Installations
Simpson Print of Bloomingdale, Ontario, in February 2018 installed a new SwissQPrint Nyala LED large-format inkjet system to expand its range of digital services.

Founded more than 50 years ago, Simpson Print is one of the country’s most-diverse printing operations running high-quality screen printing presses, a 40-inch Komori LS640 UV press and digital presses, including a 6-colour HP Indigo, as well as a range of post-production capabilities – with a team of kitting specialists.

“The Swiss Q represents the future of our digital wide format legacy,” said Simpson Print President, Carla Johanns. “Simpson Print views investment in technology as critical to our clients' print marketing and branding requirements. Each of our new acquisitions furthers our commitment to our all-under-one-roof capability. This is a wonderful new addition to our UV offset and high-resolution screen print capabilities.”

Simpson Print’s new Nyala is a high-speed, 8-colour + White (CMYKlclm – Violet, Orange and White) system. The company plans to focus its new large-format technology on a range of display graphics applications like P.O.P, banners and decals, among similar marketing work.

The Nyala LED was introduced in May 2017 as an updated version of swissQprint's existing engines, based on the addition of LED-curing technologies and a range of mechanical improvements. For example, the system’s beam architecture was reworked for more stability and swissQprint also ensured that the flatbed is indeed perfectly flat over its entire surface – 3.2 × 2 metres with the Nyala LED.
Ellis Paper Box, a member of the Ellis Group, Canada’s largest privately held manufacturer of folding cartons, is providing produciton details from its recently installed Optima 106 K die cutter from KBA-Iberica. The purchase is part of Ellis Group’s investment in new automated high-speed die cutters across its three facilities, with another new die cutter purchased from KBA North America set to be installed at its Ellis Packaging facility later this year.

The Optima 106 K die cutter installation at Ellis Paper Box will be targeted at the demanding standards required by the pharmaceutical industry. “We’re successful due in part to our commitment to the industry, commitment to our employees, and our relentless pursuit to remain the most progressive carton company in Canada,” said Dave Ellis. “We offer a total in-house capability to control all aspects of structural design, electronic proofing, and die making. Our three-phase electronic verification is critical to our assurance of full responsibility for product quality and compliance to Good Manufacturing Practices.”

Over the past several years, Ellis Paper Box explains it has detected a number of important trends in terms of production throughput at its 60,000-square-foot facility in Mississauga, Ontario. By investing in new equipment, Ellis explains it has become a one-stop shop producing as little as 500 cartons with spot colours to five million eight-colour specialty work with inline inspection. The facility holds 100 percent inline carton inspection systems to handle its international clientele, requiring a variety of languages imprinted on the boxes.

Recently, KBA explains new legislation enacted in Canada has deemed that all pharmaceutical boxes must be redesigned to include additional compliance information for plain English text. Ellis has been instrumental in working with its clients to increase the size of the folding carton or add a fifth panel to existing styles to accommodate this legislation. In addition, the packaging producer reports its over-the-counter packaging is being designed with more value-added properties, such as inline cold and hot foil, embossing, inline Braille, and specialty coatings such as matte and high gloss.

“The KBA-Iberica Optima 106 K die cutter has become our workhorse in the die cutting department,” said Ellis. “It is capable of handling production of paper, cardboard, plastic and corrugated boards up to 1.5 mm. It is running at 8,000 sheets per hour. We currently operate it two to three shifts per day, five days a week. Our preference is to schedule all jobs containing detailed embossing and critical print to cut registration on this new machine.”

Not only is Ellis receiving these benefits but it has also recorded the machine’s efficiency and savings. For example, the firm has witnessed a 63 percent increase in throughput and a 32 percent increase in run speed compared to the last six running months over the previous machine. This allows Ellis to provide faster speed-to-market and get its product to its customers in two weeks or less. It has also recorded a 20 percent to 40 percent reduction in makeready due to the Optima 106 die cutter. Ellis is also blanking more difficult jobs thereby reducing its stripping costs by $35,000 per year.

