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FLEXO Magazine : October 2009
www.flexography.org OCTOBER 2009 FLEXO 61 Another area of great change had been substrates. "At one stage, we were printing on what a lot of people referred to as sand paper. The profile of the paper was ghastly. There have been leaps and bounds in what Visy Paper has been doing, and it was unheard of to calender a sheet before they sent it to coatings. Now everything is calen- dered before it comes to preprint. The coat- ings they use now are being applied in litho by Visy Glama and we're using that very same paper printing the Smiths, Cadbury Schweppes and Fos- ter's cartons. We run a coating paper called TCP 165. "So with constant improvement of our graphic arts house; and the constant improvement of our paper; we're able to achieve great consistent results in areas like skin tones that Yellowglen gave us the opportunity to develop. We have a consultation process here, where we involve our printers in any of the new work and get their feedback, which gives them ownership. Manning called the prepress side of the business "excit- ing," particularly because of the ability to work on a job from the very beginning. "You see the gestation period; then you see the job born; and finally ready for the client. You get a phone call which says: 'I'm thinking of doing this. When can you come out and see me?' And you watch the whole thing evolve from there." At Visy 's Campbellfield site in Melbourne, Australia, the crew runs a 2.8-meter Fischer & Krecke press---one of the widest widths of any flexo printer in the world. "We have the biggest F&K press that has ever been built," proclaimed Manning. "The width of this F&K press is 2.8 meters and is the biggest CI that they have ever designed. It was designed and built exclusively for Visy. It weighs about 75 tonnes and allows us to do what we do best---produce great flexo car- tons for customers." As a company known for embracing the latest technol- ogy, Visy Flex Preprint is now also using Flint protein-based inks, eliminating the use of solvents. "They are providing a far superior product than we've had in the past," Manning said. "Ink densities and color matching is so much better, and we've reduced the time taken to do that. One of the biggest things that preprint has achieved in the past 12 months is our waste reduc- tion. That is down now to 3 percent of the 2,700-tonne-per-month product output, from about 8 percent, saving thousands of dollars to the business. "We brought all the guys in and explained what the waste cost was to the business. That's been a big win for us and a very positive thing. By using protein inks we have been able to double the speed on the F&K, as the ink rewets itself. We're still learning about the ink, as is Flint. Primarily, we purchased the press for run speed, but now it's the environmentally food safe factor which gives us advantages. "We also have possibly the most accurate state-of-the art mounting machine ever designed and built. It's called a Leader Mounter from the U.S. It has minimum interaction from the mounter, other than pushing a touch screen. So it's fully automatic and doesn't proof up, just mounts. It enables the Fischer & Krecke press to run the sort of jobs we're run- ning today." The future? Manning said it's in "point-of-sale." He added, "That's where graphics are a lot smaller and challenging to print. Print to die-cut registration is a lot tighter. With Visy Board's brand-new EMBA Flexos and Gopfert die-cutters, print to die-cut is finer than ever," concluded Manning. Prepress/New Work Manager Dave Manning. (L-R) Geoff Sparks and Frank Villella. "With constant improvement of our graphic arts house; and the constant improvement of our paper; we re able to achieve great consistent results..." ---Dave Manning, Visy Flex Preprint PLANTS & PROCESSES
Sustainable Fall 2009