Short Runs are a Tall Order

Short-run printing is no easy task, but when done right, the rewards can make it all worthwhile.

PACKAGE PRINTERS ARE facing a future marked by shorter production runs that may pose challenges for even the best of today's printers. Meeting these challenges head on will require investment in technologies that are geared toward the ultimate in flexibility.

Printers will be getting all the help they need from press manufacturers who are making tremendous strides towards maximizing the uptime potential of their new press offerings. "The well-known trend in the market is toward smaller runs for various reasons," observes Terry Trexler, product manager for Gallus. "We understand the pressure printers are facing to provide just-in-time (JIT) production, multi-SKUs, and versioning. Our innovative focus is on making the short run as cost effective as possible for the printer."

Although much of the innovation in new press features is targeted toward the needs of short-run printing, Mac Rosenbaum, vice president of Aquaflex, states the overall benefits that these new features can provide.

"Most printers who successfully print short-run jobs find themselves with a mix of both short-run and long-run work," he says. "Optimizing for the short run only improves your profitability on the long runs. The key to more successful short-run and long-run printing is flexibility, and the ability to move up to more complex jobs that generate greater profits."

High-tech is the answer

There are several technologies that press manufacturers are incorporating into press designs that focus on the key goals of reducing changeover and makeready times. Trexler provides a run down of several of these technologies, along with their impact.

"Our move to sleeve technology for the anilox rollers and print cylinders is one example. In addition, automation and single-drive technology greatly reduce the machine set-up and changeover times. The use of fully integrated servo drive technology allows the printer to preset the press and web tension from the computer memory for repeat jobs. New jobs are set up from the start almost on register and are quickly adjusted with automatic register control."

In what Trexler calls "the ultimate in short-run printing," Gallus' newest press, the RCS 330, provides the capability to perform complete changeovers without shutting down the press. Gallus demonstrated this "flying imprint" concept at an open house held in April. By having three print stations set up and ready to go for the next print run, the RCS 330 was able to switch from a ketchup label to a mustard label in about four seconds, at full run speed and in register. Gallus says that certain changeovers can be done on the fly, register to register, within one print station to print station length of material.

The key to RCS 330 capabilities is its servo drive technology. This is augmented by modular-designed stations that can provide UV flexo, rotary screen, hot and cold foil, and varnishing and laminating processes. The RCS 330 features a printing width of 13˝, a printing speed of up to 525 fpm, and infinitely variable repeat between 12˝ and 24˝.

The flexibility and productivity improvements that presses such as the Gallus RCS 330 offer a package printer can be substantial. Hub Labels is running a Gallus RCS 330 press and can attest to its impact. "We go from paper to film and back again and the press doesn't miss a beat," says Hub Label's John Flannery. "The other day, we ran 150,000 feet of material—seven items with over 21 plate changes in seven hours. This would have taken us three days on any other press."

At Aquaflex, Rosenbaum knows that changeover speed is critical, but says configuration flexibility and shortened makeready times are equally important. The Aquaflex LX Series has been designed with "the flexibility to address virtually any configuration needed in just minutes," he says.

"Our pull out inking drawer system incorporates tool-less anilox, doctor blade, and ink pan removal. It allows for removal, drainage, and clean up of the ink pan and anilox/doctor blade assembly, as well as new set up of a print station while other print stations are printing and producing. Our three-zone tension control system provides faster synchronization between the printing and converting stations. Finally, we have made the LX perhaps the most ergonomically friendly production platform in the industry. Simplified tooling and easy-access controls all work together to bring the press up to saleable product faster."

Aquaflex also offers its InstaPrep presses as a solution for short-run printing needs. This press series offers the Aquaflex ICT (Instant Change Technology) system, a cassette-driven platform that can quickly set impression and allows all makeready and wash ups to be done off line. The InstaPrep presses are offered with maximum printing widths of 10˝ and 13˝, with repeats between 8˝ and 24˝.

