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FLEXO Magazine : December 2010
• FTA President’s Award recipients, a distinguished few that rise to the top based on their breadth of service to the organization: Dave Nieman, All Printing Resources, his leadership style contributed to a significant improvement in the governing boards’ efficiency. Michelle Donohue, Global Packaging, has been extremely active in promoting sustainable green print- ing within our industry and has been willing to share her knowledge as. Global Packaging became the first flexographic printer certified by the Sustainable Green (SGP) Printing Partnership. Shawn Oetjen & Kent Esby, Dunwoody College of Technology, a team of educational professionals who, in addition to providing high-quality instruction to attending students and industry trainees, have supplied invalu- able assistance to FTA/FFTA on numerous occasions. • First Place, International Phoenix Challenge High School Flexo Competition:, Stephanie Hammond and Lianne Chang, Gordon Graydon Memorial Secondary School, Mississauga, ON, Canada. The duo was declared the winners of the 13th annual international competition, which took place at the Harper National Flexographic Center at Central Piedmont Community College in Char- lotte, NC in late March. Second Place: Grant Izukawa and Chong Wang, Gor- don Graydon Memorial Secondary School. Third place; James Jackson and Marcus Davis, Fairfield Career and Technology Center, Winnsboro, SC. • Third Annual Phoenix Challenge College Competition: Overall Excellence—Dunwoody College of Technol- ogy addressed this year ’s FTA Phoenix Challenge with both energy and attitude. The challenge—“ to redesign, print, and convert (an) existing line of personal hygiene (amenity) products used in hotel guest rooms”—required months of hard work and imagination. The Dunwoody team of Dani Nelson, Ben Paparella, Andy Williams, Matt Evanson, and Chad Quigley, were up to the challenge, sometimes working late nights after doing an eight-hour shift at intern positions. Their solution, “THRIVE” amenity products, was carefully researched, thoroughly tested, artfully executed, and presented with style. Excellence in Research & Graphics: Cal Poly—Rachel Hutchinson, Amy Laun, Tessa Libby, Kasey Reed, and C. Michael Shedd. Excellence in Concept: University of Central Missouri— Katie Bethel, Jaclyn Brunkhorst, Kelly Marshall, Misty Sharp, Marie Aholt. Excellence in Execution: Ryerson University—Nathan Plavnick, Hannah Plavnick, Lauren Lincoln, Ahmer Siddiqui, Stephanie Eagle, Lissa Davey, Stephanie McIntosh, Daniel Quattrociocchi, Jai Gandhi, Jennifer Yeung, Peter Despotas • 10th Annual FTA Environmental Excellence Award for process Improvement: Specialty Printing LLC, East Wind- sor, CT; Honorable Mention: Robbie Fantastic Flexible, Lenexa, KS. AssociAtion HAppenings • FTA unveiled a new curriculum track in its FIRST Cer- tification series. This FIRST Implementation Specialist program. It is designed for non-production personnel, including suppliers of flexographic products and ser- vices. Like the FIRST Press Operator and FIRST Prepress Operator certification, the Implementation Specialist track is divided into three levels. At the completion of all Working Smarter Bobst/F&K smartGPS Wins FTA Technical Innovation Award By ChristianR.Bonawandt Imagineyou areinyourcar. You intendtodrivetowardaspe- cificdestination. Butatthemoment,you haveno ideawhere youare.Asaresult,you drive aroundsporadicallyuntilyou findapointofreference,atwhichtimeyoucandeterminehowto getwhere youwantgo,andcanbeginyourtrip. ThisishowBobstGroup/Fischer&KreckeGmbH describes the old -f as hioned way of s ett ing up regis ter and im pres s ion. Sincetheearlydaysofanilineprinting,themanualestab- lishmentofprintsettingshasresultedintremendouswaste ofink,substrateandlabor.Inthewidewebprinting market, ithasmaderunsunder100,000ft.challengingtoproduce