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Innovative Installations

March 28, 2012



Inline foiling, UV efficiencies and color control advancements seen on recent packaging press installations. Packaging news at drupa will go beyond traditional offset: We expect more digital wide-format news and even some web offset activity. Stay tuned!

Inline Foiling Plus a Whole Lot More   Packaging Graphics (Pawtucket, RI) is a division of The MATLET Group specializing in printed blister cards, folding cartons, and clamshell packaging.  

In April 2009, Packaging Graphics installed an unusual 40-inch manroland foiling press. The 17-unit press is 127-ft. long, prints up to 10 colors and is equipped with a perfector, multiple coating units and interstation UV lamps.  

“We work with customers who are looking for high-end printing. It’s all about them and making their packaging stand out in the marketplace,” says Nick Carafa, Executive Vice President. “Five years ago we searched for a press with a unique configuration to help get us where we wanted to go. We did our due diligence, which included in-line foiling test runs.

“Typically a cold foiling application is requested for the promotional launch of a product or for point-of-purchase materials,” Carafa explains. “We can offer a unique and effective custom solution. We can lay down foil and also overprint silver foil with other colors to create some astounding special effects.”

Fast turnaround is essential. “We [are] more productive and efficient,” says Carafa. “With the kind of backside printing we handle, we could lay down our ink, dry it and flip the sheet much quicker. It gives us the flexibility to do 8-over-2 or even 10-0. If we don’t have to flip it over, we can print 10-0 on the perfector. Otherwise, we usually print up to eight colors on the front side with the perfector. And not only have we eliminated passes on the press, but we have significantly reduced both makeready times and the amount of waste. We’ve cut our makeready time by 75%.”  

See packgraph.com.  

Faster Folding Cartons   Founded in 2008, PaperWorks Industries specializes in folding cartons, serving clients across North America from 11 facilities. The company recently installed a KBA Rapida 142 56-inch seven-color press with UV capabilities at its Mt. Gilead, NC plant.

Jim Downey, general manager, says UV capabilities coupled with the machine’s closed-loop inline color density measurement and control system, will help the company achieve faster turn times with higher quality.  

Using a color camera to measure the control bar on every sheet, the Quali- Tronic Color Control system compares the density values to reference densities and triggers automatic ink-key adjustments when a discrepancy is obtained. The QualiTronic Color Control system provides corrections to be made within 10 sheets of an error being detected, cuts waste by shortening press run-up to saleable color, and provides consistent inking throughout the entire print run while cutting waste and optimizing print quality.

See paperwrks.com.

More Uptime, with Less Waste

Proteus Packaging, a Franklin, WI-based folding carton converter, recently added a 7-color Speedmaster XL 105 with Heidelberg Logistics. The 40-inch press joins a 57-inch 6-color Speedmaster 145 XL VLF press installed in 2009. For material logistics, the new Speedmaster XL 105 is fitted with a fully integrated system developed to streamline the automated material workflow to the press. The system consists primarily of a modular roller conveyor system and nonstop automatic pile-changing system in the Preset Plus feeder and delivery resulting in fewer pallet changes, reduced production downtime, and more flexible staffing. The company generally runs 10 to 36 pt. board almost exclusively, but still reports considerable waste savings vs. its 50-inch legacy press. The XL 105 achieves makeready and color at its rated speed of 18,000 sph.

See proteuspackaging.com.  

UV Perfector is Twice as Nice HOT Graphics & Printing (Memphis, TN ) has installed two Mitsubishi 40-inch sheeted presses. The $5 million commercial printer installed a 10-color Diamond 3000R convertible perfector and a six-color Diamond 3000S straight press at its recently expanded, 37,000-sq.-ft. plant.

The 10-color perfector features individual coating towers located after the fifth and 10th printing units. The drying package combines interstation infrared/ cold-air and ultraviolet (UV) curing units.

HOT Graphics & Printing produces typical commercial fare, as well as labels, manuals, DVD sleeves and inserts.  

“Differentiating ourselves from the competition is critical in our intensely competitive industry,” says Danny Wynne, assistant production manager. “When we began researching perfectors, we knew we wanted a minimum of eight colors to print process colors on the front and back of the sheet. The configuration of the Diamond 3000R enables five colors plus coating over five colors, plus coating for special effects using conventional and UV inks and coatings.”  

See hot-graphics.com.

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