“The improvements to our die cutting department have been staggering,” said Ellis. “Due to the Optima 106 K’s increased automation, there are less tools involved and our employees are pleased with its push button automation. Our quality has improved due to this new die cutter and we have no downtime because the machine is so dependable. Improvements to uptime and quality have resulted in improved bottom line. The new die cutter from KBA-Iberica has had a fantastic impact on our company.”

Founded in 1946, the Ellis Group is comprised of over 250 employees at Ellis Packaging, Ellis Paper Box and Ellis Packaging West servicing and specializing in the food, confectionary, pharmaceutical, neutraceutical and beverage industries.
ICON of Markham, Ontario, has installed a Konica Minolta AccurioJet KM-1 UV inkjet press. Founded in 1995, ICON now holds four divisions, including ICON Visual, Media, Motion and Print, specializing in large format and display graphics, digital signage, film production and commercial printing, respectively. (The company was featured in PrintAction’s February 2017 issue, All things visual, inside ICON Digital.)


“The 23 x 29-inch sheet size, speed and quality output of Konica Minolta’s [AccurioJet KM-1] technology is a perfect marriage that combines desirable traditional press attributes, with the power of digital creativity and the ability to print on the widest range of substrates,” said Juan Lau, President, ICON. “We see the KM-1 as game-changer in the digital-marketing and variable-print arenas; and as a company constantly striving to be different, we feel this system will really set us apart in the marketplace.”

The AccurioJet KM-1’s 23 x 29.5-inch sheet size allows for 6-up, full-bleed letter-size printing at 3,000 pages per hour (18,000 letters per hour). The press, explains Konica Minolta, prints on traditional offset stocks, as well as textured, synthetic and canvas medias. It is capably of handling materials like 17-lb vellum and 24-point weights, without any substrate pre-coating. The press also features automatic perfecting/duplexing up to 18 point.

ICON generated sales of approximately $37 million in 2016 with offices in Toronto, Montreal and NYC. The company’s primary markets include fragrance, cosmetics, retail, sports apparel, lifestyle and luxury CPG companies, corporate and event marketing, auto dealerships, financial institutions, hospitality, transportation, health care, property development, and digital out-of-home advertising and promotion.
Swiss Print International of Etobicoke, Ontario, is adding a Komori LS 440 sheetfed offset press to its facility, which has two existing 40-inch presses. The company’s incoming press, purchased through Komcan Inc., includes a tower coater and extended delivery, as well as a full automation package.

Swiss Print describes itself as a full-service printer with the ability to run a range of work from business cards to large format, through its digital and offset printing machines. The company also provides full finishing capabilities, graphic design, photography, copywriting, website design, data asset management, and warehousing and fulfillment.

Associated Labels and Packaging of Coquitlam, British Columbia, a premium label printing and flexible packaging company, has added a new HP Indigo 20000 digital press to its service offerings.

The converting and printing company, based just outside of Vancouver proper, works with clients throughout Canada and United States in sectors like food and beverage, pharmaceutical, nutraceutical food, personal care, wine making and household cleaning products. The company began as a small label printing plant in 1981 and has since grown to occupy more than 100,000 square feet with 24-hour-per-day press runs.  

The HP Indigo 20000 doubles the digital capacity for Associated Labels and Packaging (ALP), which until now had been providing digital printing services with two HP Indigo WS6800 digital presses. The company explains its new 30-inch press will allow it to deliver digitally printed flexible packaging and pouch applications to complement its wide-web flexo printing. 


“The addition of the Indigo 20000 will allow us to provide the market with unlimited short-run packaging,” said Shaun Ashworth, President of ALP. “In the past, it was cost prohibitive due to minimum orders. With this technology we can now produce smaller runs for market testing and development, and also stay profitable on smaller runs from existing key customers.”