economically,andanythingunder50,000ft.almostimpossible. Aspressesbegantoincorporateautomationsystems,the computerswouldemulatethesametrial-and-errorprocessof se arc hing for the opt im um im pres s ion and regis ter. Thischangedin2008whenBobstGroup/Fischer&Krecke GmbH unveileditssmartGPStechnology.Muchlikeaglobal positioningsystem, BobstGroup/Fischer&KreckeGmbH’s graphic positioningsystem(GPS)determineswhereyouare, whereyouwanttobeandwhatthemostefficient routeisto getthere—allBEFOREtheplate,sleeveandaniloxareinsert- edintothepress.The resultislesswaste,fastermakeready, increasedavailablepresstime,andimprovedprintquality, justtonameafew. Forthisandmanyotherreasons,BobstGroup/Fischer& KreckeGmbH’ssmartGPStechnologyisthe2010FTATechni- calInnovationAwardwinner. Thetechnologywasfirstdescribedonpages20-24of FLEXO’sApril2009edition.Thesystemusesaspecially designedmountingsystem, as well as enhancementstothe sleeves.Ittakesatopographicalmeasurementoftheentire platesurfaceandcircumference,aswelltheanilox rolls.All this is calculated within aone-micron accuracy. The informa- tioniscombinedwithdataonthedurometeroftheplate, sleeveandmountingtape—theentireplatepackage—and enterstheparametersintospecificallydevelopalgorithms tocalculatetheoptimum register and impressionsetting for eachprintdeck.ThedataisstoredinrewritableRFID chips embedded in both the print sleeveand anilox roll. The press thenreadsthisinformationandsetsthedecksbeforethefirst impressionisevenmade. Theend resultisaprintprocessthatrequiresvastlyless handstoachieveoptimumimpression. BobstGroup/Fischer &KreckeGmbH’ssmartGPStechnologytakestheartoutof flexography,facilitatingamorepreciseandscientificprocess. PoSitioninPractice Amongthemorethan40installationsofsmartGPStechnol- ogyintheworldisPlasticPackagingInc.,Hickory,NC.This long-timeFTA memberhasahistoryimmersedinquality controlandenvironmentalstewardship.Thecompanyisa familyownedandprivatelyheldprinting/convertingfirmwith twomanufacturingplants(thesecondinnearbyForestCity), employing 185 people. Plastic Packaging runseightpresseswithwebwidthsrang- ingfrom35in. upto66in., servingtheconfectionary,health care,frozenfoods,petproducts, nutraceuticals,snackfood, andlawnandgardenmarkets.ItemploysSixSigma,5S, 5 Whys, variability reduction and other process and qual- itycontrol methodologies.In2008,thefirmreceivedFTA’s EnvironmentalExcellenceAwardforTechnicalInnovation TechnoloGIeS & TechnIqueS 26 FLeXO june 2010 www.flexography.org HowsmartGPSWorks: • A speciallydesignedmountingsystemtakes atopo- graphicalmeasurementof thecombinedplate,sticky backandsleevesurfaceandcircumference,aswell theanilox rolls. • The informationiscombinedwithdataonthedurom- eteroftheplate,sleeveand mountingtape. • The systemcalculatestheoptimum registerand impressionsettingforeachprintdeck. • AlldataisstoredinrewritableRFIDchipsembedded inboththeprint sleeveandanilox roll. • Thepressthenreadsthisinformationandsetsthe decksbeforethefirstimpressioniseven made. TheKeytoPremiumFlexo AddMoreCommunication We l come tothe Launch Thenew FLEXPRESS15 - Ser i es It’s You r Bu si ne ss. Spo t On ! Thepe rf ec t an s we rt oyou r flex i b l e pa ckag i ng p ri n ti ngneed s. FLX _Ju ne2010_mec h. i ndd 26 6/10/1 0 9:38 AM in rec ognit ion of its b iodeg rada ble poly eth yle ne and ot her sustainabilityefforts. Thebottomline:Plastic Packaginghasalong-standing cultureofcutting-edgetechnologies,efficiencyandwaste reduction. ThatmakesthesmartGPStechnologyaperfectfit. “Our greatest challenges are managing customer lead timesandglobalcompetitivesituations,”saidPrestonBryant, vicepresidentofmanufacturingatPlastic Packaging.The company’srapidexpansionhasledtothepurchaseof more than$16millionincapitalequipment,includingpresses, laminatorsandpouchconverters,since2006.Notlongago, thecompanyembarkedonamissiontopurchaseitsthird press.Butunlikeotherpresses,thismachinehadtohelpit expandintonew markets,inparticulartheever-expanding privatelabelindustry,where,accordingtoBryant,short