New Zealand Printer August 2020

New Zealand Printer

August 2020

Digital packaging Profile: Matt Mills Waste minimisation McGrew on workflow

1987-2020

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August 2020 Cover Story Hi-Tec Ink p11-13

Hi-Tec Ink scours the world to find best in class solutions for the local print, signage, and packaging sectors. It has some exciting news from German wide format manufacturer Signracer and from alternative ink supplier Nutec Digital Inks Features p8-41

8 Techspan: When it began designing a calendar to celebrate its 40th anniversary last year, Techspan had no idea that it would end up winning a gold medal at Pride In Print 10 Fellman: Wanting what you want is fine, says sales expert Dave Fellman, but you have to go through a process to actually get what you want 14 Fuji Xerox: Speedy Print has installed the Fuji Xerox Iridesse and uses its capabilities to produce some impressive results

CONTENTS PrintNZ p16-19

16-17 Helping Hand: Iain MacIntyre profiles print leader Matt Mills from Fuzed in Auckland 18 Comment: Ruth Cobb provides insights into how PrintNZ can help your business Covid-19 Wide Format Plus p23-29

24 Aarque: Onform Signs has boosted its capabilities with a Summa F1612 cutting table and an HP F750 flatbed printer, supplied through Aarque 26 Fuji Xerox/Esko: Installing an Esko Kongsberg cutting table, from Fuji Xerox New Zealand, has brought immediate benefits to leading Bay of Plenty printer Kale Print

Advertiser’s index

Aarque 7, 25 APM 7 Currie Group 7 Cyber OBC Eamar Plastics 42 Fuji Xerox 15, 27 Graphic Lamination & Coating 5 Graphic Machinery NZ Ltd 7 Hi-Tec Ink OFC, 11 NZSDA 29 Pride In Print IBC PrintNZ 19 Techspan 9 VPR 42 Wholesale Print IFC

28 NZSDA: Melissa Coutts outlines why and how you should encourage a positive workplace culture

20-22 Product Stewardship: The government’s recent announcement has drawn a mix of support and criticism from packaging organisations 30-32 Digital Packaging: Working with the team at Nestlé, Alvise Cavallari has discovered how digital printing can change the world of packaging for the better 34-35 weko: German manufacturer Weitmann & Konrad (weko) has seen how digital technology has hastened the trend to automation, even in powder applications 36-39 Workflow: Print marketing expert Pat McGrew discusses the importance of workflow in your business 40-41 Romano: Digital printing of books has completely altered the publishing process

NEW ZEALAND PRINTER PO Box 32-395, Devonport, Auckland 0744 EDITORIAL: 021 631 559 Bruce Craig, Editor: bruce@newzealandprinter.co.nz CONTRIBUTORS: Alvise Cavallari, Ruth Cobb, Melissa Coutts, Dave Fellman, Pat McGrew, Iain MacIntyre, Frank Romano.

CIRCULATION: subscriptions@intermedia.com.au

p16 Matt Mills, managing director of Fuzed

ISSN 1171 7912

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August 2020

3

NEWS German companies confirm drupa support

IN BRIEF THE Australian printed solar panel team has installed a demonstration project at a Sydney shopping centre. This renewable energy initiative has strong possibilities for print companies. Professor Paul Dastoor, from the University of Newcastle, says the project aims to produce film based solar panels printed on PET using a conventional narrow web flexo press. The fully recyclable printed panels will create energy from sunlight, with no moving parts and no waste. A standard narrow web press will produce the lightweight solar cells at a projected cost of less than $10 per square metre.

KOENIG & BAUER has unveiled an App-based live video streaming service for sheetfed presses and other business units. It the transmission of live videos to be transmitted from a mobile device to a technician during remote maintenance. With a success rate 80 per cent for current remote maintenance methods, the company expects further growth with the new App. In practice, the technician sees what the press operator or service technician sees on the press. The technician gains a comprehensive overview of the situation at the press.

FLINT GROUP Paper & Board has introduced a sustainable water-based ink and coating range for paper and board packaging applications. The company says the range, called TerraCode, delivers on the necessary requirements for premium packaging results, such as high print quality, product consistency, and ease of use. The inks and coatings, bio-renewable content certified, are sustainably sourced. The company says it has developed TerraCode using a combination of natural feed stock options such as natural pigments, resins, additives, and biomass balance materials.

Major German exhibitors Koenig & Bauer and Windmöller & Hölscher have confirmed their participation at drupa in 2021. Both companies have attended the show since its inception in 1951.

Jürgen Vutz, chief executive at Windmöller & Hölscher, says, “As one of our leading trade fairs, drupa remains an important marketplace for us. This is where new trends in packaging printing are regularly set. With our commitment to drupa, we are also committing ourselves to Germany as a business and trade fair location.

“We are convinced that both, the hygiene and health concept presented and the shortened runtime from eleven to nine days, are the right measures.”

Koenig & Bauer chief executive Claus BolzaSchünemann, says, “We

Claus Bolza-Schünemann, chief executive at Koenig & Bauer continue to see drupa, the world’s leading trade fair, as an important building block in the graphic arts industry and we see it as our responsibility to support this industry. We want to do our part to continue to provide important impulses locally in personal discussions.”

Ralf Sammeck, board member at Koenig & Bauer, says, “Trade fairs

will not be the same as they were before Covid-19.

We are supplementing our communication with customers with virtual formats. But these formats can only convey the performance capabilities of the broad product portfolio to a limited extent. Nothing beats experiencing the latest technologies up close in action with the public and the trade fair feeling.”

Dscoop reschedules to 2021 HP graphic arts users have received an invitation to attend the rescheduled Dscoop Edge Fusion event, which will now take place in St Louis, Missouri, USA from May 16-18, 2021.

Organisers postponed this year’s event, set down for Orlando, Florida. They say the rescheduled event will comprise a smart blend of in person and online activities for a global hybrid experience. Keith Wilmot, Dscoop chief executive, says, “With the world still

uncertain in many ways, we are preparing a valuable experience for a variety of scenarios.”

He says that whichever scenario attendees choose, Edge Fusion will deliver engaging, relevant, and forward-thinking content.

Dscoop will take its lead from global health regulations to protect the safety of its community and adjust plans as necessary.

The event experience, including education tracks, business growth, keynote

speakers, networking activities, training workshops, and partner solutions sessions, caters for Dscoop members from across the world and will accommodate all time zones, which won’t affect attendees travelling to St Louis for the face to face.

For those who can’t attend in person, Edge Fusion will offer virtual and blended options using new meeting technology, interactivity, livestreaming, and recorded sessions.

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August 2020 newzealandprinter.co.nz

NEWS

RMGT unveils the 970 series Ryobi MHI Graphic Technology (RMGT) has launched a new range of offset presses, the 970 series.

Cyber New Zealand supplies the range of RMGT presses locally.

It has based the new range of offset presses, the 970 series, on the technology of its popular 920 series and flagship 10 series press. With the combined technology, the series aims to offer versatility, durability, and innovation.

Bernard Cheong, managing director at Cyber, says, “Ryobi MHI Graphic Technology has further expanded our product range with this launch. In line with its lean manufacturing strategy, the company has studied the needs of our users and to increase profits by reducing production cost and increasing efficiencies, the new RMGT 970 was introduced.”

The RMGT 970, an A1plus size offset press range, handles a maximum sheet size of 650mm by 965mm.

The press range targets a

Ready with a new range of presses: RMGT supplier Cyber’s Bernard (l) and Herbert Cheong wide range of work such as printing of multi-page materials, posters, and packaging.

Features include a benderless plate clamp; feeder and delivery operation touch panel; and other automated functionalities.

Compared to B1-size format presses, the 970 model has significantly lower plate costs and lower power consumption. RMGT says the compact spacesaving design results in

a more comfortable work environment.

Equipped with a double and single diameter cylinder perfecting device, convertible perfectors enable perfecting at up to 15,000 sheets per hour.

RMGT adds that installing LED-UV curing units at the perfecting and delivery sections makes instant drying perfecting possible.

IN BRIEF EFI will run an online conference in January 2021.

EFI Engage will build on the company’s recent webinar and online training series. Sessions will cover a broad range of technologies. EFI will make small and interactive sessions available for demonstrations of its latest software. Beginning on January 25, 2021, the event will take place on six days over the course of two weeks. Compared with its Connect event, Engage will feature shorter individual sessions, spread out over a longer number of days and with consideration of customers in varying time zones.

KONICA MINOLTA has developed a cloud printing service. It says it will manage the total print environment of its customers, that is their printers, servers, drivers, applications, and networks, through the cloud. The service aims to provide small business and enterprise customers with the opportunity to simplify their operational processes, streamline their businesses, and increase overall efficiency.

Konica Minolta will also offer solutions to use the new Universal Print from Microsoft, which runs entirely on Microsoft Azure.

HP Jet Fusion best for defence Specialist 3D printing and additive manufacturing solutions company EVOK3D has announced it will supply Australia’s Defence Science and Technology (DST) with three HP Jet Fusion 3D printing systems.

As a Currie Group company, EVOK3D works as the HP 3D Printing partner for New Zealand.

DST will use the industrial-grade HP Jet Fusion 4200 printers for production of end-use parts, tooling, and jigs, as well as concept models and prototypes. The high output from the HP 4200 machines enables their use for on demand local manufacturing of critical parts in the event of supply chain disruption.

HP says this technology can enable the reinvention of manufacturing in Australia and New Zealand newzealandprinter.co.nz

due to its flexibility and agility compared to traditional manufacturing processes.

Joe Carmody, managing director at EVOK3D, says “3D printing has moved beyond just prototyping and is now a viable and flexible direct manufacturing technology. DST’s motto is Science and Technology for Safeguarding Australia and we are proud to play a part in securing supply chain sovereignty for this country.”

The deal includes supply for automated post-processing equipment, suitable in serial manufacturing. The company’s core business sees it supplying and supporting professional and production 3D printing solutions which includes machinery, consumables, and software.

THERMAL LAMINATING • MATT & GLOSS • SPECIALTY FILMS • ADHESIVE LAMINATING • HOT FOIL STAMPING & EMBOSSING • ENCAPSULATION & WIDE FORMAT • METALLISED FILMS • SCRATCH OFF INKS SPOT & OVERALL UV FINISHES • SPECIALISED COATINGS • INDEX TABBING • NEW LAMINATES • SCRATCH RESISTANT MATT • VELVET FEEL • SLURPEX SOFT CLOTH & CHAMOIS PRODUCTS

ALBANY • PENROSE • PETONE Unit 3, 343 Church St, PO BOX 12797, Penrose Auckland 1642, New Zealand, +64 9 636 8354 reception@glc.co.nz www.glc.co.nz

August 2020

5

NEWS

Scodix introduces a workflow package Digital enhancement solutions manufacturer Scodix has launched a productivity workflow package, Scodix Studio Station.

Currie Group supplies Scodix in New Zealand.

Scodix says the package, developed to boost press utilisation and production flexibility, can process jobs up to 60 per cent faster for Ultra Digital Enhancement Press users. Amit Shvartz, chief marketing officer at Scodix, says the company launched Scodix Studio Station to “allow printers to prepare more jobs faster; handle large volume variable data jobs; and process jobs from various sources more efficiently. As every digital printer knows,

Boost: Scodix says its new package can process jobs up to 60 percent faster for Ultra Digital Enhancement Press users uptime is imperative to profitability. Scodix Studio Station will help printers maximise the efficiency and productivity of their digital enhancement operations”.

The Studio Station works as an enhancement digital front end with Scodix software running on dedicated Scodix hardware.

The system has an external

RIP server. Scodix says this makes RIPs faster and automatic, with an easy to use interface, incorporating two new registration methods.

