Orbytel's Packaging Solution from Heidelberg

HEIDELBERG, GERMANY—August 28, 2013—Formerly an all-digital operation dedicated to production of flexible packaging, labels and wide-format display work, Orbytel Print and Packaging now utilizes Heidelberg's full integrated solution to provide its customers with a one-stop solution to their packaging needs.

The centerpiece of Orbytel's solution is a highly automated five-color Speedmaster XL 75 with full UV, Prinect Inpress Control inline color measurement system, AutoPlate XL and InkStar automatic ink feed. A Suprasetter 75 CtP unit with workflow lends support on the prepress side, while a KAMA ProCut 74 die cutter provides flexible postpress processing. A special prepress link between Prinect Prepress Manager and Orbytel's packaging-specific EskoArtwork workflow provides the company with intelligent JDF connectivity.

Broad Menu of Expert Services
"We always have been intent on growth," said company president Mark Uvlin, citing the company's 50-year history and 20-year evolution from print broker to manufacturer. Founded in 1964, the company bought its first rollfed digital press and commenced the in-house production of short-run pressure-sensitive labels in run lengths from 500 to 100,000 with versioning in 2004. It later expanded into flexible and rigid digital wide-format display work and flexible film packaging. Today, Orbytel's services range from CAD design and prototyping to labels and flexible packaging, to retail displays and signage created for customers in the food and beverage, consumer products, cosmetic and chemical industries.

Of Orbytel's decision to expand into robust folding carton production, Uvlin said, "As experts in the product label field, we were ready to expand into the carton market. It was a natural fit." The new Speedmaster XL 75 UV will enable Orbytel to go after the larger, "meatier" carton and display work the company couldn't handle with its digital equipment, he explained. "We already knew that many of our customers had channels of distribution for their products and needs across all three of our product lines."

Appealing to the Source
Uvlin took no chances that his company's relative inexperience with offset printing would impede the success of the new venture. "We did shop around, but having done so, came rapidly to the conclusion that we would go with Heidelberg," he said. "Anytime you start a new venture or expand product lines and markets, you look for a partner to support your effort," he continued. "I have tremendous confidence in Heidelberg technology, and feel secure in Heidelberg as the supplier of an integrated solution that includes equipment, plates, chemistry and other supplies, not to mention ongoing access to the best expertise in the business. Heidelberg offers so many valuable services to get its products to market."

As one of the nation's leading all-digital custom label printers, Orbytel places a premium on flexibility and cost efficiency, features that are amply reflected in its choice of the Speedmaster XL 75 UV press.

Capable of production speeds to 15,000 sheets/hr, Orbytel's Speedmaster XL 75 boasts fully automated simultaneous plate changing, optimized washing programs, and a fully automated ink feed to ensure continuously stable ink density. These features, in combination with Prinect Inpress Control, enable the fledgling carton printer to make ready in less than 100 sheets, giving Orbytel "a clear advantage over our slower competitors," Uvlin said.

New Tools
Given Orbytel's interest in providing fast, flexible, value-added solutions to its customers, the XL 75's high-end DryStar UV system will help Orbytel open the door to new customer segments and profitable growth, including printing on plastic and other non-standard substrates. Fully integrated into the press at the factory, the DryStar UV features CoolCure technology that speeds production, shortens wait times, and significantly improves print quality when working with temperature-sensitive materials. Thanks also to Heidelberg's CANopen technology, DryStar UV dryers are operated centrally at the Prinect Press Center. Instant Start UV permits the UV dryer to remain in standby mode during blanket and impression cylinder washups, eliminating long waits and promoting longer UV lamp life, with the potential to boost productivity up to 25 percent. The company also has the option to run in low-energy UV (LE UV) mode on less heat-sensitive substrates, should the need arise.

"UV is the most exciting feature of the new press. It also presents a significant learning curve," Uvlin said. "Our previous experience with UV was limited to flood coating our digital products. Between getting used to our new offset workflow and mastering the art of UV printing, we have a lot of work to do," he acknowledged, "but we look forward to the challenge and to making the most of the efficiencies we've gained. Heidelberg has given us the tools we needed to expand and succeed."

Source: Heidelberg.