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FLEXO Magazine : June 2009
FTA TODAY was that glass bottles seem more upscale than plastic, but as consumers, students didn’t want to pay extra for that. Also, to optimize the bottle shape, a wrap was deemed more suitable than a shrink sleeve, which would require less material.” The fi nal design was chosen because students felt it would be easier to place in a side pouch of a backpack, be easy to take out, and, because it isn’t glass, would not break if it is inside the backpack. The unique shape, Ho added, encouraged them to reuse for other purposes. For materials, Laun insisted, “Anything that carried the black logo had to be as eco-friendly as possible.” The team considered a PLA-lined stock for the coffee cup, but this did little to aid in the sustainability of the product, as did using a bottle and wrap that were made of the same polymer. As such, they went with a 2mil polypropylene wrap on a polyester bottle. According to Miller, the cup was printed without gold in the leaves to be more sustainable. The team also opted not to print the entire cup black, a decision that saved 70 percent on ink usage. “The cup is two-color, which, when considering the registration, produced the least makeready waste.” On the wrap, the gold was knocked out, allowing consumers to see the coffee through the leaves, which are outlined with a thin gold trim. “Once the design was set, we went ahead and did prepress,” said Noble. “We used 0.667in. Cyrel plate with a .027in. releif. Then we designed the wrap in Illustrator and used Esko’s DeskPack plugins for some basic prepress work.” Laun noted that a .03in. trap was added to avoid loosing details in the leaves. Noble stated that the white was reverse trapped in case there was mis-registration. The team used Esko’s Groovy screens in PackEdge for more solid density. Costa said the limitations of the press—a 7in Mark Andy—presented problems when printing the cup, which was 10in. “We had to run the cup in the wrong grain direction. This would risk the stability of the cup.” The girls decided to chance it anyway, but noted that in industry, a 13in. press would have been used. Ho and her teammates did ink drawdowns with a bladed hand proofer on both the clear fi lm and board stock. “We were able to get a numerical target for density on press. Some of the challenges included printing in the opposite grain direction, and the 18pt. board stock, which was pushing the press’s limits of capability.” “We achieved +/-.05 density to our drawdowns,” added Laun. A water-based white was substituted for a UV white when the UV curing lamp began melting the laminate. The team also decided to go with plastic crates instead of corrugated boxes for shipping, which used 39 percent less energy and 95 percent less solid waste without having to worry if corrugated boxes ended up in landfi ll. This also averaged 29 percent less greenhouse gases, lowering the overall carbon footprint. GRAVITATIONAL PULL Judges were pulled by Center of GravaTea, the product solution proposed by Dunwoody students Trevor Olson, Matt Grotz, Cait Peschken, David Mitchell and Josiah Mitchell. The team surveyed 557 people, aged 18 to 35 years who visited WE ARE FLEXO. Most people know us for our flexo plates and equipment. But A&V is a lot more than flexo plates. Our broad product line includes everything from anilox rolls to shipping/packaging supplies. In between, we offer densitometers, doctor blades, edge sealing tape, end seals, electrical tape, Epson printers and supplies, just to name a few. We even offer respirators and safety goggles! Ask your A&V representative for a list of our products, or visit our web site and take full advantage of our complete product line. Because we are flexo. And a lot more. TM www. f le xography. org JUNE 2009 FLEXO 61
Sustainable Spring 2009