Shvartz says, “Scodix has always provided best in class registration. Until now that has been achieved by detecting four OPA dots.

With the Scodix automatic

registration process, Scodix Studio Station can achieve registration down to 100µm, using corner detection or CMYK objects detection.

For trade printers and printers receiving jobs from lots of different sources, this will simplify the process and allow them to access the full power of Scodix digital enhancement.

“With over 350 installations in more than 65 countries, Scodix is constantly developing new ways to add value for its diverse customer-base.

“As with all our products, we look to provide maximum value, productivity and return on investment. The new Scodix Studio Station does just that.”

Kodak Sapphire hits flexo target Kodak and Uteco have announced the sale of a third inkjet web Sapphire EVO M Press, targeting flexible packaging.

The North American buyer will use the press for applications requiring large quantities of short run jobs.

Kodak has other inkjet web Sapphire Evo M Presses up and running at flexible packaging printers in Italy and Japan.

Randy Vandagriff, senior vice president, Print, Eastman Kodak Company, says, “This latest sales success is clear evidence that the inkjet web Sapphire EVO Presses, featuring Kodak’s highspeed continuous inkjet and water-based ink technology, are set to become one of the

Mid-web: The inkjet web Sapphire EVO M Press leading solutions worldwide for digital flexible packaging printing.”

Developed jointly by the Uteco Group and Kodak, the mid-web digital press lets flexible packaging

printers migrate jobs from traditional printing processes to digital.

Kodak says it achieves high quality results along with tremendous time, makeready and cost savings.

The company adds that, the digital press delivers excellent CMYK print quality on a variety of plastic film materials and papers.

The Sapphire EVO M Press supports a maximum web width of 650mm and a print width of 620mm.

Kodak says that production speeds of over 150mpm, make it faster than any other digital solution for flexible substrates.

The company says the Sapphire EVO M Press offers the best duty cycle of any mid web digital press.

The press enables more cost-effective production of volumes up to 20,000sqm compared to analogue processes, according to Kodak.

Heidelberg makes strategic Gallus sale Press giant Heidelberg says its realignment strategy includes selling the Gallus Group to Swiss packaging business benpac for €120m ($210m).

The move forms part of Heidelberg’s realignment strategy. However, the 6

giant press manufacturer will work with benpac on the Labelfire digital label press. Heidelberg will continue supplying the digital printing unit and consumables for the Labelfire. Rainer Hundsdörfer, chief

executive of Heidelberg, says, “We are selling our narrow web rotary and rotary flexographic printing activities to focus more closely on innovative solutions for the entire printed sheet value chain.

We will retain our in

house digital expertise and, by collaborating with benpac on the Gallus Labelfire, we will also make further progress with the digitisation of conventional presses. We will remain a major supplier on the growing label market.”

August 2020 newzealandprinter.co.nz

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Craig Paul 027 655 4267 Ian Shemilt 027 241 5586 sales@curriegroup.co.nz

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Print Service & Supply Businesses - Stay in Front Stay in front of your prospects, New Zealand Printer readers, with an ad in the New Zealand Printer Directory. Pay just $150 ex gst a month over 11 issues and get noticed by the people who need your goods or services. The Directory is published monthly near the Print Calendar at the end of the NZP news section.

Contact Brian Moore on +61 410 578 876 or email brian@newzealandprinter.co.nz for details

PRINT CALENDAR AIP Virtual Congress

Fespa Global Expo

drupa 2020

September 10 Online The virtual congress features more than 30 speakers and 22 booth holders in the presentation area. Delegates can participate in panel question and answer sessions; live technology streams and keynotes.

March 9-12, 2021 Amsterdam, The Netherlands Organisers have moved the show again. They still have the backing of exhibitors wanting to provide an innovative wide format. It will run alongside the European Sign Expo and Sportswear Pro exhibitions.

Postponed from June, 2020 to April 20-30, 2021 Düsseldorf, Germany The world’s leading trade fair for printing technologies has changed the expo landscape with its decision to move the show to 2021, meaning other shows such as the Melbourne’s PacPrint will also have to move.

www.aipia.info/congress-registration.php

www.fespa.com

www.drupa.com

Print, Sign, Display & Graphics Virtual Trade Show

Labelexpo Americas

NZSDA Conference and Sign Expo

March 23-25, 2021 Rosemont, USA America’s largest label show includes multisubstrate presses, digital presses, laser die cutting, prepress and plate making, decoration systems, multi-process ink systems, high technology label materials, films, sleeves, and wraps.

July 8-10, 2021 Auckland The now postponed conference, awards, and Sign Expo will still feature everything that would have happened this year. The awards event acknowledges outstanding design and craftsmanship across a range of signmaking methods.

Running now until September 30, 2020 Online 24/7 Visitors will see product demonstration videos, virtual tours, sales presentations, downloadable brochures, product photo galleries, website links and show specials, accessed by clicking dedicated links on a virtual stand.

www.visualconnections.org.au

ProPak Asia October 20-23, 2020 BITEC, Bangkok Originally slated for June, the biggest processing and packaging trade exhibition in Asia says it will feature 65,000 square metres in nine halls, with more than 2300 exhibiting companies from 50 countries, but watch this space for changes.

www.labelexpoamericas.com

Interpack Feb 25 - Mar 3, 2021 Düsseldorf, Germany Considered the largest event in the packaging industry, Interpack specialises on the packaging process within the food, beverage, confectionery, bakery, pharmaceutical, cosmetics, non-food and industrial goods sectors.

www.interpack.com

www.nzsda.org.nz

PacPrint 2021 September 28 to October 1 Melbourne Convention and Exhibition Centre Since 1970, PacPrint has provided a platform for suppliers and visitors to get together and generate business opportunities through the latest technologies, solutions, and trends.

www.pacprint.com.au

www.propakasia.com newzealandprinter.co.nz

August 2020

7

TECHSPAN

Techspan Tui takes flight at Pride In Print

A

gold medal, and a highly commended, at this year’s Pride In Print Awards has given the team at Techspan a good reason to celebrate with friends and partners.

Warren Hadler, from Techspan Group, says, “We could not be happier. Our 2019–2020 Tui Wall Art Calendar was the first time Techspan had entered anything in the Pride In Print Awards and to come away with a Gold and a Highly Commended was very satisfying.

“I have been in the printing industry and directly involved with stamping foil for most of my working life and, having run foiling machines at the beginning, I understand the intricacies and challenges of producing good work. But this is not simply good work, it is a fabulous piece of art that we are proud to say was produced right here in New Zealand.

“Those who know us will

Anniversary calendar wins Pride In Print gold

appreciate our passion for foil and appreciation of good work and New Zealand made.

There is no substitute for fine print and to have it grandly displayed on a wall makes for a good talking point and constant reminder of what local businesses can achieve.

“You don’t need to go offshore for your printed material as we produce world class work in this country, and we should embrace it and be immensely proud of it.”

The calendar uses a Photographic Fine Art Print embellished with foil to create a distinctive image.

“It is quite rewarding to enter another business and see the Techspan wall art on display and, of course, when the angle of light changes as you walk past all the foiled details come to life, very cool.”

Techspan would like to acknowledge those who helped with this work. Hadler says, “They have been very generous,

Proudly New Zealand made: The Techspan Tui Wall Art Calendar won gold at Pride In Print 8

and we are grateful to each of them for their contribution in assisting us showcase how hot stamping foil can embellish print. They are: • Photographs by Bernadette Fastnedge Photography • Prepress by R.A. Design • 350 GSM Creator Gloss by B&F Papers • Foil blocks by Inline Graphics • Printing by Centurion Print • Pre-print foiling, post-print foiling and finishing by Contact Labels

Anniversary celebrated In 1979, Frank Fastnedge founded Techspan. The company has recently celebrated its 40th year in business, serving the print as well as other industries.

Techspan’s comprehensive product range has grown to include: • TSC label printers • Blank labels • Stamping foils • Plastic welding equipment • Welding rods • Tools and accessories • Ultrasonic cleaners and welders • Injection moulding machinery • Commercial purging compounds Hadler adds, “We are currently working on another wall art and feel it will have even more of a wow factor.

We are challenging ourselves as well as our production partners as registration will be even more critical and hard to maintain. However, I don’t want to go into that too much right now, except to say watch this space.

“We thank those who are helping us with our new project and getting behind us in embellishing print.

“Please visit the Techspan website www.techspan.co.nz to speak with our knowledgeable sales team to hear about our extensive product range of high quality products, and how they can work for you.”

August 2020 newzealandprinter.co.nz

NEWS

HP PageWide hits half a trillion pages HP Inc. has reached the 500 billion printed pages milestone with its inkjet PageWide web press.

Carles Farre, vice president and general manager, HP PageWide Press, says the print platform continues to expand its page capacity driven by global HP print service providers. He says, “Print service providers operating HP PageWide Web Presses are finding new success and opportunities for more sophisticated and profitable digital print applications, as well as transferring more pages from offset to digital inkjet technology.

“They have more than doubled the number of pages they print on HP PageWide Presses since drupa 2016 for a growth rate that is nearly twice that of the market. More than half of these customers have printed over one billion pages on their devices.”

newzealandprinter.co.nz

Billions: The HP PageWide T240HD HP adds that its PageWide web press has achieved a share of more than 30 per cent of the 8.8 billion page capacity added in high-volume colour inkjet page capacity in the first quarter of 2020.

It says print companies can use PageWide Web Press technology to enable high-volume digital inkjet printing of commercial, publishing, transaction, and

direct mail applications, as momentum continues worldwide.

To drive additional page growth through an expanded application range, earlier this year, HP PageWide announced its next-generation HP PageWide Web Press T250 HD with HP Brilliant Ink. This press can print on a wider range of coated and uncoated offset papers for

high-volume commercial applications.

HP has also announced a partnership with Solimar Systems for high-volume document management. The Solimar Chemistry Platform supports job onboarding, enhancement, and management and delivery of both print and digital communications, including multi-channel document delivery.

Farre says, “Through this valuable collaboration, HP customers can now benefit from Solimar’s longstanding technical expertise and market-leading workflow systems.”

The company adds that the print to order capability for publishing ensures the availability and production of books, magazines with the environment in mind.

For direct mail and commercial print, HP says its customers benefit from advanced automation and variable data tools.

August 2020

9

FELLMAN

You Can Want All You Want To recover from the Covid-19 pandemic, you have to think, plan, and act

You can determine what happens to your business

I

want this to be over with!”

I heard those words from one of my clients this morning. She was referring specifically to the coronavirus pandemic, and all of the disruption it has caused to everyone’s business and personal lives.

My response: “Me too, but we are not going to wish this away. We need to deal with reality. What will it take to make and keep your business healthy in today’s marketplace?”

It is worth mentioning, I think, that I have heard many variations on this theme throughout my 30 plus years working with printing companies. Well before Covid-19, printers have ‘wanted’ things, ranging from a return to the way things used to be to an accelerated timeline to where we might want them to be. But the bottom line is this: you can want all you want, that will not make good things happen. In order to get what you want, you have to think, plan and act.

Think and plan Thinking and planning go together, and there are three things you should think about in order to create a plan.

First, where are you now? Second, where do you want to be? Third, how will you get there? In other words, a situation analysis, then a goal, then a plan.

The situation analysis actually requires two considerations, because ‘where’ is a combination of ‘what’ and ‘why’. For many of you right now, business is down because of the coronavirus. Customers are not buying because their own business is down, because of the coronavirus. Pretty 10

straightforward, right? But let me share a situation that I worked through with one of my clients at about this time last year. His business was down because three of his top five customers were buying significantly less.

This was not related to any changes in their business. Rather, it was a reaction to a series of quality and service failures on his part. That, in turn, was a result of a significant morale problem. And that, in its own turn, was the result of my client tolerating bad behaviour on the part of one particular employee. The rest of his employees adopted a “Why should I care?” attitude, which showed in their work.