runs and multipleSKUsaretherule. “Oncewedecidedtoexplorethepossibilityofpurchas- inganothernewpresswedidasix-monthstudyofthelatest advancementsinpresstechnology,”hetoldFLEXO.The decisiontoinvestinsmartGPS,Bryantexplained,waseasy afterseeingitinaction. “WesentateamtoGermanytosee thesmartGPStechnologyfirsthand.Uponreturn, we made apresentationtoourboardofdirectorsandweregiventhe purc has e approv al .” Rightfromthe firststartup,thecompanysawaboostin capacityand, moreimportantly,flexibility.Bryantsaid,“The pressitself,withthe abilitytoturnjobsoverquicker,allowed ustoincrease ourcapacity.Italsogave ustheabilityto move jobsintoourschedule more quickly.Wehavethe abilitytorun jobsback-to-back,andrunlikejobstogether.”The newpress, aneight-colorF&K14S,also exhibitedtheconsistencyand repeatabilitynecessarytomeetPlastic Packaging’scustomers’ qualitydemands,aswellasthe firm’s sustainabilityneeds. AdAptingtoAdvAncements AccordingtoBryant,thesmartGPStechnologydidnot comewithoutalearningcurve.Henotedthatsomeadditional focusontheprepresssideofthebusinesswas neededto ensurejobsweresetuptotakeadvantageofthesystem. “The jobhistorystorageand retrievalfeatureisagreatbenefitfor repeatability.We focusedouroperators on entering data, aswellastrustingandfollowingjobhistoryinformation. Thatmeantthoseoperators runningthepressallhadtobe computersavvy,andlearntooperatemoreasatechnician, ratherthanacraftsman,” hesaid. Intruth,though,Bryantinsistedthetimeneededtotrain employeesonthenewpresswas notdissimilartoothersthey hadpurchased.“The maindifferencewasthesmartGPS. That training has beenongoing, includinghowto deal with smartGPS,howtomakeourink match,andtheauxiliariesin termsofhavingthemreadywhenthejobisthere.” Therewereconcernsamongthestaffastohoweasyit wouldbetoadapttothesystem, Bryant noted,butsaidthat, ifanything,itwasbecausechangeoverswerehappening much more rapidly.“Theyhadtostepitupbecausethispress moves workthroughsoquickly.Ouroperators neededapit crew mentality.Weneedeveryoneworkingtogetherrhythmi- callywhereyoucankeepthingsmovingonthepress.Every- thing now needstobestagedrightaway—youcan’twaituntil thejobisfinishedrunningtostartlookingforwhatyouneed forthenextorder,” he said. The smartGPS-equipped press has beendedicatedto short run, privatelabelbusiness,oranyotherrunsthatare wellunder100,000ft.Infact,Bryantestimatedtheaveragerun onthenewpresstobe25,000ft.Thecompanyaimstotriple thenumberofjobsrundailyonthesmartGPS-equipped14S. “Youwanttomovealotofsetupsonthatpress.Andthat,as Isaid,requiresapitcrew mentality.Whenonejobfinishes, thenexthastobeupand ready.Thepressissofast,thatthe humanfactoristheonlylimitingfactor.” Afterallwassaidanddone, manyoftheemployeesofPlas- tic Packaging were“wowed”by the advancement brought by thesmartGPStechnology,Bryantinsisted.“Ourleadmounter saidhewasamazedbytheprecisionofthenewmachine. Thehardestthingtoadjusttowasthefactthatthereareno shortcuts.Theprocedures mustbefolloweddeadon. Once everyoneunderstoodthis,theyhavehadnoissues.” Technologies & Techniques www.flexography.org june 2010 FLeXO 27 At a recent Bobstgroup/Fischer& KreckegmbHopen House in germany,ademonstrationwasrunonanF&KFP-15-sinwhichonejob wasstarted,stopped,changedovertoanewjob,andthenrestarted. AllartcourtesyBobstgroup/Fischer& KreckegmbH. FLX_ Jun e2010_mec h. i ndd 27 6/10/10 9:38 AM Thriving Among Competition Dunwoody Takes Top Honors at Third College Phoenix Challenge After facing off against10other colleges and universi- ties, Dunwoody College ofTechnology,Minneapolis, MN, emerged on top totakethe award ofOverall Excellence in the Third Annual PhoenixChallengeCollege Competition. Students from each of thecompeting schools gathered in Las Vegas, NV on May 1topresent to a panel of judges. The challenge:to design a line of single-serve sham- poos and soaps for a fictional hotel.Teams’ solutions were evaluated on diverse criteria. In addition to Overall Excel- lence, awards were bestowed for