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FLEXO Magazine : October 2011
Excellence in Flexography Awards dEAdlinE: dEcEmbEr 2, 2011 Technical innovation Award dEAdlinE: JAnuAry 2012 Environmental Excellence Awards dEAdlinE: dEcEmbEr 31, 2011 If you are interested in becoming a judge in these prestigious awards competitions, please send an email to Shelley Rubin at email@example.com Join the Ranks of the tRuly accomplished FTA’s 2012 AwArds compETiTions Jerry Henson, sales manager, Mark Andy; Pam Dorrough, 3M, Coffman, Fry and myself. Running the job: Tony Thornberry, press operator; Dwight Thurman, press operator; Holzknecht, Brian McNay, press assistant; Brad Norris, press assistant and James Mann, plate mounter. Holzknecht spells out the mission in printer ’s terms. He begins as Rotometrics hard case plate tooling cylinders stand at the ready at each print station. Nearby lay Harper’s anilox roll crates, some with their contents already sitting atop setup carts. Ink pans are clean and ready for pouring to begin. The media: Envirocure inks, specifically the Ultra Flex line. “Our press is 10 stations and the web is 17-in wide. The threaded web path encompasses some 80 feet. The job passes through UV inking stations, a delam unit, relam unit, turn bar, rotary screen unit, cold foil unit and three individual die stations.” He explains, “Today, we are printing the bottom pass first— the backside or inside covers containing the Dixie Graphics and MacDermid advertisements, then we turn the web, if necessary print primer, and pick up the other side—the front and back cover. CMYK goes down in that order on the first four stations, then primer for foil, then CMYK on the second four stations. This stock, 100 # Pub Gloss 88, made by Sappi, tends to be coarser. We run the press at 200 fpm. Rotary screen application limits the speed just a bit.” Holzknecht adds, “This is not a typical job. It’s a magazine cover. It might be typical in our offset operation, but not on the flexo side. ” He admits, “We have experience with similar work. ” Publishers printed the Alpinist Magazine cover that took a gold medal and best of show in its class in the 2011 FTA Excellence in Flexography Awards. “ That job also used MacDermid DMAX plates. This one adds LUX technology to the equation. ” Elaborating on that note, Holzknecht says, “We have experi- mented with LUX, but it’s not run every day. We wanted to learn flexo on conventional digital first. For our now cross trained operators from offset, flexo is a different process that requires a new mindset. We’re working on abiding by Flexographic Image Reproduction Specifications and Tolerances (FIRST). In fact, our prepress team is becoming FIRST certified. ” Turning back to the job on press, he states, “This one’s not easy. Printing both sides of the web makes it challenging. We have a lot going on. We’re running almost every aspect of the press, except for lamination. ” Reviewing the day ’s setup, he mentions, “We had to get a handle on impression. Once we did, things got easier. With LUX, everything came into impression sooner. The job gets up to image faster with the flat-top dot. We also get up to color faster. Looking PRINTER ON PERFORMANCE Publishers Printing Co., Shepherdsville, KY, a traditional offset publications printer and one of FTA’s newest members, has now turned to flexo—and the Performance Series P7 press. “In 2009, Publishers Printing began a strategic initiative to diversify its business by entering into new, previously unchartered markets,” says Mike Simon, vice president. “After much research, we discovered growth opportunities in the label and packaging industry and began the search for our first flexo press.” According to Simon, the P7’s allure is its versatility. “It was important for us to invest in the latest technology to drive productivity, flexibility and quality. The P7’s smart print deck design, coupled with sophisticated registration control and web management allows us to maximize its performance,” he says. “ T he simplicity of the print station components, open architecture and automated features have allowed our pressmen—offset operators—to easily adapt to a whole new print workflow. Since installation, we have tested the P7’s abilities and continue to find it quite impressive in all aspects.” Steve Holzknecht, production manager oversees the flexo operation—one shift (7:00 am-3:30 pm) and prints between two and four jobs daily. They range from labels to, flexible packaging. Label runs are 5,000 pieces or larger, with flexible packaging jobs often starting at 10,000 pieces. The crew can and has handled 180,000 piece runs. Cortney Etherton, sales manager, says the division is winning new business on a daily basis. He and Dan Weber, vice president of sales, are forecasting growth. All, including Pressman Tony Thornberry, agree that the piece of equipment at the heart of their flexo pressroom is smart, simple and effective. Workflow is smooth and predictable. At press time, Publishers is pondering its next moves in the flexo arena. Entry into the wide web market is being consid- ered and room is available for expansion in the label and narrow web pressroom. Publishers Printing is a fifth-generation family owned company dedicated to providing exceptional service. It opened for business in Louisville, KY, in 1866 and moved to nearby Shepherdsville in 1958. Today, at 145-years old, Publishers has grown to become the largest employer in Bullitt County, serv- ing printing needs nationwide. It has just under 1 million sq. ft. of space dedicated to commercial printing work, offering a variety of prepress, press, binding, and finishing options. The Label & Packaging division houses a 10-color Mark Andy P7 flexographic press, which enables it to offer high-quality pressure sensitive labels, foil stamping, embossing, rotary screen and lamination capabilities—the vast majority of which were applied to the production of FLEXO’s October 2011 front cover. Note: Contact Cortney Etherton at 502-925-6526 X 7135 / 1-800 -214-1073 X 7135 or firstname.lastname@example.org 54 FLEXO october 2011 www.flexography.org