The point is this, you must understand the problem in order to solve it. Some problems are obvious.

Others require more and deeper thought.

Goal and action Once my client fully understood his problem, we established a two-part goal. Part One was to improve the morale situation. Part Two was to win back customer trust. I hope you see why this had to be addressed in stages.

Winning back lost trust is very much a one-shot enterprise. We had to solve the foundation problem before we could even address the next stage.

That takes us to the hard part, the action necessary to solve the foundation problem. The bad behaving

employee was the owner’s stepson.

I will spare you the details of what happened next. It was not pleasant for my client. But he did what needed to be done, and it did solve the foundation problem. And, after allowing for a few weeks of post stepson healing internally, he took the next step and reached out to his customers.

Do you know the expression ‘hat in hand’? If not, think ‘extremely humble’ and you will understand his approach.

He said, “Let me tell you how I feel we let you down and then let me tell you what I have done to solve my side of the problem.”

Two of the three customers were sympathetic, and one of them has returned to previous spending levels.

With the other two, it is still a work in progress. Let me emphasise the work.

He thought, he planned, and he acted, and if not perfect, his situation is still better than it would have been if he only ‘hoped’ for improvement.

Action and recovery I am hoping that you have at least partly recovered from the effects of the pandemic. From what I hear and read, you are likely better off than most printers here in the US, because New Zealand did a better job of containing it than we did. Still, it was a shock to the system.

Recovering, though, is on you. If you are not all the way back, think, plan and act.

Dave Fellman is the president of David Fellman & Associates, Raleigh, NC, USA, a sales and marketing consulting firm serving numerous segments of the graphic arts industry. Contact Dave at dmf@davefellman.com. Visit his website at www.davefellman.com

August 2020 newzealandprinter.co.nz

UV Digital Flatbeds have been reinvented

Varnish Colour White

New simultaneous triple row print head configuration with white, colour and varnish, enhances and simplifies workflow.

New Special LED module for simultanious curing of varnish

New Simultaneous Triple Row Print Head Configurations

+64 3 666 0100 www.hitecink.com

COVER STORY

Hi-Tec Ink brings a range Hi-Tec Ink delivers print and signage companies more options with innovative solutions

•

W

ith a comprehensive range of solutions, Hi-Tec Ink supplies print, signage and packaging professionals across the country.

Les King, managing director of Hi-Tec Ink, says, “We source best in class solutions from around the world for our customers here in New Zealand. We are constantly reviewing our offering, which includes Nutec ink and the German based Signracer wide format solutions.”

Signracer speed The high-performance LED drying Signracer printers use Ricoh and Kyocera print heads and a range of tools to give signage and print companies more options in their production.

He says, “A good example is the Signracer Hydrospeed Turbo printer that enables automation of the production process. This all in one solution streamlines production workflow and increases productivity and profitability in every segment.”

Equipped with eight industrial Kyocera printheads in symmetrical colour alignment, the Hydrospeed Turbo uses a magnetic linear motor, providing a carriage speed of 1.2 metres per second, delivering a production output of 540 square metres per hour.

King says, “Like other European companies, Signracer has a strong commitment to the environment, which inspires the team there to create products that are better for its customers and the planet.

“The Hydrospeed Turbo’s innovative water-based ink formulation is optimised for paper printing production with media such as blueback paper, while being fully water resistant.”

The printer also features an automatic XY cutter 12

•

• • Les King, managing director of Hi-Tec Ink with integrated pneumatic controlled buffering system designed for inline cutting.

This speeds up the finishing process, cutting the printed media directly. New motorised lengthwise shear cutters, and the automatic vertical cutting correction system, guarantee maximum precision.

“It works with any feeders and offers three operation modes: crop mark, custom, and manual. It can also trim different lengths from the same printer roll.

“Its ink supply system uses industrial grade peristaltic pumps for smooth and stable ink flow; automated negative pressure monitoring and adjusting feeding; and ink degassing technology to avoid nozzle drop-outs even on high speed.”

Features of the Hydrospeed Turbo include: • A capping station with automatic cleaning.

• Easy media transport using tension-adjustable continuous winding/ unwinding control technology.

• Highly efficient infrared heating system designed for instant water evaporation.

Three heaters provide high temperature required for water resistance even in a single pass.

• A motorised collecting table with a pneumatic ejector for inline cutting. It speeds up the cutting process • High performing cutting

machine for horizontal and vertical trimming of flexible materials with automatic vertical media alignment correction. Also equipped with a buffer system for inline cutting.

An accessible stacking table allows easy on the fly quality checks.

Crash sensors on both sides of the carriage detect wrinkled media and prevent head strikes and media crashes High quality printing from variable sized droplets Extendable table up to 3.1 metres

Comprehensive UV range Signracer also manufactures a range of UV printers.

The Signracer 2512 G. 5 UV Flatbed uses Ricoh G.5/G.6 printer heads. This 2.5 metre wide printer handles rigid and flexible media up to 100mm in height and delivers a print resolution of 1200dpi.

King says, “The Signracer 2512 features a special LED module for simultaneous curing of varnish, so it can print white plus colour plus varnish printing.”

The Signracer 1610 HB uses a higher bridge to print on media up to 25cm in height.

This concept can be used for special industrial applications, like printing on shoes or furniture.

The manufacturer also produces a large UV flatbed, the Signracer 3020, optimised for high-speed applications. This printer has a symmetrical print head configuration, a high tech linear motor and Kyocera print heads.

King says the new linear motor technology allows a much higher carriage speed compared to belt systems.

He says, “In addition to the much higher productivity, the acceleration of the carriage is faster and there is much less vibration and noise.

“The small hybrid Signracer 1600 achieves with Kyocera print heads almost double the speed due to the double length of the heads.

“In contrast, the 3.2m high speed roll to roll solution uses Kyocera print heads in a

August 2020 newzealandprinter.co.nz

COVER STORY

ge of solutions to market High speed solution: The Signracer 3.2m roll to roll printer

symmetrical configuration to increase the speed. It also offers an optional kit to print mesh material.”

“Operators can make full use of the printing width with two rolls material printing, supporting different image outputs simultaneously on two rolls of media.

“A high bridge mechanism uses separate software and a touch screen, which also shows important safety information.

For safety, the bridge can only move if the finger touches the screen.

“Signracer has a heavy commitment to ongoing research and development.

To support its customers, it has opened a new demo and application centre in Rotkreuz, Switzerland.”

Digital ink Hi-Tec Ink has the exclusive agency for Nutec Digital Ink in New Zealand.

King says,“Nutec works continually on alternative versions of traditional ink chemistries to contribute to a healthier, cleaner environment.

The Diamond GBL-free range of digital inks is a prime example of these developments.

“With the GBL-free ink range, you don’t require any flushing or profiling when converting from OEM inks.

This low smell ink offers excellent outdoor durability, superior abrasion, and chemical resistance.”

Nutec supports all its ink products with its Digital’s Ink Delivery System Warranty.

Nutec continually works on alternative versions of traditional ink chemistries newzealandprinter.co.nz

Hi-Tec Ink also supplies the Nutec UV ink range, which includes Amethyst A20-HYB, a general purpose UV ink designed for rigid and roll to roll applications. The hybrid UV ink, Amethyst A50-HYB, is also designed for a wide range of rigid and roll to roll applications.

King says, “For solely rigid applications, Amethyst A50RIG, offers superior media adhesion qualities. It is suitable for use without primer, on a large variety of rigid substrates, including: polycarbonate, melamine, fluted polypropylene as well as decorative applications on glass, acrylic and ceramics.

“For roll to roll applications, Amethyst A50-RTR is a flexible, fast curing UV ink designed for self-adhesive as well as flexible media. It performs well in a demanding, high speed printing environment, providing enhanced scuff and chemical resistance. All of these inks are suitable for LED as well as mercury vapour UV lamps.

Hi-Tec Ink’s range also includes Brother direct to garment printers; Adelco screen and textile printing solutions; Stahls Hotronix heat presses; Admiral film and tape; Albatross chemical products; screen: Marabu pad printing inks; and a range of used printing equipment.

King adds, “Our suppliers continue to research and develop new technologies. So, no matter what our customers’ needs, we can continue to help them find the solution that best suits their business.”

August 2020

13

DIGITAL

Fuji Xerox Iridesse boosts Speedy Print capabilities

S

peedy Print, a Nelson-based commercial digital printer, has had a longstanding relationship with Fuji Xerox.

For over 25 years Fuji Xerox’s digital presses have allowed the company to deliver cutting edge digital printing solutions to the whole of New Zealand. The company says the recent addition of a Fuji Xerox Iridesse digital production press has opened up a whole new world of colour and specialty finishes to the digital print market.

Prior to the new installation, Speedy Print had run a Fuji Xerox Color 1000 and a Fuji Xerox Color 800. The company chose the Iridesse as the replacement for the two presses because it offers so many new digital capabilities. It runs a Fuji Xerox GX Print Server which has allowed Speedy Print to streamline its production workflows with its intuitive imposition templates. This streamlining process saves the company’s prepress and press operator valuable time.

The Iridesse arrived just before the country went into lockdown, giving the team at Speedy Print a few weeks to become familiar with the GX Print Server software and read through the training materials provided. After lockdown, a Fuji Xerox training technician visited Speedy Print and ran through everything face to face.

Dan Estes, chief marketing officer and chief information officer at Speedy Print, says, “The team at Fuji Xerox has been excellent throughout the transition. The training staff walked us through everything and worked with our prepress team to set up the most efficient way to get the print files through to the press operator.

“The new range of capabilities that the Iridesse gives us helps to provide more solutions for our clients with the excellent finish that we strive to deliver. Speedy Print works with a large variety of 14

Top of the South printer expands business with Fuji Xerox

Impressive output: Paul Montauban, press operator at Speedy Print with the Fuji Xerox Iridesse clients, many of which are small businesses in need of boutique printing and labelling for their products, looking for something a little different to help them stand out.”

“The Iridesse enables us to produce distinctive printed material like a metallic gold and silver finishes, white ink, and an extended gamut of colour that nearly matches the range of traditional offset using Fuji Xerox pink toner. Generally, these are not cost-effective for our clients to obtain a similar finish on analogue equipment for several reasons, but the main one is that their print runs are not long enough to justify those costs. For people who don’t have the budgets to order 10,000 labels, the Iridesse opens up fresh possibilities.

“The output from the Iridesse is impressive. The toner sits nicely on the page, and we’re finding light colours and greys print with an even coverage and no blotching; similar to what you get from an offset print. It allows our clients who need a quick turnaround or have short runs, so offset is not an option for them, to still achieve the high quality finish that they desire.”

With its one-pass six-colour printing engine, the Fuji Xerox Iridesse digital production press can load two specialty dry inks in addition to the standard

CMYK. Fuji Xerox says this enables rich colour expressions not previously achievable with digital printers. Its new pink dry ink joins the line up of other specialty dry inks for the Iridesse: gold, silver, white, clear and custom red, achieved by mixing and optimising a new fluorescent-type colour into Fuji Xerox’s EA (Emulsion Aggregation) toner.

Fuji Xerox adds that the ability to incorporate bright and vibrant pink hues into the design of printed materials will help broaden the scope of different styles of visual expressions, including cute, cool and elegant styles, according to the company, which adds that the mixture of pink dry ink with CMYK colours will enable printing orange, red, violet and other colours with a vibrancy that cannot be achieved with CMYK colours alone. This allows a faithful reproduction of specialised hues such as corporate brand colours.

