The transition into a new era: Smart Digital Flexo as a solution to problems

Manufacturing and packaging are one of the most subtle, yet sensitive parts in production. They form an integral part of production companies mainframe, as such managers take a lot of consideration into the equipments and technology used in making products. The very essence of their diligence is to make available quality products that will satisfy the consumers and foster relations with other companies. The advancement of technology has improved a lot of things in manufacturing and packaging, from the reduction in run lengths to the sophistication of the products. Therefore, companies have no other choice than to follow the trend to make quality products. One of such trends is the adoption of Smart Digital Flexo.

Consequently, about two years ago Dutch packaging printer VIV had to make a decision in order to cope with the trend of shorter run lengths. Like many other companies, they investigated digital printing as an option, but at the end decided for a new wide web flexo press dedicated to expanded gamut printing, or as they call it Smart Digital Flexo.

Now, they convert the second printing press to Smart Digital Flexo (SDF). This form of printing entails a lot of detailing and intricacies in its processes. To fully appreciate the shift of many companies focus to SDF, Weinand Van Kesteren, the director of VIV believes that SDF is the ticket to becoming a leader in the production of quality packaging in short runs.

Smart Digital Flexo

Flexo printing has proven to become an integral part of VIV future strategy, with several attempts being made for beef up the processes and end result. Smart Digital Flexo (or extended gamut printing) is able to achieve ca 90% of all pantone colors, saving companies the stress related to spot colours. Furthermore, it affords the luxuries of saving time, cost and materials. The ease that comes with the adoption of the SDF is incredible, it also allows for smart combination of different Jobs, also known as gang jobs or mixed jobs.

In a previous interview with the director of VIV, Weinand Van Kesteren and his brother Herman, the brothers exemplify the perks of switching over to SDF. According to Weinand, through SDF “we aim to offer our customers shorter turn around times at sharper prices”. The processes involved in using SDF is so seamless that they both recognize the satisfaction of the designers. “They are the biggest fans of SDF, it is very easy for them”. However, there is no new trend in business that doesn’t come with some form of speculation. The first steps into the new technology The shift from using spot colours to extended gamut printing will cause a bit of stare in the public eye. Inevitably, the customers will be a bit sceptical of the viability of such process. “Designers deliver the design in pantone colors so the customers don’t have to change it.”

While this is understandable on the path of those customers, Weinand goes on to emphasize an important fact, “We will use SDF. But if it doesn’t meet their requirements, we’ll do it in pantone. The cost will be for us”. According to the bothers, no customer has rejected SDF after they saw the results. They thoroughly like it because VIV will present the proof and match the expectations of the customers. Consequently, it took VIV more than a year to fill their new wide web Comexi with enough jobs for SDF. VIV explains the gradual phase of tapping into the new technology, “they are at 60 – 65% of jobs on the machines with SDF new jobs”. The other percentage remaining are spot colored or simple jobs like CMYK jobs. In addition to this, the conversion of a second wide web flexo press (also Comexi, like all of VIV’s presses) to SDF proved to be the right way to go as one of the reasons for doing so was the Inside and Outside print.

In using SDF, there is a color range that helps the processes work better. Depending on what you want to do, there is a color range with a low volume and high volume. Weinand explains the modalities of this color range, “big screen on the plates will require high volume which is better for the color range”. If you have 48, you use a higher volume, you can make mix for the pantone colors in 42. In the area of screening, some distinction has to be made to really appreciate what SDF brings and why VIV enjoys it so much.

“Screening is AM, FM is for highlighted spots while for the mix, AM is better”. Weinand continued his explanation by stating, “if you print with FM you have HD but there is a problem with the support dot which has not been fixed”. Another glance into the first steps of adopting this new technology will be on the downtime.

The downtime when using SDF has reduced significantly. In addition to saving time, customers are assured a reduction in downtime by 60%. The proofing and the end result lie close to each other, so the customers and printers can see how the work looks. As usual, there are always some form of difficulty in adopting a fresh technique, solution or technology in business. What is most important is identifying the issues and properly tackling it. In the case of VIV the major challenge in the adoption of SDF was the color. The intensity of the colors drops except the highlight is compromised, until then it becomes very difficult to print.

Current situation and future plans

Consistency is key in any process, business and sphere of life. It is a exemplary quality to have as individuals and as a company. VIV bears this in mind as they know Aniloxes play a very important role in the SDF process. To get the SDF working at optimum level, one will need a consistent and predictable ink transfer. Hence, the partnership with Apex international and their GTT anilox rollers.

Weinand talks about the significance of GTT Anilox in the interview by confidently claiming, “we have tested different anilox but GTT was chosen for constant volume. GTT is the best for this system”. In examining the current situation of the inks, Weinand makes mention to having Uper and Flint as some of the inks available in the company, “we have tested all the inks, there is no difference between them”. Doctor blades are also very significant in the SDF process. They help to remove the excess ink from the smooth nonengraved portions of the image carrier and the land areas of the cell walls. For doctor blades, “ceramics are used for the old and new one… The chance of scratching is limited”, says Herman.

According to him, VIV had tested with plastic in the past but after a year ceramics has proven to be better for longer runs. Ecograph, a Swiss company is the manufacturer of these doctor blades. Short run jobs differ in markets, as countries may have different run times for their machines. VIV for instance has the shortest New job at 25 kg while the shortest repeat jobs is 100. When it is laminated, it is 1500m for digital. This is for mixed job (some may call it gang job). VIV can do five mixed jobs if they have the same repeat.

All the machines have the same twin locks but the downside, the anilox, was not possible for all the machines because of the size of the machines. “They (the machines) run on 400, others run on 250 – 300 when on 2000 metres. Two jobs can sit conveniently on one machine as the weight is 490 for 800g. Additionally, the average color of SDF Jobs is 5-6 never 7 colors. “We don’t need Violet, Orange, Green , if you print on one machine you must change the color section”. Herman also goes on to explain the new developments in the company as they don’t mind getting a ten color machine, laser cleaners, cones, Crystal XPS from Esko.

These materials are on the company’s wish list. Conclusively, It is evident that VIV is on their way to becoming a leader in the production of quality packaging. They also have a big project coming up which is a 24 packaging innovative for pet foods. The vision is getting more distinct, as SDF has helped to solidly their claim to being at the very top. Customers are gradually warming up to this new technology. Why shouldn’t they? It saves time, money and resources. VIV boasts of customers from Sweden (Ekas), Denmark, Belgium and other European customers. They also deliver at a Dutch company and export their products to other companies.