb. litho,” says Pitts. “Our capability now covers the full spectrum. Some of our customers request foil board and other substrates, and we can now do that internally. There isn’t much we can’t print now.”

The Speedmaster XL 105’s UV capability was a big selling point for Pitts. “We chose a hybrid system for its ease of use and production capability,” he says. “We can now switch between aqueous coating and UV inks easily, which is a big advantage and enhances our capability portfolio.”

To enhance and complement the Speedmaster XL 105, Carded Graphics also purchased a full prepress system from Heidelberg including a Suprasetter 105 platesetter, Prinect Prepress Manager workflow system, Prinect Image Control color measuring system, and Prinect -Inspection Control, which monitors color consistency across the sheet.

“We use the Heidelberg system in every aspect of our prepress workflow,” says Pitts. “The color management and trap features give us the control to manage a project from proofing to production, and the Prinect Signa Station allows us to merge 1-up structures into manufacturing layouts easily and efficiently. The quality of these tools can’t be understated as a competitive advantage.”

The result, says Pitts, is that Carded Graphics can provide products at much higher color and consistency standards, “surpassing our clients’ expectations for what is acceptable in the packaging industry,” he notes. “In addition, our production efficiency has increased since the prepress color management information is directly relayed to the printing press, resulting in faster makereadies and less material waste.”

A bright future

Package printers are facing a multitude of challenges in today’s trying times. Pitts sees the rising costs of raw materials and the downward pressure on finished goods pricing as the biggest issues his company faces. He believes, however, that Carded Graphics is well positioned to compete in its selected markets. “We think of ourselves as a market leader with all the new technology we possess,” he contends. “Quality, press speeds, consistency, various substrates we are able to process, and UV technology—all are driving us to be more competitive and leading the charge. In addition to the new press capabilities, we have just purchased and brought online a new Bobst SPanthera 106 LER Diecutter.

“All of these areas provide us with additional capabilities and make us much more competitive in the marketplace,” he continues. “With all of the various systems on the press, we can prove to customers that we can provide consistency that is measurable and defined.” pP