Leading with Alternatives

Remaining competitive is one goal of many companies, but the companies that stand out are those that choose leading over simply competing. Syracuse Label Company, Inc., of Liverpool, N.Y. is one company that has worked hard to lead throughout its 40-year history. “We were one of the first rotary letterpress printers in the United States that offered high-quality print (4-color process) and chemical-resistant labels that flexographic printing was unable to offer at that time,” says Kathy Alaimo, president. “The rotary letterpress contributed to our rapid growth in the mid 1980s. Currently our goal is to continue our growth through the UV and water-based flexographic processes.” The company has been rewarded for its leadership in the label printing arena through top printing awards both nationally and internationally.

UV market

Syracuse Label is focusing on the right area. A recent RadTech study, “Status of UV & EB in North America 2006,” states that UV & EB penetration into the graphic arts ink market spans the range of print methods, reaching 21,650 metric tons in 2005, up at a greater than 7 percent growth rate per year. Although offset inks represent the largest segment, the study states that the market for UV & EB flexo inks has experienced continual rapid growth at double-digit rates during the last few years. That trend is expected to continue for the near future. The study, based on responses from 90 UV & EB industry representatives, cites one estimate that UV & EB’s penetration into the flexo market is about 25 percent, with most presses purchased today having at least one UV & EB unit. While UV & EB materials offer superior environmental profiles, survey respondents indicated that the actual decision for going with the technology is typically justified on more traditional investment criteria, according to the study. Operational and product quality benefits, and efficiency are a few factors that continue to drive UV & EB growth.

From two-color to multi-color capability

Founded in 1967, Syracuse Label started out with a Mark Andy, two-color flexographic press printing supermarket and candle labels. The company currently has a wide range of processes and products to offer its customers. Syracuse Label prints on supported and unsupported films, pressure-sensitive labels, and SBS carton material. “Our printing ranges from general pressure-sensitive labels to film, board stock, cartons, and custom applications,” says Alaimo.

A large portion of its labels is for pharmaceutical, cosmetic, and generic over-the-counter products. Its targeted markets include general consumer goods, cosmetic, food and beverage, and pharmaceutical. The company has diversified over the years. “Syracuse Label Company started out printing pressure-sensitive labels, [and] has diversified in recent years to include printing on board stock (such as ice cream cartons), silk screening, and hot stamping,” adds Alaimo.

Employee longevity

Syracuse Label has 12 presses running two shifts. Its sole manufacturing site is in Liverpool, N.Y., where 86 employees are employed. Of these employees, 67 have been with the company for five years or more. “This high rate of retention allows us to service our customers with experience, quality, and service,” says Alaimo.

Employees are cross-trained to help Syracuse Label maintain an even workflow and accommodate customer demand for quality products with short lead times. “We have implemented cell manufacturing,” says Alaimo, “with lean concepts to eliminate additional handling and improve job flows and lead times. Our goal is focused on producing a quality product, and meeting the customer requirements at a reasonable price.”

Employed processes

Syracuse Label employs combination printing of rotary screen and UV flexo, plus rotary letterpress with combination screen on Webtron, Rotopress (Nilpeter), and Sanki presses.

Its most recent addition is the Nilpeter FA-4 UV flexo press. The company purchased the press to increase its ­capacity, as well as make it more competitive by running wider webs and more colors. “The servo feature gives us the flexibility for different substrates,” says Alaimo. “The sleeve technology is beneficial for its superior print quality and quick changeover.”

The FA-Line of modular, servo-driven UV flexo presses features a broad range of printing options and the flexibility to handle future printing and converting technologies. Available in 13˝, 16˝, 20˝, and 22˝ widths, the FA-Line can handle a broad range of multi-substrate packaging materials. Easy-load sleeve technology provides fast makeready.

The press features a 100 percent inspection system, enabling immediate detection of print defects, thus allowing minimal waste. “We can also print a combination of UV flexo combined with water-based and rotary screen, as well as cold foil technology,” adds Alaimo.

According to Alaimo, acquiring the press has allowed the company more flexibility in markets in which it was not able to compete in the past. “It has also given us the opportunity to pursue shrink sleeve technology,” she adds.

Becoming a UV perveyor

UV printing is not new at Syrcause Label, having used rotary letterpress printing with UV inks for more than 20 years. “In the past,” says Alaimo, “our flexographic printing was primarily water-based. This caused us limitations with some applications. We now have the flexibility to print with UV flexo high-definition inks combined with digital plates to attain superior print quality using those technologies.”

Today, UV products make up around 40 percent of the company’s business. Using UV flexo printing has allowed the company to enhance its current product offerings, taking advantage of this printing process’s clean print quality and the ability to print multiple colors when it pursues sleeve applications.

Employing UV printing has also allowed the company to be compete for labels that require solvent resistance or solvent washdowns during the labeling process, says Alaimo.

Employing UV inks allows the company to leave inks in overnight, minimizing downtime and cleanups.

Forty years ago, Syracuse Label Company, Inc. started out with a two-color flexographic press. Its most rapid growth occurred during a time when it was one of the few in the United States to employ a four-color process for high-quality print. Today its goal is to continue its growth through the use of UV and water-based flexographic printing. Given this market’s growth, the company’s emphasis is well placed. pP