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    PostPress

    Print Decorating, Binding and Finishing

    2015 May/June

    Association News

    Letter from the manager

    Here at the BIA, we have just wrapped up our 2015 annual conference in Minneapolis, Minnesota. This year’s event brought the postpress industry, suppliers and printers together with the co-location of the Print Leadership Summit. From this event, attendees learned how to build their businesses using LinkedIn; heard panel discussions and case studies from binders, printers and vendors; and got to network with top executives. We heard some great feedback from vendors and attendees, and we will be applying this information to the BIA and our future events.

    This was my first time at the annual conference since coming on as manager of the BIA back in March. I met some great industry professionals who I look forward to keeping in touch with in the future. From what I’m learning, I can understand what a valuable and interesting area the postpress industry is, and I am thrilled to be part of it.

    If you are interested in speaking with me about the BIA or what you would like to see in the future, please don’t hesitate to contact me at [email protected]. I encourage your feedback on how you would like to see the BIA help you.

    Regards, Chrystal Kapanyko

    BIA Annual Conference Wrap-Up

    In mid-May, the 2015 BIA annual conference was held in Minneapolis, Minnesota. This was the first year the conference co-located with the Print Leadership Summit, so attendees were able to participate in the keynote sessions, as well as any of the PLS tracks in which they were interested.

    The BIA track brought in speakers TJ Tedesco, Grow Sales; Paul Reilly, New Direction Partners; Valerie Price, Coyne Graphic Finishing; Scott Warrick, Scott Warrick Consulting, Training & Employment Law Services; Patty Meyer; Corey Perlman, eBootCamp, Inc.; and Daniel Dejan, Sappi Fine Paper North America. Additionally, two informational panel sessions and a vendor rapid-fire session were presented.

    The final day focused solely on the BIA tour. This year, there was one tour that included three stops: Muscle Bound Bindery, Daily Printing Inc. and 612Brew. At Muscle Bound Bindery, attendees were given the opportunity to see binding capabilities from side-sewn case binding, Otabind and PUR layflat adhesive binding, as well as EVA and PUR perfect binding capabilities. At the next stop at Daily Printing Inc., attendees were given the chance to see the latest technology and equipment to satisfy sheet-fed printing needs. To round out the day, attendees heard the background of 612Brew, as well as the historical location in which the brewery is housed.

    New Benefits for Members

    As your postpress resource, the BIA is dedicated to supporting its members through the finest networking in the postpress industry and education on the latest innovative technologies. With the recent expansion in member benefits, members enjoy access to value-added resources that allow them to be more competitive and profitable. Here are some of the new benefits a BIA member can enjoy:

    • Discounts for Printing Industries of America-hosted conferences, which include the Color
    • Conference and Continuous Improvement Conference
    • Special pricing on publications made from Printing Industries Press
    • Discounts on courses through the Integrated Learning Center
    • Discounts on purchases made from Printing Industries of America’s National Buying Power Program
    • Access to professional peer networking forums, like virtual peer groups
    • Digital access monthly to Printing Industries of America: The Magazine, with articles written by industry professionals on a variety of topics
    • Opportunity to contribute to the new BIA blog

    See a complete listing of member benefits by visiting www.printing.org/biamembership.

    Industry Communication

    One big push from the BIA to become a top educational resource is to engage with the industry and suppliers to the industry. The plans to do this not only includes the new BIA blog, but via social media channels, a BIA resource page and the BIA listserv.

    The BIA offers this array of communication channels to the industry as a way for professionals to speak to one another to acquire ideas, tips and even assistance when needed. This connection is vital for any company trying to stay competitive in the industry.

    The BIA blog contains information on various topics that help the postpress community, including sales and marketing along with binding. The blog will help to develop the conversation on the BIA social channels on Twitter (@Binding) and LinkedIn (search for BIA Binding Industries Association). Be sure to connect with us on these channels to keep up with the conversation and the latest BIA news.

    While the BIA listserv is a great members-only benefit, it gets people engaging with one another when help is needed or when looking for a recommendation on equipment. As for the BIA resource page, which is in development, it will house links to educational material for the postpress industry. This will be a one-stop location to the current trends and tips of the industry.

    As we move into the middle of 2015, the BIA is a nonstop force to provide members and the industry with a variety of resources and education. For the latest news on BIA, connect with us on social media and check out www.printing.org/bia.

    Collotype Labels Honors South African Vineyards

    by Brittany Willes, PostPress
    Collotype Labels, Napa, California, recently was awarded the Gold Award in the Creative category for Sheet/Rotary labels in the 22nd Annual FSEA Gold Leaf Awards.

    From the Western Cape of South Africa, winemaker Graham Weerts uncorked the limited production Capensis Chardonnay. In order to create packaging as sophisticated as the wine, Capensis partnered with Collotype Labels, Napa, California, the wine and spirit arm of Multi-Color Corporation. Both corporations sought inspiration in the ancient soils, dramatic landscapes and historic vineyards that honor the greatness of South Africa.