Estes adds, “The reaction from our clients to the Iridesse: everyone loves it. A number of them have already started taking advantage of the specialty inks. From luxury candle packaging to a range of juices labels, they have been enjoying the benefits of the Iridesse. It has opened up a whole new world of possibilities.”

August 2020 newzealandprinter.co.nz

Wish you could print a stunning white ink underlay on occasion?

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by Fuji Xerox Iridesse™ – our new industry leading six station colour press.

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To find out more visit www.fujixerox.co.nz/beyond-imagination

helping hand

Matt Mills: don’t tell hi O ver the past 15 years, Fuzed managing director Matt Mills has had a defining passion to grow and secure the longevity of his family business through its evolution into a high technology driven, multiservice operation.

He grew up around the trade, with his typesetter parents Jason and Lorraine, who formed the business initially as a back shed operation in 1987.

He joined what was then known as Kingsland Print straight from school as a Mac layout and design operator.

Over the next seven years he spent time both inside and outside of the business while also dabbling in a career in the audio-visual conference field, before then returning to make a full-time commitment in 2005.

He says, “Since then, we have evolved the family company from a small copy and print shop into a digital print operation and then into what you see today: a full offset, digital, wide-format and lenticular print facility.

“I wanted growth. We still work with a lot of our competition on a daily basis, whether it be doing work for them or sending work to them, but I wanted to do more in house than externally.

“I didn’t want to be just another printer that would eventually get swallowed up; I wanted to be quite different.

Over the past 10 years, we have carved out a distinctive offering, including our lenticular products and Scodix digital enhancement with 3D overglossing.”

Print louder: a Fuzed business card that helps to describes the company’s approach 16

IAIN MACINTYRE

Iain MacIntyre talks to Fuzed boss Matt Mills about his ambitions for the innovative print company

Matt Mills, managing director of Fuzed He recalls, as a teenager, harbouring “lofty ambitions” to one day take over the business from his parents. He says he struggled to focus on secondary school studies and instead sought to learn by getting hands on as soon as possible.

He describes the progression into leading the now 12-person company, as his parents moved into semi-retirement towards the end of the last decade, as somewhat of a “natural evolution” and one that came without any formal management training.

He says, “There were pros and cons to that. It was definitely coal face, sink or swim, kind of stuff. But mum and dad are still involved, not nearly as much as they once were, but they’ve been with me the whole way through.”

Standing out Mills has developed a management style where he strives to foster a spirit of working collectively.

The means that he gets to roll up his sleeves and join in the team’s work, something he really enjoys.

He says, “I suppose I’m a lead from the front sort of person, rather than one who sits back and barks out orders.

“I also aspire to not just be one of the crowd, and I want to encourage my team in that regard. Instead, we should stand out from it, be different and proud of it, otherwise we’ll be outgunned by the big guys and gals.”

He says developing products that “no-one else can produce or haven’t even thought of yet” feature among the most satisfying job aspects in his career.

He says, “Anything from presses that give us a point of difference or using print as part of a product like our recent contact-tracing solution. The support I have from my team as well as the suppliers we have chosen to work with continues to be immense.

“There is more in the works as well so watch this space.”

Among interesting recent work undertaken by Fuzed is the ‘Open up to Mail’ mailer produced for PrintNZ and The Real Media Collective.

He says, “We printed this offset with both soft-touch laminate and 3D digital overglossing on both sides. It is an excellent, solid piece of direct mail.”

He says the business has developed and perfected its Scodix 3D overglossing and, during the past 12 months, its fine-gauge lenticular product.

Consequently, Fuzed holds some high post-pandemic market expectations.

In terms of notable achievements, Mills says most relate directly to the business, having dedicated much of his past 15 years to Fuzed.

He says, “I feel proud to have placed in the New Zealand Printer Power 50 list each year since its inception three years ago.

“The company has also achieved many gold medals at

August 2020 newzealandprinter.co.nz

helping hand

him it can’t be done the Pride In Print Awards over the past seven years and earned a place in the ‘50 Club’ in 2020, and we have achieved several PIXI Awards recently which we are especially proud of.”

Team Fuzed Mills emphasises how the contributions of his family, the Fuzed team and others in the industry “have enabled me to thrive”.

He says, “I’ve said to my wife Tegan, who runs the business alongside me, on a number of occasions that this is essentially not just a job but a lifestyle as well. You don’t go out there for the accolades and all of the hype you can get.

“You just want to do a good job every day. I like to encourage my team to be that person, to take the bull by the horns. I ask them to run with it.”

He expresses consternation at those who tar the overall print industry as one that is “dying”. He says, “Believe me when I say it’s not dying, It is evolving.

“I would love to see more New Zealand-based statistics out in the market about the returns customers get on print.

I know there is work being done in this space currently.

The statistics I would like to see could be across all print sectors: direct and personalised mail; bulk mail;

Winning with lenticular: Fuzed’s winning lenticular work from this year’s Pride In Print Awards newzealandprinter.co.nz

Points of difference: Fuzed constantly strives to offer its clients material they can use to differentiate their businesses embellishments of all types and so on.

“Everything starts with great data and I just think there are opportunities out there we can take and run with.”

He retains a strong belief in print industry training and Fuzed has an ongoing commitment to investment in its own apprentices. He adds, “Both PrintNZ and Competenz are doing a great job in this area.”

Outside of the workplace, he pursues a keen interest in watching sports, no longer having much time for direct personal participation, and he “enjoys chilling with family and friends”.

He says, “I am incredibly proud of both my daughters and their dancing accolades; not my personal achievements but I will take them.”

Print and community He expresses enjoyment at the opportunity provided by becoming the chairperson of the HP user group, Dscoop New Zealand, in 2017.

He says, “It was not something I strived to do; however, I could see the benefit of what such a group offers. I encourage any person that is eligible to enter the group with open eyes and you will soon see benefits that don’t really exist anywhere else within the competitive nature of the print industry. But even if you can’t join the group, just by talking with people regularly within the market you will learn who you can trust and build great relationships with. Not just here in New Zealand but around the world as well.”

He took particular pride in the group’s ‘Operator Saturday’

event hosted last year, in conjunction with Currie Group and HP Indigo, at Currie Group’s Auckland site. He says, “This is a concept that I saw in the United States and wanted to bring here to New Zealand.”

Regarding future goals, he says the pressing focus is to ensure the business safely navigates through to the end of this year, given the upheaval caused by Covid-19. He says, “2020 has been one heck of a ride so far and I’m sure the second half of the year will be just as challenging.”

Further afield, he holds ambitions to become more involved in other industry bodies, provide mentorship and to particularly foster networking and collaborative opportunities.

He says, “I do have those aspirations that I want to give back, but I’m not sure I’m there yet in terms of experience with what those organisations would require.

“Through my involvement in Dscoop, I have established a network of people that I can bounce ideas off which I’ve found really empowering and it provides the opening to greater knowledge. I think there needs to be a lot more collaboration between people and that’s the sort of relationships I will be encouraging people to build.”

One other aspect that Mills would like to help shape in the future, is improving certain tertiary education courses to ensure that “what you see in the classroom is a true reflection of the workplace”.

He says he has found this to have particularly been an issue in the graphic design sphere, where young graduates can be completely unprepared for a real-life workplace.

August 2020

17

Coping with Covid Avoid complacency and be prepared Safety First This month, we reached the milestone of 100 days without any community transmission of Covid-19. This amazing achievement has come from Kiwis (mostly) following the rules and doing what is best for the country. We are in a fortunate position and well ahead of our friends across the Tasman and for that we must be grateful.

In many ways, we are going about our lives almost with a sense of normality, but we are not out of the woods yet. It is important to remember that we are still operating under the Alert Level system and the ‘working safely’ regime. Level One is about being prepared; prepared that things could change. We only have to look to Victoria to see how quickly things can escalate and what that might mean if it happens here.

Something that should stay the same is the Covid-19 protocols in your workplace.

They will ensure staff members remain as protected as possible: 1. Stay home if sick.

2. Practice good hygiene. Wash and dry hands often. Cough into your elbow and don’t touch your face.

3. Keep track of where you have been.

4. Ensure there are supplies of personal protection equipment available for use when appropriate.

The state of print The industry worked hard as we climbed back through the levels, each level opening more businesses and allowing more freedoms, but the delay between levels created pressure on many businesses, which flowed through to print.

As we put together preliminary results from Part Two of our industry survey, we can see that work levels have returned to where they were immediately pre-lockdown (75 per cent) but haven’t moved 18

Many businesses have expressed interest in taking on apprentices in response to the government initiatives

RUTH COBB

beyond there. Average work levels were 60 per cent in May; 76 per cent in June and 75 per cent in July and anecdotally, would seem that this is the new normal for the next few months at least.

The government has provided a number of support packages, the most useful being the wage subsidy and wage subsidy extension which have supported businesses and allowed time to get a feel for work levels and resize businesses accordingly. The wage subsidy required a downturn in business of at least 30 per cent and 93 per cent of respondents were eligible to claim this. The threshold for the wage subsidy extension was a 40 per cent drop and 62 per cent of businesses claimed this.

As we head to the completion of those two support programmes, businesses have

been reducing both hours of work and staff numbers to ensure they remain viable and can weather the storm.

67 per cent of respondents have reduced hours of work and 28 per cent have made staff redundant at this point, however we expect that figure may climb as the wage subsidy extension comes to an end throughout August.

It was pleasing to see that 63 per cent of landlords provided some kind of rent relief over the lockdown and beyond, with the most generous covering four plus months, while some businesses had to fight for it and some got nothing at all.

A range of banks and industry suppliers provided further relief via payment holidays to 22 per cent of respondents, helping ease the financial pressure.

Business confidence levels have increased slightly since our survey taken in May when New Zealand was operating at Level Three, but the figures are still reflective of the current economy and the nervousness that prevails.

In May, 47 per cent expressed low confidence but that dropped to 34 per cent in August. Medium rose from 51 to 62, and High from two to four.

With New Zealand’s borders closed indefinitely and the subsequent inability to recruit from overseas, it will be more important than ever to train. To assist with this, the government introduced two initiatives during July and August to encourage businesses to take on apprentices and 37 per cent of respondents indicated they would take on an apprentice in the next 12 months to take advantage of this. This can only be good for the development of skills for our industry.

The single biggest concern of respondents is the uncertainty around Covid-19 with the threat of a second wave and its potential effect on the economy with its flow on effect to our industry. Which brings us full circle back to ensuring that we continue to operate safely and like all good Scouts: be prepared.

August 2020 newzealandprinter.co.nz

PACKAGING

Product stewardship sch Packaging experts share their thoughts on the govenment’s proposals for product stewardship and waste

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he government’s recent announcement on packaging product stewardship has produced mixed reactions from local packaging organisations.

As part of a wider plan to reduce the amount of rubbish ending up in landfills, Associate Environment Minister, Eugenie Sage, has announced six ‘priority products’ for the establishment of regulated product stewardship schemes under the Waste Minimisation Act. The products are plastic packaging; tyres; electrical and electronic products (e-waste); agrichemicals and their containers; refrigerants; and farm plastics.

She says, “Regulated product stewardship helps put the responsibility for waste and what happens to products at the end of their useful life on manufacturers, importers, retailers and users, rather than on communities, councils, neighbourhoods and nature.

“Old products that have reached the end of their life can be used to make something new, especially if they are designed better for reuse and recycling. “Currently, New Zealand has 15 voluntary accredited product stewardship schemes. These have had limited success in minimising waste for the target products.

“Government’s decision to require the establishment of regulated product stewardship schemes follows a public consultation in 2019 with public support for government taking stronger action on these products.

“New Zealanders’ expectations about waste have changed. We need new approaches such as regulated product stewardship which will help reduce the environmental impacts of waste by ensuring that products and materials currently lost to landfill or 20

Sharon Humphreys, executive director of Packaging New Zealand

Karen Titulaer, chair of the Glass Packaging Forum

pollution are recovered, reprocessed, or re-used. This encourages new businesses and jobs.”

