Installations
Goldrich Printpak, a Toronto company specializing in folding-box manufacturing, has installed an Esko Kongsberg XN24 finishing system and new Esko software into its 67,700-square-foot facility. Both the XN24 finishing table and ArtiosCAD software will be aimed at producing samples and short production runs for its customers.

“One of the services we offer is short-run samples for our customers. A lot of our customers work with retailers who want just one pallet or less of product,” explained Leslie Goldberg, Goldrich President and CEO. “We had an older CAD cutting machine that worked, but had hiccups. It cut samples, but we had to manually make the creases.

“We realized last year that it was on its last legs. We handle cardboard, thin corrugated and plastics and were looking for a machine that could handle these substrates. We wanted a quality machine that could cut materials very well and that was durable enough to work for us for the next 20 years.”

Using the Kongsberg for more than a month now, Goldrich has been leveraging the system particularly for more efficient cutting and creasing of specialized cosmetics boxes, as well as to cut coating blankets for its offset presses, which Goldrich describes as an environmentally progressive way to reduce waste and save costs.

Founded in 1953 as a commercial printer and lithographer, Goldrich Printpak is also focused on continuous improvement in environmentally progressive packaging. The company prints using vegetable based, non-toxic, low VOC and direct contact eco-certified inks.

Before the Kongsberg XN 24, Goldrich explains it would image a plate and then manually cut a sticky back blanket for the press. “The blankets were non-renewable. We’d throw them away. In essence, we would purchase blankets at a cost of $130 to $140 each, plus waste an hour and a half of press time,” said Simo Molkanen, Litho Supervisor and Pressroom Manager. “We are now able to set up standard templates on our Kongsberg table and cut coating blankets that can be reused on our presses. There is both an economic and sustainable benefit for us. We're in the early stages of preparing these.”

The Kongsberg XN comes with a range of specialty tools and, explains Esko, and the speed, power and flexibility to handle a variety of materials like corrugated, folding carton, solid board, foam, coating blankets, and plastics. The Kongsberg XN 24 can work with materials as large as 1,740 x 3,575mm (68 x 140 inches). The speed of the Kongsberg tables, according to Esko, allows Goldrich to produce short runs of 100 to 300 units.

“One large retail customer recently asked for a full pallet of samples – 160 pieces. Previously it was a nightmare to try to get these projects done. Now, we're excited to push the table to the limits,” said AJ Goldberg, Vice President, New Business Development. “This morning I'm meeting with a cosmetics customer to deliver 24 box samples made of virgin SBS with a bright silver metallized polyester surface. I do not think we would have been able to get there with our old cutting table. The quality would be much different. Every bad cut would show itself as wavering in the corners and the folds. This is important to us, because it's our target market – high quality upscale customers where clean folding is important."

Goldrich is also using Esko ArtiosCAD software to create structural design files to drive the Kongsberg table for both folded cartons as well as the coating blankets. At the same time, they take the artwork file from ArtiosCAD and import it into Adobe Illustrator to add graphics and to send 3D interactive virtual PDF files for clients. They also include the 2D and 3D artwork files with a die line with the factory order as a traveller and quick check of the correct art file, structural shape, and job to be produced. The final job specs are sent from ArtiosCAD to estimating and the company’s software operating system.
Kwik Kopy on Sherbourne Street in Toronto has purchased a Digixpress Bold from PDS. The Digixpress Bold reaches print speeds of up to 50 pages per minute in both colour and monochrome, while providing a resolution of 1,200 x 1,200 dpi.

The system handles stock of up to 360 gsm, as well as 3 x 5-inch cards up to 52-inch banners, while also supporting tabloid extra (12 x 18 inch) and Super-B (13 x 19 inch) sizes.

In addition to the optional external Fiery XF 5 server, Digixpress Bold has paper capacity expandable to 2,950 sheets, 1 Gigabit network, and front access to toner cartridges and image drums.
Pazazz Printing has acquired the first Xerox iGen 5 Press (installed in November 2015) equipped with both the optional extended colour gamut and the optional capability to print on thick stock. The new press, according to Warren Werbitt, founder of Pazazz, will help the Montreal-based printer expand its product mix, particularly with short-run packaging.