    Once the initial design was in place, Killer White paper stock was chosen as the label’s base. With background texture created by rotary debossing, the proprietary, wet-strength material is made exclusively for Collotype by Fassion. The solid, cream-colored background serves as a contrast to the darker colored foils of the text. Despite the limited color palette, the final effect is one of understated elegance.

    Production of the Capensis label required a combination of rotary foil stamping, rotary texture debossing, flat-bed sculpted embossing and flat-bed diecutting. With the exception of the sequential numbering, which was completed on a second, offline pass, all of the processes were done inline, in a single pass on a Gallus TCS 250 semi-rotary offset printing press. When asked about the use of semi-rotary versus flexo printing presses, Tim LaPoint, TCS technical coordinator for Collotype Labels, explained, “Offset printing differs from flexo printing in how the inks are transferred from printing plates to paper stock. The advantage of semi-rotary technology is faster set-up and changeover times. Also, offset printing offers a higher print quality that is achieved by using a finer dot size.”

    The advantage of a finer dot size was utilized in the label’s embossed images. Infused with intricate images of plant life, such as vines, leaves and flowers, the label also is decorated with an image of an antelope, evoking the wine’s South African heritage. In order to create these highly detailed images, the solid background was offset printed in cream with reversed illustrations, as well as positive plate and conventional dot-and-line work. Furthermore, in order to better ensure the Capensis name and supporting text stand out against the cream-colored background, “Capensis” was foil stamped using Kurz 347 brown foil with MTC release. The sequential numbering was done with MTS release in Kurz 362 black foil.

    With its complex production process, the Capensis label proved to be quite a task for Collotype. “The flat emboss was a challenge,” stated Lapoint. “It required a high-level of expertise to achieve the customer’s desired result.” Despite the difficulties presented by the label, Mark Schmick, one of Collotype Napa’s leading sales representatives, reported that both Collotype and the customer were pleased with the final result. “Our client and its brand managers worked collaboratively with our production and prepress teams to engineer a stunning label,” Schmick stated. “We are all thrilled with the final product.”

    As evidence of Collotype’s confidence in the label, the company chose to enter it in the 22nd Annual FSEA Gold Leaf Awards, where it was honored for excellence by being awarded the Gold Award in the Creative category for Sheet/Rotary labels. Capensis wine and its award-winning label will be released to the globally in late spring of 2015.

    2015 Narrow Web Supplement

    Q&A: Common Issues in Laminating

    by MACtac global
    Static electricity is an issue that may arise and is impossible to prevent. However, it easily can be kept under control by taking a few precautions.

    Laminating can be a delicate process with several potential process flaws that can affect the final look of a laminated print. Well versed in pressure-sensitive technologies, MACtac has identified some of the most common issues that can occur during the laminating process.

    Question: What causes laminating bubbles?

    Answer: Few issues look worse than when bubbles appear under the film. Bubbling can occur for many reasons, the most common of which are listed below.

    Tension
    Lack of supply roll tension can cause the film to not be taut as it enters the nib. This insufficient tension causes bubbles when air gets trapped between the film and image. Too little supply roll tension will cause bubbles before it will cause wrinkles in the film. Insufficient tension easily is fixed by adjusting the tension of the feed spool to the proper specifications for the type of film being used. For instance, thinner film needs less tension.

    Speed
    Feeding too quickly causes bubbles if the item is pushed into the nib faster than the speed of the laminator. The solution to this problem is too obvious to mention.

    Heat
    “Hot spots” are a key problem when laminating inkjet prints. Inkjet printers dump a lot of ink onto the print and a rushed operator may try to laminate the image before the ink is completely dry. The problem can be exacerbated by the fact that, if a laminator is allowed to sit for extended periods of time without the rolls turning, there can be varying degrees of temperature on different parts of the rolls. This creates hot spots. When running a laminator at 85°C, the point where the rolls sit together easily can become a hot spot of +95°C. When a moist inkjet print encounters one of these hot spots, the ink easily can boil, creating bubbles. Among the solutions to heat-related bubbling is not to let the rolls sit idle for extended periods of time, to speed up the laminator so less heat gets into the printer or to work with a temperature about max 40°C. Always use the appropriate pressure.

    Silvering
    Silvering is caused by the capture of tiny bubbles of air, which look like hazy or reflective areas in the lamination. It may go unseen over light areas of an image, but will be more obvious over dark or black areas. Silvering usually is caused by too low an operating temperature and most often is seen when a machine is not given time to warm up or if the film temperature drops too low. When a large machine is warmed up without the motor on, one side of each laminating roll remains relatively cool. When lamination is begun, a pattern of repeated silvering can be seen each time the cool side of a roller is applied to the lamination. “Cool spots” are areas that aren’t hot enough to melt the adhesive. If bands of silvering alternate with bands of properly adhered areas, it means one part of the roller was too cool.