The converter explains that it has also invested in a sustainability program as a strategic company mission, developing what it describes as a unique backyard compostable stand-up pouch product. The film is able to run on the HP Indigo 20000, which the company explains to open new marketing opportunities.

“With digital printing on eco film, these innovative products can enjoy high-quality packaging SKUs, test market interest and also stay true to their eco-values,” said Jay Ashworth, Marketing and Sustainability Manager, who notes specialty brands, including boutique organic and natural products, are increasingly interested in a fully sustainable packaging solution as part of their product marketing.

The Calgary, Alberta, location of ARC Document Solutions has added a Seal 62 Pro D laminator, largely based on an earlier successful installation of a Seal 65 Pro MD laminator at the company’s Burnaby, BC, facility.

The installation of both systems were overseen by GBC Canada, one of the country's leading providers of print finishing technologies for digital production, as well as hybrid digital-offset environments, focusing on Seal and GBC finishing, laminating and media products.

The Seal 62 Pro Series offers industrial performance, explains GBC, based on its capabilities for running a range of media at high speeds. It features fully adjustable temperature, speed and pressure settings and, according to GBC, it is ideally suited for experienced finishing departments requiring a versatile laminator.

“The dual heated rollers make most applications, including encapsulation, really easy to use. It maximizes versatility, minimizes waste and is a real value add for us,” said Joyce Wong, ARC’s Production Supervisor in Calgary.

ARC (formerly American Reprographics Company) is a global company, with approximately 170 service centres throughout North America, in addition to European centres, specializing in the distribution of information through printing and IT services. Founded in 1988 in southern California, ARC’s fiscal 2017 revenue was more than US$400 million generated by more than 2,600 employees around the world.

The company has nine service centres in Canada (BC, Alberta, Ontario and Quebec) focusing on providing document solutions to businesses of all types, with an emphasis on the commercial segments of the architecture, engineering and construction (AEC) industry. The company is also investing more into providing more health care document services.
Groupe dpi of Drummondville, Quebec, has installed two Agfa wide-format-inkjet systems, including a Jeti Titan HS and a Jeti Ceres 3200. Founded in 1974, the company, with more than 70 employees, focuses on providing turnkey display graphics solutions, working with clients throughout Canada and the United States, from the concept stage to final installation.

The Jeti Ceres is a 3.2-metre roll-to-roll UV LED inkjet printer that produces print of up to 10.5 feet wide. The system, capable of unattended printing, reaches speeds of up to 2,002 square feet per hour.

Leveraging Agfa’s Asanti workflow software, the Jeti Ceres provides six colours plus an optional white and/or primer. It is also configurable with an optional dual-roll and back-up camera, allowing the Ceres to print mesh and porous substrates without a liner. 


The Jeti Titan HS is a flatbed, 3-metre–wide, 6-colour UV inkjet system that reaches speeds of up to 160 square metres per hour (1,722 f2/hr) in Express Mode. The system, which can include a flat-to-roll printing option, producing a resolution of up to 720 x 1,200 dpi.
Groupe Lettra of in Boisbriand, Québec, has installed an Agfa Anapurna M3200i RTR wide-format inkjet system. Founded in 2000, under the name Lettra D.Sign Inc., the company originally specialized in vehicle lettering.

In 2008, the company changed its name to Groupe Lettra Inc. and acquired industrial printing equipment making it one of the first companies in Quebec to move in this direction for wide-format imaging.


Lettra today specializes in all types of vehicle lettering and large-format printing on both rigid and flexible medias. The company’s new Anapurna M3200i RTR is a 3.2-metre wide roll-to-roll UV inkjet printer that produces indoor and outdoor applications at speeds of up to 123 metres square per hour.
Printing Icon of Scarborough, Ontario, installed a Duplo DPB500 perfect binder purchased through Print Digital Solutions. Owned by Readers Legacy Canada ULC, Printing Icon provides full printing services and specializes in advertising collateral, books, publications, direct marketing, stationery and corporate communications.

