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Jul 1, 2008 12:00 AM

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Hybrid UV XL 105 goes to Carded Graphics

Carded Graphics (Staunton, VA) recently installed one of the first hybrid UV Heidelberg Speedmaster XL 105 presses in the United States. The packaging printer and folding carton converter built a 60,000-sq.-ft. addition to accommodate the press, which will double the company's production capabilities.

‘There isn't much we can't print’

In addition to the the 7-color XL 105, Carded Graphics installed a Suprasetter 105 platesetter and Prinect Prepress Manager workflow system, Prinect Prepress Interface, Prinect Image Control color measuring system and Prinect Inspection Control, which monitors color consistency across the sheet.

“The XL 105 gives us a way to serve our existing UV clients better, and gives us a value-added sales approach for customers who are looking for higher gloss and different printing substrates,” says Murry Pitts, president and owner.

A plastics and substrates package enables the printer to tackle any grade of folding material up to 40-pt. thickness. “Our capability now covers the full spectrum,” Pitts says. “Some of our customers request foil board and other substrates, and we can now do that internally — there isn't much we can't print now.”

Key features include:

  • A larger format (29.53 × 41.34 inches) that allows for more “ups” per sheet, boosting the net output of packaging and label printers.
  • A wall-screen control, the Prinect Press Center screen, permits extensive workflow integration on the basis of open, future-proof standards.
  • Fully automatic pile changing, automatic material conveying and pile buffering ensure a constant maximum production speed with thicker board substrates.
  • Preset Plus Delivery — aerodynamically designed gripper bars and Venturi air sheet guide plates stabilize any size substrate at maximum production speeds. Fully remote-controllable sheet breaks and high-frequency joggers secure perfectly aligned delivery piles that are ready for finishing processes.

About Carded Graphics

The company serves national accounts in the food, medical and medical devices, consumer electronics, tobacco products and pharmaceutical packaging industries. Pitts bought the company in April 2006 from Manchester Industries and merged it with his own North Carolina-based Pell Paper Box. The 75-employee company is one of the largest folding carton converters in the region.


Eye-catching oversized options

Register Litho (Clifton, NJ) has added a KBA Rapida 205 6-color 81-inch press with inline UV coating and dryers as well as extended delivery, the first of its kind in operation in the Northeastern United States. The printer can produce display and oversize jobs on substrates from 80-lb. coated to 48-pt. board with improved productivity.

“The inline UV and aqueous coating, and the infrared dryers allow us to produce a large-format sheet completely dry and ready for the bindery or finishing area,” says Joe Fishman, president of Register Litho. “Plus we are offering our customers the ability to use different types of shines — full, satin, matte or spot — to draw attention to their large-format jobs. By having the UV coating and IR dryers inline on our press, we differentiate ourselves from our competitors.”

The KBA Rapida 205 has a maximum sheet size of 59.5 × 81 inches and a rated speed of 9,000 sph. Register Litho's press includes a fully automatic plate changer with lifting facility for loading and unloading the plate holders on the tower guards; automatic blanket and impression cylinder washing systems; an inline anilox coating system and; IR, UV or hybrid drying options. It also includes KBA's Densitronic quality control system and inline perforating and slitting.

An ACR automatic camera register control system lets operators achieve color registration quickly.

About Register Litho

This 50-employee, family-run business is headquartered in a 53,000-sq.-ft. facility in Clifton, NJ, outside Manhattan. Register Litho is a trade printer. A direct sales arm, SignSource, was created to serve retail customers. While both companies utilize the KBA Rapida 205, they do not compete with each other.


Faster than ever before

The Orange County Container (OCC) Group (City of Industry, CA) recently installed a 56-inch Mitsubishi Diamond 6000LX press equipped for inline aqueous and ultraviolet (UV) coating. The new press replaces a legacy 7-color, 56-inch carton press.

The Diamond 6000LX prints on 0.004-inch to 0.04-inch stock at high speed, including packaging board and synthetic substrates.