The Ministry for the Environment will work with the manufacturers and retailers of the priority products and with stakeholders to co-design product stewardship schemes and regulations that will work for them and the environment.

The government contends that mandatory schemes for these problem products help level the playing field and ensure everyone involved in their design, production, sale, and use contributes to diverting the materials in them from landfill at the end of their useful life.

It says that this helps to ensure proper materials recovery, re-use, recycling, or disposal and that many countries overseas have product stewardship legislation.

Not all one size Packaging New Zealand says that, while it welcomes the investment in waste minimisation, one size must not fit all in any new plastic packaging regulation Sharon Humphreys, executive director at Packaging New Zealand, says the government needs to provide far more detail and expert input around its plans for regulated product stewardship.

She says, “The broad targeting of ‘plastic packaging’ as one of six

products in today’s priority announcement suggests a lack of understanding of the full suite of issues that legitimately form part of the determination of a package as fit for purpose.

This includes determining the right material to use.”

She says the priority for members of Packaging New Zealand is the effective, safe, efficient delivery of goods into the New Zealand and global markets. She adds that the organisation will take the opportunity to have significant input into the design process of any mandatory product stewardship schemes, particularly given the “limited success” of the voluntary accredited schemes.

She says, “Putting the responsibility for what happens to products at the end of their useful life on manufacturers, importers, retailers and users, risks unintended consequences such as driving up costs, and the possibility of less sustainable outcomes overall.

“Our industry knowledge and expertise will be essential to identify how environmental and economic harm can be avoided or mitigated to meet the broad social outcomes desired by all of society.”

Forum backs the plan The government says that the cost of dealing with packaging waste and a crumbling international recyclables market has, until now, been paid by ratepayers, and

August 2020 newzealandprinter.co.nz

PACKAGING

heme brings controversy

Malcolm Everts, chair of the Soft Plastics Recycling Scheme ultimately by our environment.

The Packaging Forum says that, for this reason, it backs the government’s announcement, noting that under the Waste Management Act 2008, plastic packaging will be declared a priority product. It says that the declaration allows for new regulation that will require all importers, producers, and retailers to take responsibility for their packaging under a product stewardship model.

The Forum’s independent chair Rob Langford says regulated stewardship is a highly effective way of dealing with packaging and is the most significant move to date by a New Zealand government.

He says, “However, there are pitfalls. That is why it is crucial that solutions are developed and led by business, in consultation with other stakeholders. Effective solutions require not just the right regulations, but the mechanisms, infrastructure, and innovations that business can provide to solve challenges throughout a product’s life cycle.

“Successful product stewardship schemes are not just collections systems. They must address the entire life cycle of packaging material including product design that minimises waste, collection systems, labelling that is clear and meaningful for consumers, onshore recycling infrastructure, through to geniuine and valuable use of recycled products. A circular, newzealandprinter.co.nz

Dominic Salmon, Glass Packaging Forum Scheme manager

evidence-based approach is critical.”

Packaging Forum members have been funding voluntary solutions for packaging for a number of years. This includes the only governmentaccredited schemes for glass bottles and jars, and for soft plastics, alongside delivering the public place recycling initiatives such as the Litter Less, Recycle More project.

He says, “While our voluntary schemes have achieved great results, regulation should allow us to step up the scale of impact by allowing for the removal of free riders: those brands that currently choose not to contribute.

“We will now work to transition our voluntary schemes to comply with new guidelines for regulated schemes when they are issued.”

While beverage containers were not announced as a priority product, they were included in the initial consultation.

He says, “There is a working group looking at a Container Returns Scheme (CRS) for beverage packaging, however we believe glass, which already has a recovery rate of over 70 per cent and an established onshore recycling solution, should be excluded from any CRS. “We are already working on an alternative whole of life cycle model for glass that we are confident will cost consumers substantially less than a CRS scheme.

Rob Langford, independent chair of the Packaging Forum “We also look forward to working with Ministry for the Environment, local government, the resource recovery sector, and key community groups on codesigned and regulated solutions for packaging types that currently have no stewardship scheme in place.”

The Forum accepts there will be a cost to business and ultimately consumers but it believes doing nothing comes at a high price to our environment and future. With regulation bringing the entire industry to the table, they say solutions will be robust, efficient, and cost effective. Most importantly, if well designed, they will deliver better environmental outcomes for New Zealand.

The Soft Plastics Recycling Scheme also broadly supports the announcement.

The Packaging Forum set up soft plastics collections in 2015 and the scheme received accreditation as a voluntary product stewardship scheme under the Waste Minimisation Act in March 2018.

Malcolm Everts, chair of the Soft Plastics Recycling Scheme, says the collapse of global markets for mixed plastics forced a major re-set of the scheme in 2019 and this has been further influenced by Covid-19 limiting collections and processing for a period of time. He says, “Our scheme is focused on supporting local processors.

Continued on page 22 August 2020

21

PACKAGING Continued from page 21 “Two years ago, there was no onshore processing of postconsumer soft plastics. Today there are two North Island plants Future Post in Waiuku and Second Life Plastics in Levin which are great examples of Kiwi ingenuity and we are increasing every month the tonnes which we send for recycling.

“With the expansion of their capacity we can now offer soft plastic recycling to around 60 per cent of the population with drop off points across Auckland, Waikato, Northland, Bay of Plenty and Wellington.

We will be adding more stores in more regions throughout the year.

“As a voluntary scheme, we already have over 70 per cent of industry by volume funding the recycling programme and membership has increased by 20 per cent in the past year to 75 companies.

“We are also working with members on the design of their packaging, reducing creation of plastic packaging waste, and advocate using our “return to store” labelling system.

“Scheme members’ levies fund collections from stores, quality checks, baling, transport to end markets and contribute to the processing costs as well. This is different from the traditional model where the processor pays the collector/recycler for the materials, so we are well prepared to transition to a regulated scheme model.

“We hope to see soft plastic recycling processing projects funded in this year’s Waste Minimisation Funding Round and through the proposed $124m investment in recycling announced by the government earlier this month. It is only with a substantial increase in processing capacity including the South Island that the scheme can deliver its full potential.

“We will work with the Ministry for Environment to develop a sensible co-design process to transition our voluntary product stewardship scheme to meet the new regulations over the next three years. In the meantime, it is business as usual for our scheme.”

The Glass Packaging Forum also sees the announcement as a step in the right direction.

Forum chair Karen Titulaer 22

The GPF Scheme captures more than 70 per cent of glass bottles and jars sold in New Zealand says the GPF took part in the consultation process in August 2019 after the Ministry for the Environment proposed beverage containers as one of the priority products under the Act. She says, “We note glass beverage containers were not included in the announcement.

While we would welcome the level playing field inclusion in the announcement that would have allowed for, we will continue to improve and build on our voluntary product stewardship scheme.

“We are already working on an alternative whole of life cycle model for glass that we are confident will cost consumers substantially less than a CRS scheme.

“There is currently a working group underway looking at a container return scheme for beverage containers, and we expect further announcements around this. However, we will continue to work towards achieving our goal of capturing over 80 per cent of the total glass going to market, by 2024.”

Dominic Salmon, the GPF Scheme manager, says its member brands have funded over $3.5m in grants to date to improve the outcomes for glass.

The scheme currently captures more than 70 per cent of glass bottles and jars sold in New Zealand, preventing them from going to landfill.

He says, “This is an enviable recovery rate for any recyclable material worldwide.”

Titulaer adds, “The GPF prefers an approach which takes the whole life cycle into account, from design right

through to recycling. This is as opposed to a container return scheme, which focuses on just collection and which we believe will cost consumers more than the model we are working on.”

New initiatives Eugenie Sage has also announced Auckland-based TechCollect would receive a $320,000 grant from the Waste Minimisation Fund to allow the company to build on its successful e-waste pilot programme, expand to more collection points and to design options for a regulated e-waste product stewardship scheme.

She says, “TechCollect represents product stewardship in action. TechCollect reduces the increasing amount of waste ending up in landfills and the amount of raw materials needing to be mined by collecting electronic goods, such as computers at the end of their life, and recovering valuable materials.

“Much of what is currently sent to landfills can be recycled, composted or reused.

The government is taking a leadership role in reducing waste through investment in waste minimisation.”

Earlier this year, the government announced it will invest $124m in new materials recovery and recycling infrastructure and expand the national waste disposal levy.

The initiatives the government will fund could include plastic recycling plants, weighbridges for improved waste data collection and improved equipment for recycling plants.

August 2020 newzealandprinter.co.nz

WIDE FORMAT +Plus

Aarque gets Onform with Summa and HP Esko Kongsberg arrives at Kale Print l Encouraging a healthy workplace culture

WIDE FORMAT

Aarque supplies Onform Signs

A

uckland-based signage specialist Onform Signs has installed a Summa F1612 cutter and an HP FB 750 UV flatbed printer, supplied through Aarque.

Jared Percival, founder and owner of Onform Signs, says, “We had a different printer but, after lockdown, we were inundated with jobs for site signs. Although we were lucky to have some great partners who helped us with our workload, it showed clearly that we had a weak link in our production flow.

“We identified that we needed a faster machine that could handle the workload.

I have seen several other machines in other companies and I had the chance to see this particular machine, the HP FB 750 UV Flatbed printer, working well for a similar sized business as ours in Dandenong, Melbourne, so I had kept an eye on it.

“It prints multiple jobs at the same time and the speed works well for us. The HP range has constantly improved over the years, and it is great having the back-up from a service partner like Aarque.

“Before getting the flatbed, we outsourced a lot of jobs that we now do in house. It keeps our staff busy, something we are aware of with a slowdown possibly approaching our industry.”

Onform operates a lean business model. He says, “Whenever we can introduce proven equipment into our workflow to save time, rework and increase quality.

“The Summa F1612 cutter works as a good all round model for us, allowing us to CNC all the jobs we used to outsource. This gives us a quicker turnaround and increased margins.

“The cutting features are a bonus. It cuts faster and more accurately and completes tidy and fast cuts on our wall wrap products. It is easy to use and we have cross-trained multiple staff on how to use it with no issues.

“Since we started, Aarque has supplied our sign equipment. We enjoy working with Aarque, which offers 24

Jared Percival, founder and owner of Onform Signs, with the new kit from Aarque

Onform Signs boosts its business with an HP FB 750 UV flatbed and Summa F1612 cutting table

a wide range of product, and the team members are knowledgeable. Also, the Aarque management are available when you need them, and they know you on a personal level.”

Challenges ahead Onform started eight years ago, working out of a garage in Pakuranga, doing mainly fleet graphics for local business owners.

He says, “We would often be weeding graphics on the kitchen bench. We then started to focus on the retail sector, doing a lot of new shops for many household brands in New Zealand, Australia, and the Pacific Islands. We have, bit by bit, added to our arsenal, with Aarque a key supplier from day one.

“We face a challenge navigating through these interesting times. We have had a recession plan in place for a while now and buying these two latest pieces of equipment will help to future-proof the business. Our staff members know we can retain work in house to keep them busy as sales may slow down.

“The additional technology can also help us to be as aggressive as we need to be. It opens up new markets in the future, where we would not have been competitive in the past.

“We look forward to becoming more agile as a business, staying up to date

with, or even ahead of, market trends to help our customers to keep ahead of their competition. We are currently building a new purpose-built manufacturing facility that will allow us to offer new products into new markets in the future.

We are actively mobilising our workforce to become more independent through technology as we have seen through the lockdown period worldwide.”

The team at Onform enjoys the challenges the work creates.

He says, “We all love getting up knowing that each day we’re doing something different.