“The first time I compared an image printed on the iGen 5 with four colours to the same image printed with five, I almost lost my marbles. The fifth colour made it just so much more vibrant,” ,” Werbitt said, explain the investment decision was also based on the iGen 5 handling thicker stock and a larger sheet size.

The iGen 5’s extended colour gamut is enabled by a fifth toner station that supplements CMYK with orange, green or blue to match a wider variety of spot colours, including up to 90 percent of the Pantone Plus Coated library. The thick-stock capability enables the iGen 5 to feed, image and stack media as thick as 24 points.
The DATA Group, headquartered in Brampton, Ont., has invested $6.7 million to acquire multiple new Xerox presses, which Xerox describes as one of the single largest toner-production upgrades by a Canadian printing company in 2015.

Installations of the new Xerox equipment, which are to be used across Data Group’s nine production facilities in Canada and Chicago, began in December 2015. The DATA Group has approximately 1,400 employees and generates around $313 million in annual revenue. All of the Xerox systems are built around Xerox FreeFlow Core workflow software.

“The biggest thing we’re getting from this deal is improved productivity, primarily from having a single, consistent workflow,” said Alan Roberts, Senior VP, Operations, The DATA Group. “We’re also getting more capacity, and we’re getting an expanded colour gamut, to closely match brand colours that we couldn’t match before with Xerography.”

The expanded colour gamut, according to the companies, largely comes from the optional fifth toner stations on the Xerox iGen 5 presses acquired by DATA Group. The fifth toner station enables either orange, green or blue in addition to CMYK, which enables the iGen 5s to more accurately match up to 90 percent of the Pantone Plus Coated library.
 
In addition to the iGens, DATA Group acquired the following Xerox printing systems: Versant 80 Press, Color C75 Press, DocuPrint180MX Enterprise Printing System, D125 Copier/Printer, D136 Printer, inline/near-line C. P. Bourg booklet making solution, and several Xerox workflow products, including Xerox FreeFlow Core and the Xerox FreeFlow Print Server.
Clean Edge Bindery of Vancouver, BC, has installed the Duplo 600i Booklet System, which was introduced in August 2015 as Duplo’s new flagship collating and booklet-making technology. This is the first 600i installation in Canada, sold through Bell & Howell.

The 600i System produces saddle, side, or corner-stitched booklets as well as letter landscape applications, running at up to 5,200 booklets per hour or collating up to 10,000 sets per hour into a stacker.

Booklet production can be doubled, for certain applications, by adding the optional 4-stitch head kit along with the DKT-200 Two-Knife Trimmer and Gutter Cutter for 2-up booklet-making. Clean Edge Bindery’s 600i installation includes four stitch heads and square-back finishing.

The Flyershop of Calgary, Alberta, has added the first Ricoh Pro C9110 in Canada, following the system’s installation this past November.

The Ricoh Pro C9110 runs at speeds of up to 130 pages per minute in full colour and monochrome, running media stocks from 52 gsm to 400 gsm, with duplex capabilities. The system can also print on a range of textured, coated and oversized medias of up to 27.5 inches, producing a resolution of up to 1,200 x 4,800 dpi VCSEL.

First on Colour, located in Calgary’s East Village, added a Ricoh Pro C7110x press with a fifth station, allowing for the printing of clear and white toner. The press, installed in March 2015, prints at 90 pages per minute with resolutions of up to 1,200 x 4,800 dpi.

The Ricoh Pro C7110x supports oversize media of 27 inches through its LCT or Bypass Tray, while also holding the ability to feed stacks of special media, including envelopes. First on Colour plans to leverage the maximum sheet size of 13 x 27.5 inches to open up more business in short-run brochures.

First on Colour, founded more than 20 years ago, focuses on both toner and offset colour printing, while also providing design and finishing services.

Impression Paragraph Inc. of Saint Laurent, Quebec, has installed an Agfa Avalon N8-80 imaging system, with a capacity to image up to 60 plates an hour. The company is running Agfa’s Energy Elite Pro plate on the new CTP system.