Dan Domino, vice president/general manager of the OCC Group, says the Diamond 6000LX's high running speeds and faster setups will help the company turn around short runs while maintaining efficient production on long runs.

“We can complete more jobs in a day on this press than we could have probably run on our best day with the previous machine,” he said. “We can do six or seven jobs in two shifts depending on the run lengths.” The Diamond 6000LX is equipped with a Peak UV and infrared drying package from Air Motion Systems. Other features include closed-loop color control and an X-Rite spectrophotometer-powered color management system.“

“The X-Rite system automatically scans color control bars and makes adjustments to the press as it is running,” says Domino. “ Setups are much faster as a result. We have better control over color, so there is less material waste.”

About The OCC Group

Founded in 1981, The OCC Group specializes in retail and industrial corrugated manufacturing, graphic packaging and point-of-purchase displays. In-house services include printing, converting, design, sheet supply, label production and fulfillment.

The organization currently employs 2,800 people across 12 locations spanning 2.2 million sq. ft. of space in the United States, Mexico and China. Sales for 2008 are projected to reach $340 million.


Bigger sheet size wins fans

LandmarkPrint (Stamford, CT), has installed a fully automated, 5-color Komori Lithrone SX29. The company already had two Komori presses on the floor, a 4-color SPICA and a 5-color Lithrone 28 with coater.

The new press replaces the three-year-old Lithrone 528 with Komori's LSX cutting-edge automation. Highlights include automated plate-loading and blanket washing, a redesigned feeding system, and a built-in spectrophotometer that automatically monitors color quality and consistency throughout every press run. The LSX 529's 24-percent larger sheet size as well as its ability to handle press-ready skids made it an attracitve choice.

“The press is so automated that makeready time is only 10 to 15 minutes. We do a lot short-run jobs on that press, so it's important to have a press that minimizes setup time,” says Carmine Iannacchino, a principal partner of LandmarkPrint. “And the spectrophotometer is built into the console. As the pressman pulls sheets, the spectrophotometer can automatically scan them and make adjustments to the ink wells. It automatically compensates to give us consistent color control.”

About LandmarkPrint

This general commercial printer offers offset and digital printing as well as a full range of fulfillment and mailing services.


New plant, press and more

St. Louis-area printer Kopytek has completed its relocation to Olivette, MO. According to Kopytek CEO John Peterson, “We have more than doubled our operating environment as our new $2.4 million facility equates to 20,000 sq. ft. of office, production and warehousing space. We also purchased an additional $2 million in the latest digital imaging technology.”

New equipment highlights include a Ryobi 784 convertible perfector and Halm Jet press. In addition to the 6-up, 12-page, 23 × 29-inch Ryobi press, Koptek added a Polar 92 XT 36-inch paper cutter from Heidelberg.

Working with Dial Architects, Peterson and the Kopytek team helped design a facility with streamlined material handling. The new layout is expected to expedite turnaround time and facilitate the company's growth.

Founded in 1986, Kopytek is a $4.1 million full-service printing, digital imaging, mailing and fulfillment company.


Put your packaging on a DI press

Presstek, Inc. (Hudson, NY) introduced a UV printing option for the Presstek 52DI and 34DI digital offset presses at Drupa.

“Printing with UV waterless inks on Presstek's DI presses expands [our] opportunity to provide a high-quality, low-cost 4-color offset solution for consumer packaging, point-of-purchase, direct mail and other markets,” said Klaus Schleicher, Presstek group product director, digital printing.

Two UV printing options will be available for both the Presstek 52DI and 34DI, including field upgrades. The hybrid UV option that allows for switching between standard waterless and UV waterless inks will be available in Q4 2008. The UV option for operating the DI as a UV waterless press will be available in Q3 2008.

Presstek will conduct “Digital Power Printing Forums” in East Rutherford, NJ, from August 19 to 21 and in Seattle from August 26 to 28. A Canadian event will be held in Calgary September 2 to 4.