The fully automatic Duplo DPB500 features a single-clamp design for speeds of up to 525 cycles per hour, while operators can adjust, program and save up to 20 different jobs. Its automation, explains Duplo, makes it well suited for short-run and variable-data production.

To change format sizes, for example, operators select one of the stored memories, load the book in the clamp, and press the size change key to initiate the process. The side glue wheels, scoring wheels and cover positioning guide will automatically move into the desired position, according to the thickness of the loaded book. Once the size change is completed, covers can be loaded into the cover-feed section which provides controls where the operator can make and verify any adjustments aligning it with the nipping section.

Friesens Corporation of Altona, Manitoba, installed a Heidelberg Speedmaster XL-75-5+L press with coating. The company is one of North America’s leading book, yearbook and packaging manufacturers serving publishers, institutions, schools and businesses from two facilities in Altona. The 110-year-old printing company employs approximately 600 people in more than 250,000 square feet of space.

The Speedmaster XL 75 is Friesens’ first mid-size press in a plant dominated by VLF offset equipment, including a 73-inch, 8-colour Manroland R900 HiPrint XXL perfecting press installed in mid-2015 (featured as PrintAction's September 2015 cover story, World Book Giant).

Friesens’ new Heidelberg XL-75 replaced an older generation Heidelberg CD 102 press. “This press will be predominantly used for book covers and, when we analyzed the business, 80 percent of the forms would fit the 23 x 29 format,” said Byron Loeppky, GM of Friesens. “ The other 20 percent we can simply run a few more sheets to make up for the smaller layout. It is a short-run market.”

The Speedmaster XL 75 is equipped with features branded by Heidelberg as Push to Stop technology, including: Inpress Control 2, automatic colour and register measurement, Auto Plate Pro fully automated plate loading, and automated wash programs. This technology is now driven by Heidelberg’s recently introduced (May 2016) Intellistart 2 press software, activated through the Press Center XL with Wallscreen. These features can allow the press to process jobs autonomously within Heidelberg’s Push To Stop operating philosophy.

“We may have downsized the format, but we have upsized the technology,” added Friesens’ Andrew Fennell. “The plan was to drive automation into our process. This press can make job changes in 50 percent less time than our older press, and doing it with one operator. The technology is like having a second man. We are putting more sheets on the floor each day. All the targets are being met or exceeded, and we are still in a learning curve.”

Innovative Design & Print of Millbank, Ontario, recently completed the installation of a Kodak NexPress NX3900 digital press. Featuring long-sheet capabilities, the company’s new 5-colour press reaches speeds of up to 120 pages per minute with the ability to run sheet sizes of up to one metre (39.37 inches) in length. The NexPress is compatible with more than 800 qualified substrates.

The Fifth Imaging Unit of the NexPress platform, to be leveraged by Innovative Design & Print, provides Dimensional Clear Dry Ink for a tactile feel with raised or textured printing for a 3D effect; Clear Dry Ink for watermarking, spot or flood-coating techniques; and Light Black Dry Ink for what the company describes as ultra high-quality printing, particularly with neutral tones, gray layers and flat fields.

“Innovative was looking for a new digital press with long sheet capabilities and high-resolution imaging for photo products,” said Calvin Frey, President, Innovative Design & Print. “We spent time doing our research and performing press tests and chose to proceed with the NexPress.  We have been very impressed by the image quality, the flexibility of the press and the reliability.”
Earlier this year, Imprimerie BBM, based in Laval, Quebec, made a significant investment in its sustainability position by installing a Kodak Achieve T800 Platesetter, and converting to Kodak Sonora XP process-free thermal plates.

The Achieve T800, leveraging Kodak’s thermal imaging technology, features a compact footprint and consumes up to 70 percent less power than previous CTP generations. By combining this CTP installation with a switch to Kodak Sonora XP process-free thermal plates, Imprimerie BBM also eliminated plate processing and, therefore, chemicals in the plate-making process. The new technology is also designed to reduce water consumption and energy costs.  

