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FLEXO Magazine : February 2011
Plants & Processes “Nearly everything in the plant is new ” Bray declared. “First, we moved further into lamination in 2006. It began with installation of a Nordmeccainca Supercombi 2000. Two years later, in 2008, in went a Nordmeccainca Super Simplex. “In 2007, came an eight-color wide web Uteco Onyx press. It was followed in 2010 by a 10-color Onyx. We replaced four presses with two. Our new Onyx presses, featuring match- ing footprints, have the capacity to produce what many other converting operations put out with four.” Both presses have BST ProMark video inspection / print fault detection sys- tems, Inkspec viscosity controls, and X-rite color formulation systems that take graphic ink and press side measurements. To bolster consistency, we’ve added two Microclean units for aniloxes and plate cleaning. Both serve to remove variables associated with reproduction. ” “In 2008, we added a stand-up pouch machine from PPI Technologies. Slitting upgrades saw acquisition of some Deacros with the latest technologies in digital drives and shafts with roll locks. Bray said this year, 2011, brought with it a new W&H Optimex three-layer extruder. “ It’s been up and running for several weeks now. This is a very exciting time. Nothing is being overlooked.” Thinking back on the equipment recapitalization experi- ence, Bray stated, “What we just went through, with the press and extruder, is Phase 2 of our overall capitalization plan. Phase 3 will bring additional lamination, wide-web slitting and stand-up pouch capacity. Target time frame is 2011-2012.” Citing other moves, Bray pointed out that, “We did move into Digital Facility Management partnering with OEC Graphics. We have been running with this since June of 2009. This arrangement allows us to make our printing plates onsite with separation work done at OEC and at FLEXSTAR. The prepress activity is managed via a customized Workflow Management tool provided by OEC Graphics. This system allows for order tracking and managing the customer ap- proval process.” “OEC has also brought along technology, such as High Definition Flexo to our operation, thereby increasing our offerings to our customers. With the introduction of HD flexo, we will be able to print sharper, cleaner, crisper images with smoother vignettes and improved contrast. We are right there with rotogravure printing. We have been able to transition a number of jobs from offshore roto to traditional and HD flexo. These tools, along with an optimized flexo printing process, give our clients packaging solutions focused on their unique requirements. ” Poised & PrePared “By carefully controlling our manufacturing process, we re- main nimble in our ability to jump in and out of orders,” Bray noted. “Our whole group shares one attitude, and embraces these words: ‘If we need to do it, we will!’” According to Bray, “Customers today have a tendency to order products to avoid obsolescence. Thanks to shorter lead times, they are better able to predict their requirements. It’s changed everything and created the playing field under which we operate. “...We are going to continue to get more efficient and be able to put out increasing volume with the same workforce. Challenges exist to be overcome!” n www.flexography.org February 2011 FLEXO 25 The 7 r’s of Packaging aT flexsTar Sustainability is at the forefront of business decisions at FLEXSTAR Packaging Inc. Bob McQueen, director of market- ing, states, “Our goal is to constantly improve and move forward with sustainability in mind for all aspects of the busi- ness. ” T he plant is by and large powered by hydroelectricity. McQueen said, “We feel it is very important to understand the overall impact of our decisions. That is why we support the Life Cycle Analysis approach to sustainability.” He then pledged, “As sustainable raw material technology advances, we will be continually highlighting new product offerings and technologies in regard to sustainability. FLEXSTAR is a company based on honesty and integrity and being a good corporate citizen is a part of that goal. ” A summary of FLEXSTAR sustainability initiatives lists out as follows: Remove FLEXSTAR works with customers to optimize package sizes and minimize other waste factors wherever possible. Reduce A substantial volume shift to solventless laminations and water-based adhesives has been made. It has resulted in a significant decrease in VOC generation. Reuse Solvents are recycled for use in automatic wash-up systems, and customers are afforded the opportunity to return peripherals for re-use, thus reducing their waste stream. Renewable Use of sustainable materials and the overall weight reduction of packaging is the focus. Continual developments are expected. Recyclable Recycled cores and re-usable pallets are purchased. Currently, a plant-wide recycling program captures and re-cycles 85 percent of what was previously landfill. Revenue Streamlined supply chains achieve improved results and realize cost savings. Read FLEXSTAR is an active member of the Plastic Processors Environmental Association of BC, CFECA and the Packaging Association of Canada to help it improve the overall knowledge base and further educate customers. FLX_Feb11_mech.indd 25 2/16/11 8:50 AM
Sustainable Winter 2011