Labelexpo Americas 2004 saw the launch of Mark Andy's XP5000 (XP—Xpanded Productivity) press that features state-of-the-art servo-driven print stations, diecut stations, and tension systems. According to Ken Daming, director of product management for Mark Andy, the XP5000 incorporates the Mark Andy Multi-Process Productivity Platform that features a fully interchangeable Quick Change cassette system. This provides capabilities for eight different processes including rotary screen, hot foil, inter-station die, and cold foil modules, as well as inkjet cassettes.

To improve makeready times and reduce waste, the XP5000 includes pre-registration functions in both print and die stations, along with fully electronic job handling and electronic register control. It also has advanced diagnostic capabilities that allow for Internet connectivity to maximize productivity and uptime.

One of Ko-Pack's answers for shorter runs can be found in its CI GearlesSleeve STEALTH™ 650 press. Ko-Pack's All-in-One-Pass-Technology can provide front- and reverse-side printing, water-based or UV flexo inks, solvent-free laminating, gluing, diecutting, and non-stop production with flying splice and turret rewind. The servo-driven printing units (plate cylinder, anilox roll, register, and pressure adjustments) significantly reduce changeover times, and press set up for repeat jobs can be done quickly with stored data from previous set-up conditions.

PCMC's Evolution™ Converting System is a gearless in-line flexo press that offers multi-substrate capability in 18˝, 26˝, and 30˝ print widths. According to Lisa Prunty, marketing specialist for PCMC, a key feature is its Deck x 2™ print head that features a rack-in/rack-out quick changeover system. "This unique design has a single impression cylinder operating between two color decks, allowing for an industry-shortest web path and versatility to add additional print modules and converting options," she adds. Prunty reports that an 8-color changeover can be done in less than 30 minutes.

To ensure that set-up time and waste is kept to an absolute minimum, Nilpeter is offering servo-drive technology as an option with its new F-Line flexo presses. Versatility is also built-in, with a modular, cassette-based system that provides any combination of printing units that run substrates ranging from thin films to carton board. Nilpeter also offers real-time diagnostics via Internet connectivity to evaluate press performance.

Omet's new "Twin-Cut" tool-less rotary diecutting system was developed as a cost-effective solution for short-run printing requirements of labels and folding cartons. Steve Leiben, sales manager for Matik North America, a distributor of Omet and Codimag presses, says that the system can eliminate the need for costly hard tooling and magnetic cylinders.

"Twin-Cut provides very fast changeovers and variable diecutting repeats (from 10˝ to 24˝) from a single set of magnetic cylinders," says Leiben. "The Twin-Cut system can also be used as a standard full-rotary system and converters can use their existing tooling in the Twin-Cut die stations. This provides for flexibility and cost-saving solutions for short, medium, or long run jobs."

Ancillary support

If a printer is fortunate enough to have a press that can turn jobs around at such a fast rate, it will quickly discover that there are potential bottlenecks in supporting systems that could keep it from reaching the full potential from these high-tech presses. Trexler says that one place to start is with a good quality plate mounter "to get the plate mounted correctly the first time."

He also recommends the use of ergonomic and specific-machine designed carts to prevent damage to the equipment and make the job smoother. And, of course, "the use of a good workflow is a must," he notes.

Rosenbaum believes that printers should take a look at overall workflow improvements that free up equipment for more production of saleable product. Workflow in this context is more of an industrial engineering look at material flow, planning, and value-added processes.

"Aquaflex introduced LEAN manufacturing principles into the package-printing industry back in 2002 as a way to help printers improve their workflows and better manage the demands of short-run printing," says Rosenbaum. "Concepts like pre-staging jobs and off-line cleanups will help printers become more profitable by increasing press productivity. At Aquaflex, we believe in integrated press floor operations where the workflow is in balance with the production capacity."

Successful short-run printing will require the investment of money and time. The money will be needed to acquire the technology incorporated in today's state-of-the-art presses. Time will be needed to review, and possibly overhaul, how work gets done to meet the needs of short turnaround package printing.

By Tom Polischuk

Editor-In-Chief