Excellence inResearch, Graphics, Concept and Execution. Overall excellence: DunwOODy cOllege Of TechnOlOgy Dunwoody College of Technology addressed this year’s FTAPhoenix Challenge withboth energy and attitude. The challenge—“ to redesign, print, and convert (an) existing line of personal hygiene (amenity) products used inhotelguest rooms” —required months ofhard work and imagination. The Dunwoody team of DaniNelson, Ben Paparella, Andy Wil- liams, Matt Evanson, and Chad Quigley, were up to thechal- lenge, sometimes working late nights after doing an eight- hour shiftatintern positions. Their solution, “THRIVE” amenity products, was carefully researched,thoroughly tested, artfully executed, and presented withkiller style. The solution began with copious research to determine everything from our target market,package shape, product color, product name and even the design itself.Sustainabil- ity was put atthe forefront to prove an eco friendly solution, taking into consideration everything from materials and inks toprintlayoutand even minimizing web paths.Thestudents contacted many industry professionals togain advice and guidance ineverything frominks and substrates to end-use requirementtests. The“THRIVE” amenities package would nothave been completed without spending hours mixing inkin theinklab, working to minimize delta E variations and achieving an overall colormatch.The key toDunwoody’s success was the terrificcommunication betweendesign,prepress and press. This communicationnotonly allowed fora bettersolution,but also fostered a greatlearning environmentforthe students involved.This teamutilized marketsurveys,hours ofresearch, and industry contacts to assurethe substrate,label,container and designs remained environmentally friendly,economi- cally sound and graphically appealing.“THRIVE” is a printed productsolution they can beproud of. excellence in research & graphics: cal pOly CalPoly’s entry inthe 2010 PhoenixChallenge College Competition involved researching,branding,and producing fourhotelamenity products underthefictitious brand name: The PhoenixLuxury Resortand Spa.Fivestudents competed as CalPoly’s team:RachelHutchinson,Amy Laun,Tessa Libby,Kasey Reed,and C.MichaelShedd. These students worked forsixmonths preparing a line ofamenity products that would speak to the premiumnature ofthebrand they fTa TODAY • Overall Excellence: Dunwoody College of Technology • Excellence in Research & Excellence in Graphics: Cal Po ly • Excellence in Concept: University of Central Missouri • Excellence in Execution: Ryerson University Bettylyn KrafftandJoe Tuccitto(left, respectively) present the awardfor Overall Excellence to The PhoenixChallenge Team from Dunwoody College of Technology atthe Awards Banquet during FFTA Forum 2010: Tom Herold(instructor), Andy Williams, Benjamin Paparella, Danielle Nelson, Chad Quigley,Matthew Evenson andShawn Oetjen (instructor). “Thrive,” the challenge solution submittedby the team from Dunwoody College of Technology. Photo courtesy Dunwoody College of Technology. 8 flexO JulY 2010 www.flexography.org FLXO_July10_v2.indd 8 7/16/10 9:35AM Bobst Group North America, Inc. 13325 South Point Blvd, Suite 400, Charlotte NC 28273 Tel: 704 587 2450 Apparently we’re not the only ones who think smartGPS is a big deal. The smartGPS is our exclusive Graphic Positioning System which automatically generates registration and impression settings offline during plate mounting. This eliminates almost all set-up waste, providing stunning print quality starting with the first impression. n Automated set-up saves substrate, ink, energy, press time, labor and more. n Achieves perfect impression and register from the very first repeat. n Increased efficiencies open new markets to flexo printing. n Available on all Fischer & Krecke flexo presses. F&K FTA Award_Layout 1 5/27/10 7:18 AM Page 1 14 FLEXO december 2010 www.flexography.org FTA TOdAY FLX_Dec10.indd 14 12/15/10 12:59 PM