Respecting the Needs of the Trade

Short-run printing is a reality today for any package printer, and a converter’s ability to adapt to this reality will go a long way toward customer retention. Being able to offer customers the option of shorter runs is the equivalent of offering them a new product—such as a new substrate, a specialty ink, or the ability to soft proof. However, integrating the shorter jobs into conventional press runs can be a challenging proposition. On the one hand, no one wants to turn down business, but on the other hand, fitting the shorter job in between two longer runs means more planning and makeready. Profecta Labels, Boucherville, Quebec, addressed this challenge by investing in a digital press and associated finishing equipment.

Building a network

Profecta Labels was born from the merger of two companies—Proflex Labels and Perfecta Labels—in 1997. Owners Pierre Roberge and Sylvain Rivard founded Proflex Labels in 1992. During their first five years as brokers, Roberge and Rivard saw the need for a trade manufacturer that not only had hands-on experience and understood the label market, but also a supplier who would make the commitment to support and respect the needs of the trade. The knowledge each gained during those first five years became the basis for Profecta’s corporate philosophy.

Merging Proflex and Perfecta began the next phase, which was “building a network of agents throughout the province of Quebec who would distribute our products while continuously working to expand our product lines,” says Roberge. The business plan worked. “Over the years,” he adds, “principles like sharing information and honoring commitments have made us a reputable, dependable supplier in the eyes of our agents all over the country.” Since its founding in 1997, the mission of Profecta Labels has been “to develop the pressure-sensitive trade market and offer a complete and professional manufacturing alternative for brokers—a supplier who understands and respects brokers.”

Sales-oriented philosophy

Providing the latest technology to its customers allows access to new opportunities, and is what, according to Roberge, makes the company distinctive. “While many companies are production-oriented, Profecta prides itself on being sales-oriented,” he says. “Profecta Labels was built with the total collaboration and loyalty of our agents and we remain centered on meeting the needs of end users in all markets through these agents. Continuing to provide the latest in technology so that they have access to new opportunities is one of our commitments.”

Profecta also provides its agents with training and marketing tools so they are equipped to sell the solutions. “Our research and development team is constantly testing new inks, new stocks, new methods of production, and doing research in various markets to stay on top of the latest trends influencing markets,” he adds. “As a result, we create new products that accommodate customer needs on a bi-monthly basis.” Profecta sends e-newsletters to its agents informing them about new opportunities, new products, and detailing new equipment.

Process flexibility

Profecta uses a variety of flexographic inks to suit different applications and substrates. Roberge notes that water- and UV-based inks remain the most commonly used, but Profecta also supports applications requiring specialty inks.

The company prints on an array of substrates that includes pressure-sensitive label paper, synthetic stocks, films, tag stocks from 8 pts. to 12 pts., as well as 60-lb. coated stock. “We also have special construction applications such as redeemable coupons, where a pressure-sensitive material is laminated together with a 60-lb. stock,” Roberge adds.

Profecta uses Aquaflex, Mark Andy, and Allied Gear narrow-web presses, and it recently added an HP Indigo ws4050 and Rotoflex Vericut2 at its 25,000-sq.-ft. facility to produce its labels. Target markets include pharmaceutical, nutraceutical, food and beverage, consumer durables, chemical, and retail.

HP/Rotoflex combination

Fifty percent of Profecta’s business comprises short runs of less than 6,000 linear feet, and that number is ­growing because businesses seek to have little inventory and greater flexibility to change the designs in order to stay ahead of the competition, explains Roberge. The addition of the HP Indigo press means Profecta can now offer the option of shorter runs to its customers. “The Indigo has opened up a market we couldn’t have touched before. Now we are seeing new orders from existing customers, and new clients are bringing different applications,” says Roberge. “We are now in a position to offer the best of both worlds: flexo for long runs and digital for short runs.”

Profecta has found that the HP ­Indigo/Rotoflex Vericut2 combination enables it to do small-volume print runs from start to finish, reducing downtime on its conventional units. When the two machines are combined, according to Roberge, a streamlined label production facility is formed, capable of meeting short-run, on-demand requirements for all segments of the label market.

By switching the small runs Profecta had been running on its flexo presses to the digital press, “we have substantially reduced the downtime and also have opened up a lot of hours for longer runs on the existing flexo presses,” says Roberge. “This should retard the purchase of new flexo equipment for some time.” Other resolved issues include faster turnaround, increased quality of print, reduced waste, and simplified proofing process. “The proof the customer receives is output on the HP Indigo on the actual substrate, eliminating any confusion or misinterpretation,” Roberge adds. “By reducing the waste and [downtime], we have begun to penetrate new markets with new and existing customers.”

Profecta’s Vericut installation includes a laminating station, dual rewind shafts, and a servo-driven flexographic printing unit for spot varnishing and printing. Working with the same principles as semi-rotary diecutting, the unit includes first impression positioning with the advantage of flexible plates.

Digital not the end-all solution

Adding the digital press/finishing solution has paid dividends because the shorter runs are printed on a dedicated system, instead of Profecta’s flexo presses. But Roberge cautions that a digital press will not solve all problems. “The only advice I could give would be to take a hard look at what you are printing, for whom, and do the math,” he explains. “The purchase of a digital press is not going to solve all your problems, but consider [the consequences of] competing with someone who [presently] has the technology. Customer retention is the name of the game!” pP