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FLEXO Magazine : November 2008
NOVEMBER 2008 VOLUME 33, NO. 11 In This Issue CASH & CARRY In the folding carton arena, sheetfed offset remains the dominant force, largely as a result of size restrictions. But flexo continues to gain marketshare, and is doing so due to efficiencies and the lower cost associated with the flexo print process and in-line rotary die cutting. Speaking of die cutting, this issue’sBeginner Flexographer focuses on the history of the flexible die, its benefits, and instructions for proper handling. In addition, long-time FTA member Cascades Boxboard in Canada talks about being a leader in sustainable carton production. Also be sure to check out our coverage of the Fall show circuit, and aSpecial Supplement on sustainable platemaking, reprinted from our Sustainable FLEXO online exclusive publication. CARTONS Spectro Study Lean in Action Labelexpo + SuperCorr FTA HEADQUARTERS & FLEXO EDITORIAL, ADVERTISING, SUBSCRIBER SERVICES 900 Marconi Avenue Ronkonkoma, NY 11779-7212 Phone: 631-737-6020 Fax: 631-737-6813 PUBLISHER Robert Moran, ext. 17 firstname.lastname@example.org EDITOR Christian R. Bonawandt, ext. 31 email@example.com DIRECTOR OF BUSINESS DEVELOPMENT Jay Kaible, ext. 20 firstname.lastname@example.org TECHNICAL DIRECTOR Bill Pope Phone: 585-267-5434 email@example.com EDUCATION DIRECTOR Joe Tuccitto Phone: 651-319-5003 firstname.lastname@example.org DIGITAL DESIGN & PRODUCTION Red Flag Media www.redflagmedia.com FTA TODAY 6 Pub Ink 8 Association News 76 Engaging Ideas 10 Happy Birthday, TEST! It’s been a little more than one year since FTA announced its bold new educational initiative. What have we accomplished? Where do we go from here? 68 Wide Web Council Investigates ITR Bill Bower of Flint Group Flexographic Products spoke candidly about the cur- rent status of in-the-round (ITR) plates and platemaking with FTA’s Wide Web Leadership Council. 72 Flexo in Front FTA members and flexographic printing stood out and got noticed at the 2008 TLMI Awards. 16 73 Class is in Session! The TEST Virtual Campus is now live with more than 150 courses in many areas that are valuable to the occupational development of flexo- graphic industry professionals. INDUSTRY INDICATORS 14 Pressing Issues LABELS 16 Long Live Labels LABELS BEGINNER FLEXOGRAPHER 36 Flexible Dies Jim Doedderlein A history of the flexible die and step- by-step instructions for mounting, de-mounting and cleaning. 42 ’Round We Go Tim Reece What is TIR, how does it affect you and how is it measured? 46 Cleaning Christian R. Bonawandt & Robert Moran Labelexpo Americas 2008 proved the narrow-web industry can and will sur- vive the current economic climate. 22 New Vision of Narrow Web Christian R. Bonawandt Dean Scarborough, president and CEO of Avery Dennison discusses the changing face of the label industry. CORRUGATED 24 SuperCorr 2008: Parade Best practices, sustainability, energy and economics were on everyone’s lips at North America’s largest box making trade event. TECHNOLOGIES & TECHNIQUES 28 How Accurate Spectrophotometers? A study by VIGC has found deviations of up to 4 delta E in various devices, includ- ing those by the same manufactures. CARTONS 32 Productivity & Efficiency Mike Pfaff In-line printing and die cutting of flexo folding cartons is more economi- cal than typical sheetfed production. Are Your Corrugated on Goes Cold Dry ice blasting is a unique cleaning method that cuts down on labor and could prove more environmentally friendly than solvent-based cleaning products. PLANTS & PROCESSES P’S & Q’S 50 Cascades: it was Trendy Cascades Boxboard in Cobourg,ON, Canada has been thinking green long before it was hip—and its pioneering has paid off in spades. 54 Applying Lean John J. Morgan Examples of Lean Manufacturing in action, including in one flexo pressroom. SUSTAINABLE FLEXO SUPPLEMENT 59 Great Plate Debate How do plates and the platemaking process factor into the sustainability picture? Two manufacturers released independent studies on this issue, and they are reported here for readers to review and analyze. 60 DuPont Packaging Graphics Study 64 Flint Group Flexographic Products Study FLEXO® Magazine (ISSN-1051-7324) is published monthly by the Foundation of Flexographic Technical Association. Address all correspondence to FLEXO® Magazine, 900 Marconi Avenue, Ronkonkoma, NY 11779-7212. Telephone: 631-737-6020. Fax: 631-737-6813. Copyright ©2008. All rights reserved. Subscriptions: 1 year: $55 U.S./$76 foreign; 2 years: $92 U.S./$125 foreign; 3 years: $125 U.S./$170 foreign. Single copies: $7 U.S./$10 foreign. Periodicals postage rates paid at Ronkonkoma, NY 11779, and at additional mailing offices. POSTMASTER: Send address changes to FLEXO® Magazine, 900 Marconi Avenue, Ronkonkoma, NY 11779-7212, USA. Printed in USA. Publications Mail Sales Agreement No. 1558153. FLEXO® Magazine is the official journal of the Foundation of Flexographic Technical Association, devoted to education, technical and research support to advance flexographic technology. Acceptance of advertising in FLEXO® Magazine does not imply endorsement of the product or service by the FFTA. Opinions expressed in bylined articles are not necessarily those of the FFTA. Green Before NOVEMBER 2008