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FLEXO Magazine : April 2008
PLANTS & PROCESSES ing the staff so that anyone person can do any other person's job. "We focus on flexibility," Jay proclaimed. "We focus on being able to move people to where we need them. The key is minimizing downtime." David explained further, "Miguel Castaneda, who is our plate- maker, is a very accomplished press operator. He has run every press out there, including our MPS. Our floor supervisor is one of the best operators in here. When some people are on lunches and breaks, other people will run the press. When we aren't doing maintenance, we are running presses." This emphasis on efficiency was exacerbated when Jay joined the company in May 2006. "When Jay came on board, we were running two shifts. Through his insight and hard work, we were able to get rid of the second shift," said David. "We changed our philoso- phy to focus on the down- time," said Jay. "Why wasn't a press running at a given moment? So we got more flexible. Once that happened, we had a huge increase in uptime and efficiencies. That puts the onus back on sales, where it belongs." "And it's my job is to keep the onus on production," re- plied John.. - FLEXO A PR I L The brand owner for the Authentic and Original Signature cologne was originally concerned that the designs for each of these labels could not be reproduced. The artwork calls for two foils per copy. The "Black Mark" has a black and silver foil, the "Blue Mark" has a blue and silver foil, and the "Silver Mark" has two different silver foils. Furthermore, these foils are hot-stamped in incredibly tight registration to one another. To add the finishing touches, we created a multi-dimensional emboss effect to accentuate the brand owner's "mark of authentic and original." -John McDowell Each year, we produce a fin- ished printed and packaged prod- uct for self-promotion purposes. We strive to create a product that is consistent with each annual theme. This year, our theme is, "To accelerate in 2008!" Thus, we felt it was fitting to create a McDowell Label-sponsored NASCAR replica. For this heat shrink sleeve, we wanted to incorporate very edgy, electrifying graphics. We con- verted holographic foils to yield different effects with the flames, the hood with our logo, and the number on the side of the race car. 2008 www.flexography.org We printed with different colors and graphics to demonstrate the dynamic effects yielded by both color and design, with very tight registration. Additionally, this is a very uniquely shaped container. Understanding the various and subtle shrink curves is critical. Making sure that both the graph- ics (tires, wheels, windows, hood, roof, etc.) and the foils shrink proportionate and specific to the corresponding location on the car is more difficult than it appears. -John McDowell