by clicking the arrows at the side of the page, or by using the toolbar.
by clicking anywhere on the page.
by dragging the page around when zoomed in.
by clicking anywhere on the page when zoomed in.
web sites or send emails by clicking on hyperlinks.
Email this page to a friend
Search this issue
Index - jump to page or section
Archive - view past issues
FLEXO Magazine : August 2011
70 Quick, Seamless Change David Darder When connecting productivity with efficiency, you must apply new concepts to get the same, consistent results in a shorter window of time. Current press technologies are seen as facilitators. 83 Intelligent Machines are Maintenance Minded Tom Jacques Today ’s tech-savvy workers expect a high degree of automation and ease of operation, which the latest press technology can give them. PLANTS & PROCESSES 28 Calculating Your Facility’s Carbon Footprint Three basic steps to determining total CO2 emissions from a facility are list, convert and add. 54 Optimizing Your Business for Short-Run Printing Glen Galloway & Mike Reinhardt When filling and processing a short order, printers/converters need to focus efforts on answering one question, “How fast can we get the job ready to run?” 78 Lightning Quick Turnaround, No Compromises in Quality A new press can change the operational dynamics of a plant. At England’s Norprint, a new, short-run flexo press is proving a good fit with Lean manufacturing. INDUSTRY INDICATORS 60 The Lean Mid Web Press Steven Leibin Now that flexo print quality rivals gravure and offset, it is bringing increased interest in mid web flexo press solutions in the folding carton market. AUgUST 2011 VOLUME 36, NO. 8 In This Issue (con’t.) 70 FLEXO AUGUST 2011 www.flexography.org Quick, Seamless Change WhattoLookforinaPress&Howto Make it Possible By David Darder Googlethewordsproductivity andefficiencyandyou’ll getthefollowing results: Productivityistherelationshipbetweenoutputfrom aproductionprocessandtheresourcesusedtoobtain thatverysameoutput.Itcanalsobedefinedasthe relationshipbetweenresultsandthetimeusedtoobtain them. Theshorteramountoftimeneededtoobtainthe expectedresult,themoreproductivethesystemis. Efficiency is defined as the capability to have some- oneorsomethingat yourdisposalinordertoachieve EFFICIENCYATITS CORE • Improvementsinergonomics takeefficiencytoits pureststate. • Designoffers easyaccess formaintenanceand daily operational needs. • Partsreplacementissimplified. • Continuousimprovements,toincludeself-cleaning andself-inkingsystems,breed userfriendliness. Efficient pressesareequipped withanoverheadplatformthatallowsaccesstoallelementsrequiring maintenance, withthe purpose of simplifyingpartsreplacement;aswellasupkeepand cleaning. Photos:Comexi. TECHNOLOGI ES & TECHNIQUES www.flexography.org AUGUST 2011 FLEXO 83 Intelligent Machines Are Maintenance Minded Advanced Electronics Minimize Manual Labor & Boost Efficiency ByTomJacques “Whatarethelatestautomationtechnologiesfoundon today’s modernflexopresses?”“Howdothesenewtech- nologiesmaketheoperator’sjobeasier?” “Whatdomodern pressesofferinterms of maintenanceschedulesandhowdo theyalertpressoperatorstotheirrequirements?”—theques- tionsarehard-hittingandplentiful. Everyoneissearchingforsecretstopeakperformance andpepperingpress manufacturerswithqueriesdirectedat maximizingproductivityandprofitability.Acriticalconcern: “Whatcaveatsarethereforoperatorsusingtheseadvanced systemsforrunningand maintaining modernflexopresses?” Also,“Whatflexibilityisthereinsettingupmaintenance schedules,sothatthealertscanbeissued,basedonempiri- caldataandexperience,versus standardfactorysettings?” ENERGY& ERGONOMICS Convertersarefocusedonbeingevermoreefficient.As such,theyarealwayslookingforbetterresourceutilization, lowerwasteandlessenergyusage,allofwhichtranslateto lowercostsandhigherprofits. Recentdevelopments,whichhavecontributedtoquicker set-ups,include:automatedregistercontrols,idledeck makereadysystems,pipe-freedoctorbladeholdersand SIMPLEUPKEEP, TARGETEDPROMPTS • Convertersarelookingforbetterresourceutilization, lowerwaste,andenergyefficiency; orinotherwords, lowercostsandhigherprofits. • Machineinterfacesaregraphical,intuitiveandeasy- to-learn. • Tech-savvy workers expectahighdegreeofautoma- tionandeaseof operation, whichthelatestpress