We could be up a tower crane installing a LED Sign; wrapping a fleet of cars or trucks; coming up with a marketing strategy for a new business; or working with a multinational corporate to develop a trade stand. Each job is different to the next, and you need to adapt quickly, or you will be left behind.

“We are lucky to have great suppliers who keep us informed of new products that we can show our awesome clients so we can always offer an edge.

“I hope that businesses continue to not undercut themselves through these upcoming tough times, as no one wins when it becomes a race to the bottom. Signage will not go away anytime soon. During the GFC, Forbes Magazine described the signage industry as one of the most resilient because ‘everyone needs a sign’ in some form or another.

August 2020 newzealandprinter.co.nz

Professional flatbed finishing systems The Summa F Series offers a line of digital flatbed cutting systems based on 30 years of experience.

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The F Series with its wide range of tools will provide the means to create applications of all shapes and sizes. From packaging, folding boxes, roll-up banners, vehicle graphics, counter displays, routing, outdoor signage and much more.

An arsenal of optional add-ons further expand the capabilities of the F Series, allowing for a custom-tailored machine to perfectly fit your specific workflow and cutting requirements.

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WIDE FORMAT

Fuji Xerox and Esko Kongsberg help Kale Print expansion

R

ecently, leading Bay of Plenty digital and offset print company Kale Print installed the Esko Kongsberg XN24 cutting table, supplied through Fuji Xerox New Zealand/ Fujifilm New Zealand.

Peter Lloyd, general manager at Kale Print says that, with the demand for signage and packaging solutions increasing, the Esko Kongsberg XN24 cutting table purchase marked a natural progression for the business.

He says, “It has been well received already, with our sales team taking on new enquiries for a diverse range of products.

The automation has increased the speed of workflow, creating additional capacity, and enabling our wide format team to spend more time on innovation.”

The Esko Kongsberg XN24 features a powerful 3kW engine, central to Kale Print’s decision making. Peter says, “The MultiCUT-HP (High Power) is equipped with a super-strong, water-cooled milling spindle delivering up to three times faster milling speeds. It can handle a wide range of heavy-duty materials too, such as thick sheets of acrylic, wood/MDF and aluminum composite material.”

The Kongsberg also has an automatic tool adjusting system that uses camera inspection and digital image processing to adjust the tool in the machine at the start of each job. He adds, “When we have a new job and we need a different tool, it sets up that tool for the selected substrate. So, changing over jobs is simple and so much faster than manually. One of its best features is the ease of operation.”

The Bay of Plenty’s top printer finds new markets using Esko Kongsberg technology

He says, “We have had a lot of fun making cool prototypes as well as products we could not dream of prior to purchasing the Kongsberg. These include furniture and flooring for boats.

“The Esko Kongsberg XN24 cutting table complements our larger offset technology. These samples often turn into high volume packaging projects. Our A2 and A1 Offset UV presses can print up to 800 micron, suitable for most packaging needs.”

“We have enjoyed working closely with the sales, prepress and production teams to come up with innovative designs to fulfil our client’s needs.

Prototyping is a growth market for us.

“Who knows what the account managers will throw at us next, but we will give anything a go. We even found a way to repurpose the large cardboard packaging that comes with purchasing metal plates for our offset presses.

It is now being recycled into cartons we can use for customer deliveries.”

Trade commitment Kale Print has a reputation for making the most of technology and innovating to stay ahead of the market, overcoming whatever challenges that it faces. Peter says, “Even though it has been another turbulent year for our industry, we continue to invest in best in

class technology. In 2019 we purchased the Ryobi RMGT A1 LED offset press, a first for New Zealand.

“We also plan to upgrade our digital technology in early 2021, which will further enhance our offering. This is proof of our commitment to supporting our customers’ wide range of requests now and into the future. In particular our trade clients, where the combination of quality and speed is paramount in today’s market.

“We are really pleased with the purchase from Fuji Xerox New Zealand/Fujifilm New Zealand. The installation went smoothly and the training from Chris Cordes was excellent.

We were up and running in a couple of days.”

Grant Blockley, packaging and applications specialist at Fuji Xerox New Zealand, says, “We are delighted that Kale Print has already found ways to use the Esko Kongsberg XN24 cutting table to improve its business.

“One of the features that makes the Kongsberg XN24 cutting table such a smart choice is its expandability for the future. Possibilities include tooling and functional addons; an innovative extended beam clearance capability; and productivity options such as conveyor feed, sheet feeder and a roll feeder unit.

“As its business environment changes, the company can take advantage of this feature.”

Open for innovation In adding the Esko Kongsberg XN24 cutting table to its range of solutions, Kale Print has created opportunities for innovation and product development.

Rob Murphy, wide format manager for Kale Print, says developing clever packaging solutions is a real passion.

26

Cutting through at Kale Print: Rob Murphy (l) wide format manager and Peter Lloyd, general manager with the Esko Kongsberg XN24 cutting table

August 2020 newzealandprinter.co.nz

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Why you need a healthy workplace culture

W

hat does the term workplace culture actually mean, especially in the context of our modern business environment?

For most of us, the oftenused phrase workplace culture implies and refers to the shared values, work patterns, expectations, and behaviours amongst people within the workplace.

Informally described as “the way things are done around here”, a strong and healthy workplace culture can provide an invaluable contribute to the emotional and relational environment at your workplace.

For most New Zealand work environments, these values generally remain unspoken.

However, they play a huge part in the overall vibe of the workplace and, for that reason, managers need to understand how to make the workplace culture more positive.

You may wonder why you should strive for a positive workplace culture important?

What makes it so important?

In reality, you can create and or enhance the workplace culture, the environment that your employees inhabit. How well you do this can facilitate or impede how well employee’s work as individuals and in a team.

More and more, managers find workplace culture as important as business strategy.

Part of the reason for that concerns the way it either strengthens or undermines their objectives. It plays a powerful role in determining employees’ work satisfaction, relationships, and performance.

A positive workplace culture also attracts talent. Potential employees who can recognise a healthy workplace culture tend to see it as a major advantage and so should managers.

It can help your business build a competitive advantage.

It also helps to show potential and current employees the expectations that they will have to meet.

A positive workplace culture leads to a safer and generally happier workplace environment. This can add immeasurably to the overall success of the business.

28

Influences

MELISSA COUTTS

Take steps to make your business environment a great place to work

Essentially, everything will affect the culture of your business, but you need to consider the major factors that can make it better.

Significant factors include leadership, management, workplace practices, policies and the people involved.

As a leader, you need understand that how you manage your business and the leadership styles you embrace will influence the work culture a great deal. Other important considerations include how you communicate and emphasise content; your vision for the future; what you celebrate and recognise; your expectations and how you communicate those; the stories you tell; the way you organise the business; and your decision making processes.

Another major influence is who you hire because their personalities, values, skills, and experiences will contribute to your workplace culture.

Positive cultures While we discourage any manager from trying to find shortcuts to creating a positive work culture, you should still take an active interest in how it evolves.

Many business leaders make the mistake of letting their workplace culture form on its own, without defining what they want it to be. But each workplace culture will have requirements specific to the needs of that business environment.

Every now and then, give yourself the chance to step back, evaluate, and identify your workplace culture. Keep

in mind that your workplace culture itself counts as a work in progress. Taking the time to understand where your workplace culture sits right now and knowing how you want it to look in the future will move your entire business in the right direction.

You will find the following actions relevant and useful in creating and maintaining positive workplace cultures: • Cultivate healthy employee relationships.

Strong relationships in the workplace can lead to increased effective communication.

• Build the universal traits that employees seek from employers. These include the ability to collaborate with others; supporting fellow employees and team members; respecting the work and the people who perform it.

• Encourage everyone to develop a comfortable workplace.

• Boost career development training. Learning never stops. The importance of providing your team with developmental training so that each member can upskill and grow. Many of them will aspire to become leaders and that will make your business stronger.

• Be mindful of burnout.

Overworked and stressed staff can be a key indicator that you have an unhealthy workplace culture.

When you regard positive workplace culture as important as your business strategy, you can move your entire business in a positive direction. It is too significant to ignore and, as a business leader, you should make it a priority.

Take care: each workplace culture has requirements specific to the needs of that business environment

August 2020 newzealandprinter.co.nz

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DIGITAL PACKAGING

Enabling the connected Alvise Cavallari, from Nestlé, says the trend for digital printing makes packaging more exciting

R

ight now, the world of packaging faces many changes.

The drivers behind these changes include new routes to market such as e-commerce; new supply chain models like multichannel supply; new regulatory and sustainability requirements; and new customer demands for more customised and personalised products.

New technologies and materials are required for, and indeed enable, these changes to occur. Digital printing is one such breakthrough within the packaging world and one in which Nestlé has invested in recent years, observing developments, and driving them towards the specific needs of food packaging for their businesses.

What a privilege to see how the centuries-old analogue printing industry is reinventing itself digitally in such a short time.

It has only taken about twenty years for digital printing to enter every sector of printing per se. It is fast getting real even in the challenging area of

Companies must now support the need for more environmentally sustainable production 30

August 2020

Variable data printing: Nestlé has responded to customer demands for more customised and personalised products food packaging, where volumes together with compliance aspects were once considered unsuitable for digital.

Long-term trend ALVISE CAVALLARI

At Nestlé, we are confident that digital printing is a long-term trend that has come to stay, not just a fad that will fade, such that the digitalisation of printing is itself a major step in reshaping the whole converting industry.

As the last drupa exhibitions have shown, it has become all about digitalisation.

The main print press vendors are well advanced on their digital roadmaps and newer players are entering the scene on the same road. This said, while the digital printing industry is very lively, it is still quite fragmented and we expect a phase of business and market consolidation in the coming years, driven by the need to adapt to new technology needs or usages.

We are also witnessing a strong surge in print in production, with history seemingly repeating itself as printing comes back to production. This has to do with late-stage customisation: customisation that is itself achieved at a late stage in the process. I will return to this later.

As our journey advances, and as technologies mature and prices fall, we will always find

new opportunities to leverage the benefits of digital printing, from modest to bold as well as small to large. But we will also be confronted by new requirements and barriers to overcome. Currently we foresee two specific aspects that are becoming ever more critical for the efficient adoption of digital printing.

Sustainability The first aspect is all to do with supporting the need for more environmentally sustainable production, and this includes print production.

In our case, we have made a commitment to use only recyclable or reusable packaging by 2025. To help us meet our commitment, we established the Nestlé Institute of Packaging Sciences, which together with suppliers and other external partners is exploring alternative packaging materials.

We can already anticipate that these materials, such as paper-based laminates, have lighter barrier properties compared with materials in use today. This presents a challenge to the related printing processes and will constrain their usage.

It is true, of course, that digital printing inks have made huge progress in food compliance and are still improving significantly.

However, on new packaging newzealandprinter.co.nz

DIGITAL PACKAGING

factory of the future

Digital: The HP Indigo V12 offers up to 12 colours on press and a speed of up to 120 metres per minute materials with lighter barrierproperties, some printing systems (the combination of a printing process, an ink, and its finishing process) will need to be adapted to meet our strict requirements for food packaging.

Additional requirements will also affect targeting, for example, reusability, recyclability, and compostability. Are today’s ink formulations, developments and finishing processes ready for this transition?

There are only a few years left to crack all this; sustainability is becoming a primary decision-making criterion and the printing industry must prepare for it.

Data management The second aspect underlying the promise of digital printing has to do with variability in the printout (output) as well as flexibility in the printing (process).

Print jobs are more and more related with data management as each output is potentially distinctive with its own variable data that is newzealandprinter.co.nz

managed flexibly within an agile printing process.

And so, I return to the topic of late stage customisation, which appears in so many presentations, media articles and literature on digital printing.