Impression Paragraph, a GRACoL-certified facility, runs six sheetfed offset presses of varying sizes and capabilities, as well as a robust toner-printing department for both colour and monochrome work. The company also houses large-format systems and a range of finishing technologies.

Design Label Systems of Mississauga, which produces integrated product ID and label solutions, is acquiring a new Durst Tau 330 UV inkjet press to be installed in January 2016 at the company’s 25,000-square-foot facility.

“The decision was sealed after our staff attended LabelExpo in Brussels earlier this year and came back with a glowing recommendation that verified our preliminary research… We’re looking forward to having the Tau on-site in January,” said Zeb Faruqui, President of Design Label Systems.

Faruqui also noted that nearly 40 percent of Design Label’s jobs are below 7,000 feet. Design Label is installing a seven-colour Tau 330 with an in-line SMAG finishing system as its configuration.
 
The Tau 330 is designed for short- and medium-run narrow web applications, covering widths from 16.5-33.0 cm (6.5-13.0 inches) and running at print speeds up to 48 metres (157 feet) per minute – output capacity can reach 950 sm (10,225 sq. ft.) per hour.

The inkjet system is based around Durst’s proprietary UV inkjet print head technology, which features drop-on-demand, variable drop size, and gray scale capabilities to deliver a print resolution of 720 x 1,260 dpi.
 
Durst explains the Tau 330 can be integrated with any third-party finishing system – conventional or digital – and requires no in-line priming to handle industry-standard substrates.
 
Founded 26 years ago, Design Label Systems focuses on Canada’s pressure-sensitive label market. The 75-employee company provides label and packaging solutions to a wide range of industries including food, household products, health and beauty, wine and spirits, pharmaceutical, petrochemical and manufacturing.
Encore Print Solutions of Kitchener, Ont., has installed a DigiXpress Bold Digital Envelope Press, purchased through PDS. In addition to its digital printing capabilities, Encore provides wide-format and a range of finishing services.

The DigiXpress, in addition to its envelope feeding system, works with a range of applications and substrates like postcards, labels, banners and card stock up to 14 point. It feeds sizes from 3 x 5 inches up to 12 x 18 inches. In addition to duplex printing, DigiXpress also features scan, fax and email capabilities.

In a single pass, DigiXpress can produce around 50 full-colour, personalized envelopes per minute, or up to 36 full-colour 11 x 8.5-inch pages per minute (40 ppm in monochrome). The system has a print resolution of 1,200 x 600 dpi and a monthly duty cycle of 150,000 pages.
Marlin Digital Imaging Inc. of Richmond Hill, Ont., has added both a Ricoh Pro C7110x and monochrome-based Pro 8100. The commercial printing operation has been running Ricoh systems for 12 years.

The Pro C7110x system, which reaches colour printing speeds of up to 90 pages per minute, uses what Ricoh describes as an elastic fusing belt to support working with a range of textured and coated media. Marlin Digital added a fifth colour station to its system to print with white or clear inks.

The monochrome-based Ricoh Pro 8100 produces a resolution of 1,200 x 4,800 dpi working with media weights from 40 to 300 gsm.

Marlin Digital also runs sheetfed offset and wide-format inkjet technologies, in addition to thermographic, laser and screen printing, as well as a range of finishing services.
Arc Digital Canada Corporation of Woodbridge, Ont., purchased a Duplo 616 Pro system from distributor PDS. The 616 Pro system, designed to remove white borders and prevent toner cracking on colour documents, is an all-in-one finisher that can process up to six slits, 25 cuts and 20 creases in a single pass.
Full Frame Signs and Scenic Art of Toronto installed the first Kongsberg V table in Ontario to create a range of items that appear on screen for the company’s film-industry clients, as well as materials for their business clients.

Sean Vizsy, Full Frame Signs’ Executive Director, has catered to the film industry since developing a relationship with Cinespace Film Studios, and is now located in two of Cinespace Film’s properties at the East and West Ends of Toronto. Full Frame Signs’ headquarters are located with their sister company, The Custom Apparel Shoppe, in Paris, Ontario.

