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FLEXO Magazine : September 2013
PRESSROOM ISSUES Nearly 18 percent said end seal leakage was a common issue, making it the most popular response (See Chart 3). Excessive downtime for cleanup/turnaround came in second at 17 percent and doctor blade wear was the third-most com- mon issue at 10.7 percent. Anilox scoring in the press, web guiding and tension, and anilox damage from handling and storage were said to be the least seen, with 35.4 percent, 33 percent and 32.7 percent, respectively, marking them as rare. More than 10 percent of respondents indicated that they commonly had issues with anilox damage from handling/stor- age, end seal leakage, doctor blade wear, excessive down- time for cleanup/turnaround and material costs/availability. However, in many instances, a greater percentage actually indicated that these same issues occurred “rarely. ” When analyzing flexible packaging printer responses, trendlines indicated that they have less issue with anilox scoring and wear, high plate wear, UV ink spitting, die cutting and registration. Conversely, they take greater issue with excessive downtime than the composite. Flexible packaging showed end seal leakage as the most common issue, affect- ing 22.7 percent of respondents. Cleanup/turnaround down- time took second place at 16.7 percent and material costs and availability came in third at 13.6 percent. Anilox scoring in press was the least-seen issue by 43.3 percent. TLD printers had more worries than the industry as a whole. Platemaking, UV ink spitting and diecutting issues proved more eyebrow raising. They had fewer issues with anilox cell plugging and damage, end seal leakage, doctor blade wear, print quality, excessive downtime, ink runability and web guide tension than the more typical respondent. The top three most common issues for the segment were excessive downtime for cleanup/turnaround, with 16.3 per- cent, print quality, with 9.8 percent and plate/platemaking, with 9.3 percent. End seal leakage was “rare” according to 46.5 percent, making it the least common. TURNAROUND TIME In general, those facilities with in-house platemaking ca- pabilities post faster turnaround times (See Figure 1). Among firms with in-house operations, nearly 60 percent reported one-to-two-day turnaround times. The results suggest that the biggest bottleneck in opera- tions is press changeover, followed by press makeready (See Figure 2). When asked if facilities are applying lean manu- facturing principles to the production process, 37.6 percent stated they have already implemented lean practices and 41.3 percent said they were in the process. Flexible packaging printers reported 30.3 percent and 46 percent, respectively, and TLD printers, 41 .9 percent in both instances. This would seem to support wide acceptance of lean manufacturing principles. When questioned about requests from customers for a “greener” supply chain, 55 .5 percent responded in the affirmative and 44.5 percent in the negative. SURVEY DEMOGRAPHICS Roughly 150 printer/converters participated in the FTA Printer/Converter Process & Technology Survey 2013, with about 90 percent also holding FTA membership. The major- ity of respondents—80 percent—were located in the U.S. , with 10 percent in Canada and 5 percent in Latin America. A commanding 92.5 percent employed more than 20 individuals PaperWorks Industries, Baldwinsville, NY IT’S ABOUT PEOPLE YOURS AND OURS A staple among prepress trade shops since 1903. After 110 years, we think it’s time for something new. dixiegraphics.com | (615) 832-7000 | email@example.com MEET THE TEAM AT DIXIE GRAPHICS Pat Meadows - President Matt Williams - Executive Vice President Scott Hillstead - VP of Operations Johnna Imel - Account Services Director BUSINESS DEVELOPMENT Jay Gieske - firstname.lastname@example.org Mark Coffman - email@example.com Randy Lee - firstname.lastname@example.org 32 FLEXO sePtemBer 2013 www.flexography.org