What does late stage customisation mean exactly?

Well, it means having the ability to customise the output at the latest stage, which itself means moving printed packaging from a conventional rigid supply chain to a networked supply chain where different players can print different static and variable layers of an artwork in one or several locations.

It means moving away from a monolithic approach, where the full printing and converting processes are entirely outsourced, to where there will be a variety of supply chain options to cover the high variety of products, business models and routes to market, ranging from fully outsourced supply to fully internalised printing and converting, with mixed approaches in-between.

This is our definition of variability and flexibility,

derived from data driven print production and late stage customisation.

In order to achieve all this, the dots need to be connected, meaning the print job data as well as the printing and converting process must connect seamlessly into an integrated end to end supply chain workflow.

This integration and connectivity happens in two dimensions, namely horizontally and vertically.

Horizontal integration involves the progressive digitalisation of the complete converting machinery and processes, streamlining the repro whilst still ensuring colour matching and consistency. This digitalisation has already occurred for the artwork and prepress, is happening for the printing step, and will progressively include the decorating, cutting and folding-gluing steps as well as any more particular converting steps. Vertical integration relates to the printand converting-data. It ensures that the right output is achieved Continued on page 32 August 2020

31

DIGITAL PACKAGING Continued from page 31 from the right data in a make to order or print-to-order model.

Both static as well as variable artwork-data must be aggregated dynamically together with production specific data coming from a production order, making in the end every pack specific, if so required.

At first glance, this degree of integration and connectivity to achieve a batch of one might sound futuristic and it is definitely ambitious, but the reality is that all the necessary technology building blocks already exist today.

Digital front ends rip dynamic artwork for the printer. Manufacturing execution systems dispatch production order information to the various assets of a production line. Dedicated servers ensure additional functionality, such as serialisation or aggregation.

For each and every type of data, a dedicated and well optimised channel exists.

In addition, connectivity standards are maturing and being adopted to ensure both horizontal and vertical communication between all the modules of a production environment. All these channels, which are today mainly independent, can start to be interconnected to combine, on demand as and when needed, the relative data, rip it accordingly, and finally print it to produce every unique packaging item.

Data is the fuel of today’s economies, as shown so quickly and efficiently by the famous GAFA (Google, Apple, Facebook, and Amazon) companies. The ability to create, collect, handle, combine, extract, analyse, process, and convey data is what will drive the most efficient businesses.

Printing is no longer about accurate colour matching and process efficiency. It is rather about conveying to buyers and consumers digital information that that has been applied physically on the pack.

Some call it the blended reality. It marks a paradigm shift combining digital printing with connectivity. Such a shift is a prerequisite for achieving personalisation and customisation, the holy grail of the digital transformation in consumer package goods.

It envisions the connected 32

August 2020

Packaging printing can physically convey information to buyers and consumers production floors and factories of the future.

Let’s look forward to seeing much of this at drupa in 2021.

With a background in mechanical engineering, Alvise Cavallari spent nearly 20 years in the machine

industry which is where he first discovered and fell in love with the “fascinating world of packaging printing”. He then joined Nestlé research and development, where he now heads Nestlé’s corporate digital printing programme as well as other related activities.

Touchpoint packaging glimpses the future Packaging printing continues to be a sector with tremendous growth potential.

At drupa, its market relevance is reflected in the special touchpoint packaging forum.

Touchpoint packaging serves as a stage for presenting the future world of packaging, especially packaging design. Examples include new substrates; customer specific solutions that reduce environmental impacts; networked packaging; and more possibilities now under development.

As a highlight, visitors can look forward to a presentation of specially developed prototypes incorporating innovative design and packagingsolutions, which were developed in response to the needs and demands of future consumers and brand owners.

At drupa, visitors will have the opportinity to see working examples of prototypes in packaging printing technology newzealandprinter.co.nz

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OFFSET XXX

The future for liquid and

S

ince 1953, German manufacturer Weitmann & Konrad (weko) has developed, built and sold high precision liquid and powder application systems.

In general, print operators use the technology for moistening and applying release agents. In this interview with VDMA (the German Printing and Paper Technology Association), Carlheinz Weitmann, managing director at weko talks about digitally controlled precision, changing markets, growing environmental awareness and about weko in 2030.

VDMA: Can you tell our readers about your company?

Carlheinz Weitmann: We are a medium-sized company with 140 employees, around 100 of whom are based in Germany. Marcel Konrad and I continue to manage the company that our fathers built up in 1953. Today, we have five subsidiaries, a good 30 agencies on five continents and broadly diversified target markets.

We are specialised in the development and construction of high-precision liquid and powder application systems.

These are mainly used in printing and paper technology, the tissue and nonwoven sector, and in the processing of textiles, fibre composites, wood fibre boards or films. Until a few years ago, four fifths of our sales came from the graphics sector.

Thanks to consistent diversification, this share has fallen to about 35 per cent.

As part of this strategy, we invest almost seven percent of our sales in research and development.

VDMA: CW:

Where do you see your main growth potential?

There are still some spots on the map. We are currently hiring an employee with Asian experience to have an even greater presence in that region. In addition, quality demands and the requirements for intuitive operability are growing in all areas of 34

Carlheinz Weitmann, managing director at weko

Digital technology has hastened the trend to automation, even in powder applications

industrial production. This suits us as a provider of high end technology.

VDMA:

What function do your products fulfil in printing and paper technology?

Our fathers developed a powder applicator, which was the basis for the company. Previously, the health-endangering rubber arabicum was the common release agent. Powder was a welcome, cheap alternative based on potato starch.

Release agents are necessary so that the printing ink does not smear or stick to the printed sheets. With powder as a spacer, further processing also works more smoothly.

High gloss books are often dusted with our application technology. Even at printing speeds of 22,000 sheets per hour, it applies the powder so precisely that it only lands on the paper. To do this, they dose it to the milligram, depending on the format, and blow it evenly onto the respective sheet with slightly increased air pressure. One teaspoon of powder is enough for the area of a football field. There are not

CW:

many suppliers in the world who can provide such accuracy.

VDMA: CW:

And what’s with the

liquid application?

The beginnings in contactless dampening of offset printing units in newspaper presses were followed by applications in the textile sector after our fathers had presented their technology at textile trade fairs. Meanwhile weko systems apply various fluids in different industries. In the printing industry, humidification is used to relax paper fibres that have shrunk in drying processes.

During the drying process, 80 percent of the liquid is removed from the natural fibres, resulting in wavy paper or cardboard.

Our humidification systems return the liquid to them without affecting the print image. This depends on the size of the droplets and their exact distribution: They must be larger than in a floating aerosol, but small enough so that the colours do not run. Our application systems automatically adjust the dosage to the printing speeds.

August 2020 newzealandprinter.co.nz

OFFSET XXX

powder applications

and networking are therefore well advanced. The printing industry was very advanced in this area at an early stage and has consistently pushed ahead with automation in the pressroom. When I started out, there were two or three workers per press; today the ratio is reversed.

VDMA: CW:

Automation: weko’s modules work in a range of offset presses They obtain the necessary information from signals from the printing press or from sensors.

VDMA:

Your customers can choose between roller and spray application as well as encapsulated systems.

When is which procedure recommended?

Roller application is used where things must be quick and easy. For example, for silicone application in web offset. Spray application is much more complex and elaborate. For reasons of occupational health and safety, encapsulation is mainly used in the textile sector. Some manufacturers of digital printing systems also use encapsulated dampening modules to prevent contamination. It should be noted that our systems operate almost loss-free thanks to consistent recirculation, which minimises the consumption of critical media and fresh water and thus also the cleaning effort and operating costs. It is important to us to develop environmentally compatible solutions.

CW:

newzealandprinter.co.nz

VDMA:

The printing industry strives for minimal changeover and cleaning effort. Doesn’t the use of water and powder conflict with this?

Contamination occurs where fine particles in poor powder or aerosols vagabond during spray application. This is exactly why precision is so important in the application. Compared to the alternative, drying with UV or infrared light, our systems have clear advantages in energy consumption and environmental compatibility.

Incidentally, UV printers also use powder to eliminate adhesive forces between the sheets of paper in finishing.

CW:

VDMA:

To what extent are digitalisation and networking working in your niche?

We usually supply modules to press manufacturers who have had digital control technology for many years and communicate with the presses. The printer sets his formats on the machine. With the data, our systems do everything else fully automatically. Digitalisation

CW:

What will weko show at drupa next year?

First and foremost, we will be represented with our modules in the presses of printing press manufacturers. They will present innovations to which we have made our contribution in close cooperation. But there is also a weko stand. A lot is currently happening in the digital printing sector. Many large manufacturers now rely on our humidification technology; smaller suppliers will follow suit. We would like to be just as responsive to them as we are to printers who can achieve significant quality improvements with our retrofit solutions for digital printing.

VDMA: CW:

What role does service

play for you?

The maintenance effort of our systems is minimal and very rarely anything breaks down.

However, we have service staff and trained partners worldwide who provide our customers with fast and reliable support in the event of problems.

VDMA: CW:

What do you see when you imagine yourself in 2030?

Without doubt, the technology will be more complex. We must extend our know how in all directions in order to achieve optimal integration into automated process chains and to realise self-adjusting repeatability with closemeshed sensor technology.

Remote plant monitoring and camera-supported guidance of customers during repairs will be just as commonplace as cooperation with machine manufacturers based on digital tools and platforms.

August 2020

35

WORKFLOW

Assessments and platforms

Every conversation you have with a client has a financial impact

Pat McGrew provides insights into how you can use a better workflow to grow your business

T

he most expensive things you do in your printing plant every day involve talking to clients and physically touching their work.

You talk to clients to better understand the work they want you to do, and you touch the work, in prepress or at other points in the process, to ensure that the client’s intent is rendered on to the substrate. But every conversation, and every touch has a financial impact.

While you rely on workflow tools to aid the process, in most companies there are also spreadsheets, whiteboards, 36

PAT MCGREW

and sticky notes used to gather and communicate information about the jobs-in-progress. It is only natural. However, the more you talk and touch, the less money you make on the job.

Workflow should be the infrastructure that allows you to do the most work at the least cost but over time, the solutions put in place to meet a specific set of needs, job types and clients, begins to wear and rub. Well meaning team members add additional steps; circumvent steps; create spreadsheets to track things that the workflow software isn’t tracking, and before you realise what has happened, your workflow is a series of disconnected steps that is undocumented and inefficient.

How can you tell if your work is no longer flowing, but moving through a series of hoops and hurdles? Start by taking a quick look at what you have, and then begin looking at the emerging solutions that can help you become more efficient.

Location, location, location You need to assess where you are to plan for the future.

Workflow has never been the big talk track in printing. Some look at workflow software as a necessary evil.

The complaints about workflow range from difficulties in installation and set up to complicated user interfaces that take too much time to understand. The complaints have some basis in the reality of dealing with software that was often created to meet the needs of a specific print shop configuration before being marketed to the print industry at large. Add the changes in print production over the last decade, and the odds that the workflow installed is perfectly suited to the work being done today are not good.

Some of the common symptoms of a workflow that is out of sync with the current print work mix include: • Trouble getting a larger number of short run and

August 2020 newzealandprinter.co.nz

WORKFLOW

to improve your workflow

How can you tell if your work is no longer flowing, but moving through a series of hoops and hurdles? small batch jobs onboarded, into production, and out the door so they can be invoiced.

• A growing number of overtime shifts impacting job profit margins.

• Automation solutions that require manual touch points, islands of automation.

• Installed software that no one is using.

• Multiple processes for the same function, sometimes the result of mergers and acquisitions.

Any of these conditions will cost you time and money, but as they add up, they can seriously impact your ability to run profitably. Sadly, these situations do not fix themselves over time, and trying to add more software on top of a challenged workflow often only adds more cost without repairing the underlying problems.