At 2,400 dpi, the Achieve T800 has a rated throughput, for plate sizes of 1,030 x 800 mm, of 16 plates per hour (S speed) and 22 plates per hour (F Speed). Plates go directly from the CTP to the press, which Kodak explains to eliminate processing variability, resulting in fewer remakes and higher quality on press.


Cartonek of Sainte-Marie, Quebec, has installed a Canon Océ ProCut 1600-3XL system, which joins the company’s existing Océ Arizona flatbed printer. Primarily focused on the packaging market, Cartonek has a growing interest in large-format signage.

Designed to be run by a single operator, the Océ ProCut flatbed cutter leverages a modular tool system, which can simultaneously cut and crease a piece of cardboard, or transition from routing a piece of Dibond to kiss-cutting a roll of vinyl. The machine’s vacuum system automatically adjusts to materials put on the table.

The Océ Arizona is a UV-curable inkjet printing system aimed at mid-volume print producers. It is available with a Roll Media Option and features Océ VariaDot grayscale printing technology.
The RBW Graphics facility in Owen Sound, Ontario, which is owned by TC Transcontinental, recently completed a suite of upgrades to a Goss M-3000 press. The project consisted of a drives and controls system upgrade, an Omni Make-Ready bundle and ink fountain rebuilds.

The drives and controls upgrade involved replacing existing consoles with new Omnicon and Omnicolor consoles, new Siemens PLC CPU hardware, controllers and drives. Goss technicians rebuilt the ink fountains on eight existing units and added new four- and 16-channel driver boards, embedded controller boards, ink fountain balls, and single piece ink keys. The Omni Make-Ready package, a combination of hardware and software functions, is designed to reduce waste.

“We have invested a significant amount of money into this press to ensure longevity and reliability, says Ted Schneider, Maintenance and Engineering Manager of RBW Graphics. “The new upgrades will also help to gain efficiencies and help to provide consistency in quality. By adding the Omnicon control system to this press, it aligns with the operating platforms on our other Goss Sunday presses which all run the Omnicon system.”
Imprimerie Bourg Royal, a full-service printing company located in Quebec City, Quebec, recently installed two Standard Horizon finishing systems, including a creaser/folder and an inline booklet-making system. Three generations of the Paquet family, which owns Imprimerie Bourg Royal, continue to work together today.

Their new finishing systems purchased from KBR Graphics, the exclusive Canadian distributor for Standard Horizon, includes a CRF-362 creaser/folder that will be primarily be used for handling digital colour output across a range of coated or uncoated light and heavy weight stocks.

In 2009, Imprimerie Bourg Royal, led by President Yves Paquet, shifted its production toward digital printing. The CRF-362 can be used for one-pass processing of applications like restaurant menus, greeting cards, book covers and many types of marketing collateral.  

“Attaining an accurately finished product is categorically the most-important step the production of digitally printed material,” said Karl Belafi Jr., Vice President KBR Graphics Ltd. “The CRF-362 is a really good fit for them and we are so pleased on how the operators have easily taken to the equipment and have hit the ground running.”
 
In addition to the creaser/folder, Imprimerie Bourg Royal purchased a Horizon SPF/FC-200A booklet-maker with a VAC-1000 collator. This upgrade replaced a 20-year-old Horizon system. The SPF/FC-200A is described as a high-performance inline bookletmaking system with collating, stitching, folding and fore-edge trimming.

The SPF/FC-200A can process up to 4,500 books per hour and features a 200-job memory storage and an icon-based touch-screen for job set-up. The 10-station VAC-1000 collator features a patented rotary-pulse vacuum feed system, which can operate at speeds up to 9,900 sets per hour. The system is expandable from one to six towers, with the ability to run in both directions at full rated speed.

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