Green printing and packaging accolades

Teaming with Premier sponsors Heidelberg and Kodak, AMERICAN PRINTER, in conjunction with the National Association for Printing Leadership (NAPL), has created the Environmental Excellence Awards. Winners will be announced in our September 2008 issue. Watch this space!

Earlier this year, our sister magazine, Paper, Film & Foil Converter, earned some green plaudits. PFFC's September 2007 issue was named the “2008 Publication of the Year” by the Printers' National Environmental Assistance Center (PNEAC) in the Book/Collection: National Publication category. The award was presented March 11 during the National Environmental Health & Safety Conference.

Feature articles covered environmental compliance regulations, energy efficiency, Wal-Mart's packaging initiative, adopting a corporate culture of sustainability, and five ways to create eco-conscious packaging.

Consolidated buys dozens of HPs

HP (Palo Alto, CA) announced at Drupa a multimillion-dollar agreement with Consolidated Graphics Inc. (Houston) for the installation of as many as 36 HP Indigo digital presses — including HP Indigo 7000s — at Consolidated facilities this year.

With annual revenues of $1.2 billion, Consolidated Graphics has 70 printing businesses in the United States and Canada, as well as a facility in the Czech Republic.

Press installations are scheduled to begin in June, starting with the company's Prague, Czech Republic, and Medford, OR, facilities.

KBA North America will move to Dallas in 2009

KBA North America, currently based in Williston, VT, announced plans to move its corporate headquarters to Dallas in the summer of 2009. The relocation will join the KBA sheetfed and web divisions under one roof along with the sales, service and parts departments, as well as the corporate demonstration center.

KBA will be inviting its current employees to seek relocation to the new facility in Dallas. The firm will continue to maintain offices in Florida and Minnesota as well as its KBA Canada offices in Toronto and Montreal.

Stepping up to large-format presses

At a recent customer open house, manroland (Westmont, IL) showcased its rebranding as well as all things large format. Echoing a statement attributed to one of Chicago's best known architects, the press vendor urged its guests to “make no small plans.”

Think big

In addition to six demonstrations on the Roland 906LV and Roland 706LV with Prindor inline foiler, attendees heard presentations from Kodak, Bobst Group, MBO and Prism. Additional sessions led by manroland's Hal Stratton and Jon Surch highlighted manroland's printnet system for workflow integration and faster makereadies as well as how printnet and CIP control can be used to manage business costs, performance and quality. Other sessions discussed the nuances of ColorPilot and the Drupa featured Inline ColorPilot, which reads and corrects color in 14 seconds.

Getting the XXL edge

Strine Printing (York, PA) has three offline sheeters to supply stock for a dozen offset presses, including a Roland 73-inch 900 XXL press, a UV-equipped Roland 64-inch press and two 56-inch presses. Strine's printing and packaging operation is among the largest in the Northeastern United States. The printer produces everything from greeting cards to pocket folders, and point-of-purchase and plastics jobs. In a panel discussion, Dave Kornbau, Strine's vice president of operations, said Strine's large-format capabilities give it an edge: “It's helped us survive and grow in a competive 40-inch market.”

It's easy for operators to switch from slitting to non-slitting mode on the large-format presses. Changeover takes about 25 minutes, and, according to Kornbau, the accuracy of the cut is good. “It does very well,” he said. “You can [go on to] do some 40-inch die cutting without tolerance problems.”

For those stepping up to large format, some requirements are obvious: XXL platesetters, folders and cutters will be on their shopping lists. Kornbau noted some little things are easy to overlook. Can your tow motors handle the weight? How about your skids? Getting paper merchants to stock large-format sheets is no longer a deal breaker. Strine characterized it as a “non-issue.”

Seeing is believing

“[Attendees] gained an understanding of manroland's partnership advantages through printnet, printservices, telepresence and printcom,” said manroland CEO Vince Lapinski. “They have a better understanding of what manroland can do for them now that they have seen the 900 in action and talked their peers who are already using it.”