Before you write that cheque for a new workflow solution, do a self assessment that starts with a walk through your workflow. This is a best newzealandprinter.co.nz

practice recommended by most workflow experts as the starting point for the move to operational excellence.

Begin your workflow walk with a whiteboard. Identify the types of work you do at the highest level. List your equipment and your software.

If you have asset lists, start with them, but be prepared to edit.

The next stop is the point where you begin to work with a print job.

Some organisations have embraced web to print solutions, bought or built, while others still work by taking orders over the phone or exclusively through a salesperson or print broker.

You may have all these onboarding points. You may discover that you have several web to print solutions as well as different onboarding methods depending on the salesperson or broker you work with.

Make some notes on the ways work comes to you because this is the area cited

Before you write that cheque for a new workflow solution, do a self-assessment that starts with a walk through your workflow.

in industry surveys as being the most disruptive. This is especially true for companies that have transitioned with their customers from long runs of static work that was on the same cadence year in and year out to shorter runs with more variations.

Once you look at how jobs come on board into the print shop, walk with the different types of jobs through the shop. Listen for how many phone calls back to customers are needed to confirm specifications, decide on substrates, adjust expectations on delivery.

As the jobs move into prepress and pre-flight, how many jobs are rejected for missing elements? Is everyone using the installed workflow solutions, or are private spreadsheets and notebooks the true measure of job progress?

Review the job scheduling and watch for the number of reworks. Is there work that has Continued on page 38 August 2020

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WORKFLOW Continued from page 37 been printed that is waiting on finishing? If you have production dashboards, how close are their indicators to what you found on your walk?

Record everything you see.

Now, go back to your asset lists and look for the software that is installed and compare it to what is being used. Do you have unused software packages for which you still pay maintenance? Here is a place to capture some savings.

Look at every software tool that is installed and identify where it is used and how it moves the workflow process forward. Once you have this refreshed view of your print production workflow, it is time to consider the trends and emerging technologies that can help you eliminate the inefficiencies and make money with your workflow.

Head to drupa in 2021: The giant show will have a focus on workflow solutions

Build your platform From the data-centric solutions informed by Industry 4.0 to the platform and framework orientations of an emerging set of Software as a Service (SaaS) workflow options, the opportunity to remake your production workflow lies in your grasp.

Since drupa 2016, the industry has seen established workflow solutions retool to take advantage of cloud-based computing; subscription models for both delivery and payment; and compatibility with an emerging set of platforms designed to allow a workflow architect, creating a bespoke flow by plugging tools into platforms and frameworks.

Platforms, as a method to allow disparate software tools

Workflow should be the infrastructure investment that allows you to do the most work at the least cost 38

to work together in a workflow, provide distinct advantages.

Consider a platform like Enfocus Switch, with more than 70 apps available for integration into the Switch platform. From CloudPrinter to handwriting generators, PDF tools and metadata handling applications, the Switch platform allows a workflow architect to assemble tools to optimise large segments of the production workflow.

HP offers a similar approach with its PrintOS platform, introduced at drupa 2016, and continuing to expand with new solutions added to the its marketplace regularly. The defining characteristic of these platforms is that applications used well defined application programming interfaces (APIs) to integrate into the platform, making it easier to try a tool before committing to it.

Expect to see more platforms introduced by the key workflow vendors and announcements of well recognised tools available as plug-ins to existing platforms.

Ryan McAbee, director of production workflow for Keypoint Intelligence, makes this statement on platforms: “The need for workflow platforms will only intensify as the industry converges and analogue heavy segments like packaging undergo further digital transformation.

All types of applications, regardless of the eventual printing method, require

well-defined workflow steps from pre-flighting to colour management.

“As a result, print workflow platforms are well suited to support the changing industry needs by leveraging best in class components that create a universal workflow for processing and routing orders intelligently in one system.”

Production printers should also take note of the emerging world of print customisation platforms that connect print buyers with print producers.

Companies like Cimpress, Cloudprinter, Gelato, and InkRouter have developed global network platforms that make it easier to access print providers with different capabilities and delivery locations that can expand the footprint of any printer, anywhere.

If you are not quite ready for a platform, look for tools and suites that can be integrated into your current environment that can capture data on jobs at every touch point and relay that information to production dashboards that inform not only the production floor but management. In the modern print shop, it is essential to be able to identify every cost associated with every job to ensure that margins are met.

Next year, take your shopping list to drupa and spend time with both the independent software providers and the partner solutions features in the hardware

August 2020 newzealandprinter.co.nz

WORKFLOW solutions stands. Ask questions about scalability as your business changes and grows and take the time to review any case studies that are offered.

A few minutes of reading may prove extremely useful.

Workflow makes money The promise of a well-designed workflow is that it includes only the needed software tools.

It also captures and provides usable data to production and business dashboards. It can be scaled up or down over time to accommodate new product lines and new printing and finishing technologies to give you operational excellence.

Importantly, it provides the infrastructure that eliminates unnecessary costs, unnecessary touchpoints, and unnecessary handling.

In the 2019 InfoTrends European Software Investment Outlook, workflow was identified as the most overlooked â‚Ź1.4m ($2.44m) cost centre. The goal should be to turn that into a profit centre by proactively managing prepress activities, how jobs are sold, and files are received.

Your workflow assessment should help you identify the real costs of job onboarding, which is the single biggest point of cost in the workflow process.

Other surveys support the identification of job onboarding, getting the job from the point of sale to the point of print, as a key element to investigate when looking for places to streamline.

If you have multiple web to print and file capture

A well-designed workflow provides the infrastructure that eliminates unnecessary costs, unnecessary touchpoints, and unnecessary handling portals, this is a good time to consolidate them. It should be scalable and secure. If jobs are arriving in email, or through FTP, they are difficult to automate. The best solutions make it easy for customers to upload files and provide options to automatically check the files for assets, preflight, and ensure that all job specifications are complete for the job. That alone can save hours of time. More sophisticated solutions might automatically route jobs based on business rules you establish, again taking the people out of that process.

Remember that any of these solutions will require a keen understanding of your work processes and time to set up

You need to find a platform that works for you and suppliers offer a range of options. HP introduced PrintOS at drupa in 2016 newzealandprinter.co.nz

The need for workflow platforms will only intensify as the industry converges and analogueheavy segments like packaging undergo further digital transformation.

Now, you need to know how to combine print with other communication channels.

and implement. Once done, however, the cost savings will follow. And that is how you make money with your workflow: you take costs out that should not be there.

Follow the same path as you look at Print MIS solutions, ERP solutions, approval management systems, and connectivity to the business platforms for invoicing and payment management.

Your Next Steps The value of drupa is that every solution provider will be there.

As you plan your time at the fair in 2021, plan at least a day of time talking to the software vendors. Bring your challenges and don’t be afraid to explain where you have friction in your workflow.

These vendors have seen and heard it all and they will have ideas on how you can get from workflow as a headache to workflow as the infrastructure of your ongoing financial success.

Co-Author of eight industry books, print technology evangelist Pat McGrew has three decades experience of using her technical and marketing background to help print businesses deliver better outcomes for themselves and their customers. She currently helps to educate the industry in production workflows. Contact her at pcm@mcgrewgroup.com August 2020

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ROMANO

The New Book Man Digital printing of books has completely altered the publishing process with the removal of inventory costs a key advantage

E

FRANK ROMANO

book volumes are static, yet demand is surging for printed books.

Readers have discovered that you can give books as gifts, lend them to friends, sell them and read them years later without a device or software. And books look great on a shelf, which is useful in this time of Zoom meetings.

The growth of printed books is based on two trends.

The first is self publishing. I went to an authors’ event and the aisles were filled with tables of self published books of many genres. Self publishing has been engendered by the second trend: on demand printing.

There are the very visible online book printers. They offer tools and advice to get a book into print and help with marketing.

The concept of On demand printing has been around since the 1980s when Kodak and Xerox had toner-based printers that could print and bind in the same machine.

When I wrote my first book in 1971, I asked the offset printer for 500 copies. The printer said the minimum run was 5,000. He said, “You can throw away 4,500 of them.�

In 1988, I did the first research about on demand printing. I was hired by R.R. Donnelley and other large book printers to talk to their executives. They all said they could not make money with short runs.

I once consulted for the University of Vermont to set up an on demand book facility.

They linked to the Copyright Clearance Centre so that content could be used in course materials sold on campus.

Some will remember the Kodak Ektaprint that they used. It recirculated the originals to create one copy set in paginated

order. In 1990, the Xerox Docutech scanned the pages to a file and then printed them out. It added more binding options.

By 1992, the concept was catching on and by 1993, Indigo and Xeikon printed in full colour.

It took a while for on demand printing to gain traction. Quality and workflow issues needed to evolve. Once they did evolve, on demand printing became a euphemism for digital printing which is growing in use by publishers worldwide.

I contend that of the 700 million books produced in the US last year, more than half were printed on demand using digital technology. No one really tracks this area very well. There are still very long print runs of best sellers that require big web offset presses, but the changes in the book world are being wrought by digital technologies for shorter and even medium runs. Some of the long run book printing companies have suffered.

In 1994, many printers moved into CTP to feed their offset presses by installing

On demand: The Screen Truepress prints books digitally 40

August 2020 newzealandprinter.co.nz

A printed book can be re-read and passed on to a friend. It also looks great in a Zoom background.

Creo and other platesetters that imaged plates directly.

Offset and CTP are still best for long runs. And it is the run that determines the printing approach.

Actually, on demand printing succeeded because of the longer short run. We went from runs of one to 10 to runs of 100 or more at a time.

The Screen Truepress Jet in 1990 was one of the first roll fed colour inkjet printing systems.

An inline Hunkeler or other finishing system linked into the press via a turner system. The workload on this press rapidly built up with both monochrome and colour work. Today, the output of many plants is mostly colour and overwhelmingly digital with several different digital systems that are all linked in a cohesive workflow.

The move to inkjet was important. Printers have been able to establish a niche as cost effective book producers.

Many on demand production plants look like a mini trade exhibition, with many different printing systems and loads of specialty binding equipment.

This mix of systems allows them to produce almost any newzealandprinter.co.nz

book in any format. But the key is automation. It is said that ‘Printing Industry 4.0’ is all about automation. For all printers, automation should be a mantra.

Some workflows go beyond Job Definition Format (JDF).

Many printers have their own proprietary approaches. It is for this reason that a crew of just over 50 can produce millions of books a year.

When Howie Fenton and I wrote the first book on on demand publishing in 1992, it was printed on a Xerox Docutech. At one point, customers were told that the book was out of stock. This was weird because the book was produced on demand. GATF, the publisher, had run out of the channel bind covers, which were produced by an outside supplier. If you are going to make a book, the finishing is as important as the book block.

That is what many printers get right.

They can give you any kind of binding you specify: hard and softcover, saddle stitch, spiral wire and plastic binding.

And every one of these methods is growing. In addition, many

produce beautifully printed book jackets.

But printers have not just made printing and binding more efficient. They have changed the way publishers operate. At one time, it was all about inventory. Print and bind the books and ship them to a warehouse; then ship them to a booksellers’ warehouse to sit in silence or even multiple warehouses.

Today, it is all about Virtual Inventory Management. We live in a ‘Just In Time’ world and it has changed the way publishers operate. Books are shipped to booksellers directly. Inventory costs have gone away.

Publishers now print what they need when they need it and this has expanded a printer’s market. It has also cut shipping costs.

I love to visit innovative printers who not only think out of the box, they invent the box. They have succeeded by integrating industry available technology with unique workflows. They have built great service businesses that have gone on to change the publishing industry; one book at a time.

August 2020

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