Full Frame products used on screen range from taxi-cab decals to coffee shop store fronts and from background posters to flooring. “Unfortunately, until recently we were basically cutting everything by hand and were very limited to the designs we could offer. They could only be square cut. We would try using a belt sander to get rounded corners, but they are tough because it adds to the risk of introducing imperfections to the product,” said Vizsy. “We were also limited to the materials we could work with. We didn't even bother with MDF or Dibond. We stuck with substrates that could be knife cut.”

Esko launched the Kongsberg V cutting table in May 2014. The system designed for sign-and-display work is based on a MultiCUT tool head for cutting and routing. The MultiCUT has various insert options with an air-cooled milling spindle of up to 45,000 rpm, suitable for acrylics and other synthetics.

“We were looking for a table that could accelerate file setup, and do so easily—a table on which we could train someone in hours, not weeks, and which did not require advanced CNC software experience to program files. It's difficult to find a graphic designer who can also program a CNC machine,” said Viszy. “The Kongsberg table set-up is simplistic for super things. Using Esko i-cut Layout, we can step and repeat a number of pieces. The best part is that the interface feels and acts like Adobe Illustrator, because it's a plug-in for Illustrator.”
Summit Print Corporation of Port Coquitlam, BC, has integrated Esko’ Automation Engine software and workflow server for automating and controlling prepress. Housed in a 15,000-square-foot facility, the company is a custom label manufacturer specializing in digital label production as well as various printed packaging, for clients in the craft beer, grocery, cosmetics, sports nutrition, nutraceutical and wine industries.  

Summit Print, which recently celebrated its 10-year anniversary, moved into its newly renovated facility, located on Kebet Way in Port Coquitlam, to have more space for administration and production. The facility offers a new customer resource centre where customers can view product displays that showcase the labels Summit Print has recently created. To support this move, the company has also designed a new logo, Website and building signage.

“The majority of our clients are small and mid-sized companies,” said Ryan Lees, Production Manager at Summit Print. “Periodically we do work for larger companies when the project is very targeted, for example, 5,000 containers for one store.”

Summit Print operates two digital presses: an HP Indigo WS6000 press next to the company's new HP Indigo WS6600 press. Prior to the implementation of Automation Engine, Summit used the Macintosh OSX file system to hold and store files, relying on a directory that structured files alphabetically. Files were opened and RIPped with HP’s digital front end, which is OEMed from Esko.

“Using the Mac OSX system was tedious and time consuming,” said Lees. “With the number of daily jobs on the rise, the result of short run lengths and new orders, I came to the realization that we would either have to hire more people or invest in new technology… Our prepress team is essentially three people, including myself.”

The MIS interface within Automation Engine works seamlessly, explains Lees, with Summit’s MIS solution from Label Traxx. The data is acquired from the Label Traxx system to automate overall job processing. Jobs and the necessary data, entered into the Label Traxx MIS, are launched through Automation Engine with the workflow automatically pulling the correct files, even if a job has over 100 SKUs. MIS integration with Automation Engine also allows for automated step-and-repeat or imposition to generate gang runs.
Atlantic Printers Inc. of Mississauga, Ont., has installed a 28-inch, 6-colour Akiyama Bestech press, including an inline AQ coater. The company, which was founded in 2002 based on the primary publication work, has also added a Stahl Pile feed, folder and Pro Cut cutter.

The printing company, which recently changed its name from Atlantic Web Printers to just Atlantic Printers, is now branching out to produce trade and commercial printing, including packaging. The family run business is led by Avtar and Malika Bedi

Atlantic Printers has also installed new equipment for the web press, including a Reema Stacker that runs at speeds of up to 40,000 impressions per hour to match the production of the Web Press, as well as a new Agfa chemistry-free processor.

The Akiyama Bestech press, points out Atlantic Printers, can run anything from 60-lb offset up to 28-pt board, giving it the ability to do commercial work like direct mail, publications and packaging.

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