The redundancy, explains Jet Label, is necessary to maintain customer satisfaction – in terms of diminishing delay due to scheduled or sudden machinery downtime – and to also grow revenue by double digits annually.
At its Edmonton production plant, Jet Label has doubled up on all equipment, including its twin HP Indigo presses and Delta die cutters. Other couplings include a pair of wide presses, eight-colour flexo presses, and rewinders for each press width. The company also is moving toward complete redundancy at its Coquitlam, British Columbia, facility, which it secured by acquiring United Label Company last year.
“Although outliers rarely occur, we don’t want to jeopardize our customers,” said Darrell Friesen, Jet Label’s President & CEO, describing the redundancy move despite the robustness of modern press equipment. “Our customers do not worry about having all their eggs in one basket.”
Jet Label explains its commitment to total redundancy is a calculated risk, considering most printing-industry manufacturers typically make infrastructure investments based on anticipated business needs. “Our decisions in adding redundant equipment has been realized across platforms,” said Friesen, “with causes like unexpected downtime, unexpected operator availability to unexpected growth.
“Part of our commitment to total redundancy is an expectation of continued growth,” continued Friesen. “We're willing to put the pieces in place as a landing zone for new business, a proactive approach that lends itself to in-person appraisals by prospective customers or, increasingly, cyber-tours.”
With manufacturing facilities in Edmonton and Vancouver, Jet Label produces labels and printed tape for what it describes as a diverse portfolio of customers, including grocery stores like Safeway and Sobeys, international forest product companies like Canfor and West Fraser, consumer product companies like Bee Maid Honey and Arctic Chiller, industrial application companies like Acklands Grainger, Gregg Distributors, and All Weather Windows.
Jet Label also supplies parking and boarding passes and baggage tags to the Toronto, Calgary and Edmonton International Airports. The Edmonton Police Service has also been a longstanding customer. In addition to Edmonton and Vancouver, Jet Label has sales and distribution operations in Calgary, Prince George, Kelowna, Surrey, Saskatoon and Winnipeg.
KBR Graphics explains the RD-4055 DMC is a reliable, precise system that can die-cut, crease, perforate, slit, hole-punch and round corner in one process, both digital and offset-printed sheets up to 0.5 mm. Its repeat-register function enables the running of multiple-up imposed applications with a smaller die to reduce costs (up to five repeats in a single pass). The RD-4055 runs at speeds up to 6,000 cycles per hour.
Since operators can also run male and female dies simultaneously, KBR Graphics explains that finished products come out clean with sharp creases and without cracking or slitting. The RD-4055 DMC is ideally suited for applications like shaped promotional items, business cards, greeting cards, playing cards, coasters, door hangers, coupons, tickets, packaging, stickers (pressure-sensitive, gum back, static), merchandise labels, pocket folders, and unique mailers.
“Lowe-Martin is now far more efficient, and turnaround times are much faster,” said Karl Belafi Jr., Vice President of KBR Graphics. “In fact, they've doubled capacity with this innovative and cost-effective method. The flexible cutters are more accurate and jobs can be initiated from a PDF file, making the set-up times faster with less material wastage. This is always an important factor when considering digital printing.” Belafi also notes the RD-4055 DMC adds more creativity and flexibility to Lowe-Martin's existing range of products and services.
Lowe-Martin has production facilities in Ottawa, Ontario, where it is headquartered, and Mississauga. One of Canada’s largest printing operations, Lowe-Martin provides integrated printing and communication solutions that span an range of products and services like offset, digital large-format and security printing; direct mail; marketing; bindery services and more.
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.
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.
“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 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.
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.
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.
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.
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.”
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.”
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 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.
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DIA Meeting - Marquis/Webcom tour
February 20, 2019
InPrint USA 2019
April 9-11, 2019
Graphics Canada 2019
April 11-13, 2019
AICC Canada Trade Show and Conference 2019
April 24-25, 2019
Packaging Première 2019
May 28-30, 2019
Gala Gutenberg 2019
May 30, 2019