technologycangivethem. However, thereisalsoa degreeofjudgment andcommonsensethatmustbe applied toanysituation. • Maintenancepagesonthetouchscreenalertthe operatorwhenactionis needed. Flexotecnica’sXG-10incorporatesadvancedelectronicsin an intelligent,operator-friendlyformatthatattimes alertstheusertobasicmaintenance needs. TECHNOLOGIES & TECHNIQUES 54 FLEXO AUGUST 2011 www.flexography.org Optimizing Your Business for Short-Run Printing Materials Prep & Positioning + In-Plant Workflow are Critical By Glen Galloway& Mike Reinhardt CustomersareincreasingthenumberofSKUs.Typi- calrunlengthsaredecreasing.Many jobsofseven ormorecolors requirecomplex process printingwith photo-likequality.Clearly,industrytrends forflexographic printers arechanging. Tobesuccessfulinthismarket,thepressesandorganiza- tionofplantsneedtobeoptimizedforquickchangeoverand wasteminimization. Priorto2000, mostprintingpressesweregearedcylinder typesandwash-up systemswerejustintheirinfancy.Depend- ingonthenumberofcolors,changeovertimes betweenjobs rangedfromafewhours tothebetterpartofaday.Inaddi- tion, a significantamountof wastewasgeneratedcleaning uptheusedinks andthengettingthepress intoimpression/ register.Nomore! SUCCESSFUL SHORT RUNS • Presschangeovertimeis reducedtolessthanone hour. • Wasteis minimizedtoonlyafewpounds. • Maintenanceworkis accomplishedinminutes after thepresshas beenshutdown. • Registrationand impressionona10-colorjob can be accuratelysetin5 minutes,withlessthan50feet of wastematerial. • Properscheduling ofsimilarjobsoptimizes press timeandeliminates unnecessarycolorchangesand wash-ups. • Materialflowisorganized toallowpresspersonnel tofocusonthemakeready. Thecontrolpanelofa modernpress,where registrationandimpressioncanbe accuratelysetin5 minutes. Photos:W&HCorp./BemaInc. TEC HNO LOGI ES & TECHNIQ UES 78 FLEXO AUGUST 2011 www.flexography.org Lightning-Quick Turnaround, No Compromises in Quality Norprint, Single-Largest Print Production Facility in U.K, is Ever-Evolving Brightcolors,perfectregistration, highqualityprint, satisfiedcustomersthatkeepreturninganda160-year history inthelabelprintingbusiness—it’s quitethe resume!ItbelongstoLincolnshire,England-basedNorprint. Widelyrecognizedasthesingle-largestprintproduction facilityintheU.K.,thisoperationisoneofEurope’s largest labelingsolutionsproviders.Itprintsmorethan7 billionlabels annuallyandkeepsmorethan30presseshumming24 hoursa day.Its reputationissteadfast.Thisis anever-evolvingplant. Today,a majorcapitalinvestmentprogram, withinstallation ofahighperformance,servo-driveneight-colorflexographic press atitsheart,iswellunderway.Recentdevelopments, associatedwiththeongoing£800,000upgrade,arechang- N O RP RI NT AT-A-GLAN CE • 160-yearhistory,startingas FisherClark&nowa partof MagnadataGroup. • Billionsoflabels manufactured annually. • Revenues exceed£20millionannually. • 200+employees. • 30presses run24hours aday. • Leanmanufacturingbusiness philosophybridges conventionalflexoanddigitaltechnologies. Sinceinstallation,Norprint’snew pressisdemonstratinga23percentsavingsinmakeready time. PLA NTS & PROCESSES THE FUTURE IS ROUND Copyright © 2011 DuPont. All rights reserved. The DuPont Oval, DuPontTM, The miracles of scienceTM and Cyrel® are trademarks or registered trademarks of E.I. DuPont de Nemours and Company or its affiliates. DuPont Packaging Graphics “Advancing Flexography” www.cyrel.com/na Until now, if you wanted the superior print quality and high press speed of continuous-print flexo sleeves, you had to accept the long lead times associated with custom-made products manufactured in Europe. Faced with a fast turnaround project? Your options were limited. Not anymore. DuPont is opening its first North American manufacturing site for Cyrel® round sleeves. Finally, you will be able to enjoy the benefits of Cyrel® round sleeves—gravure-like image quality, near-perfect register, improved tonal range, excellent ink laydown, high press speed and more— all with improved lead times. Whether you’re interested in solvent-process continuous print blanks or our new Cyrel® FAST round system, your choice has never been clearer. And, the results have never been faster. At DuPont Packaging Graphics, we create print technologies—innovations that move the flexographic industry forward. DPG-Rev Round AD-FLEXO.indd 1 5/23/11 7:57 AM