    Be sure to pay attention to any defect which repeats. This is typical of debris, damage or low temperature on a section of the roller. Bubbles also can be caused if the adhesive doesn’t bond properly to the image. It can look like a sheen on the image. Bonding problems also can be caused by inadequate heat, inadequate or uneven pressure or too much speed. Inadequate pressure can cause silvering if the film isn’t pressed onto the image hard enough, preventing the adhesive from properly bonding.

    Question: What causes wrinkles during lamination?

    The film will wrinkle if there is not enough supply roll tension. Every laminator needs a certain amount of resistance in the unwinding of the supply rolls so that the film lays flat as it goes into the nib of the laminating rollers. Thinner film needs less tension, thicker film needs more. Also, respect the laminating temperature of 40°C to avoid wrinkling due to damp materials during the laminating process. The moisture content of the printed substrates must be the lowest.

    Question: What are “orange peel” wrinkles?

    Answer: The industry term “orange peel” refers to very fine wrinkles or waves in the laminate. This is a common condition resulting from too much heat. Simply adjust the temperature to a lower setting. NOTE: A quick fix can be to speed up the laminator. As the film runs at greater speeds, the actual film temperature is reduced. Some orange peel may occur when laminating prints with a lot of solvent residues or oil-based prints.

    Question: Why does waving/blistering/dimpling occur?

    Answer: These occur from the natural moisture in the item making it swell during printing. When too much heat is used, the moisture is dried out, but the areas that swell prevent the item from lying flat. They can also be caused by too little tension and uneven pressure.

    Question: How does pressure affect lamination?

    Answer: Users should start with as little tension as possible and then add more as needed rather than starting with a lot and loosening up. Some of the most common problems with laminated prints due to the wrong amount of tension or pressure are as follows:

    Infeed waves are mars in the finished product that result from the original image being somehow distorted before it went in. For instance, if there is insufficient tension on the image as it is going in, it could end up crooked or folded as it enters the nib of the rolls. When feeding an image into the laminator, make sure it is parallel to the roll. Once it gets pulled in, grab the back of the image and hold it taut so any wrinkles get smoothed out before they enter the nib.

    Print curl occurs when an image is unrolled and wants to roll itself back up again. A little bit of this is normal, but if the print doesn’t lay flat after some gentle smoothing, it is a problem. Print curl happens when one side of an encapsulated image changes size out of proportion to the other side, causing the print to curl towards the smaller side. This can be caused if the user puts a heavy laminate on the top side and something thin and cheap on the back, but doesn’t adjust the tension to allow for the different dimensional stabilities of both types of film. For instance, if the user applies the same tension to both the top and bottom film, the bottom film will likely stretch more than the top since it is weaker. As the image cools, the bottom film will tighten up a little more than the top film since it was stretched farther, causing the image to curl towards the back.

    Boat wake is an undesirable ripple pattern in a “V” shape on a finished print. Boat wake is caused by several things. For example, when trying to encapsulate something thick, the edges of the film hanging off the sides of the print will not get as much pressure, so they’ll drag behind, causing the ripple pattern. “Reverse boat wake” can be caused when too much pressure is applied to the sides of the roller, forcing the middle up and causing the film to drag behind the film on the sides.

    Ripples occur when too much pressure is exerted on the item when it goes through the rolls on the way out of the laminator while the film is still hot. To prevent this, make sure the pressure is at the proper ration of speed for the pull and front rolls. Make sure to work with a low temperature without exceeding 40-45°C.

    Question: How can static electricity build-up be handled?

    Answer: Static electricity is an issue that may arise and is impossible to prevent. However, it easily can be kept under control by taking a few precautions.

    Removing or neutralizing static electricity by induction is the oldest and simplest method. Tinsel is the most common tool for this application. However, tinsel oftentimes is misused and, therefore, sometimes not successful. When using tinsel, it must have a metal core. Tinsel with a string (non-conductive) core will not function properly. Secondly, the tinsel must be well grounded electrically, stretched tight and placed ¼ of an inch from the material to be neutralized. There also must be “free air space” under the material to be neutralized, directly under or over the spot where the tinsel is placed. If done properly, the tinsel will reduce static electricity on both sides of the static-laden material.

    In addition, grounding all plant machinery and related equipment is most important. Besides the safety factor, a grounded machine will help drain off extremely high charges of static electricity from partial conductors.

    Static electricity is an issue when laminating lighter weight films since they have a tendency to curl back towards the rear rolls. The film then can begin to wrap around the rear rolls. To alleviate this problem, put the laminator in reverse and gently pull the wrapped film off the rear rolls. To prevent wrap around, laminate all documents using a continuous feed as the weight will hold the laminations away from the rear rolls or leave a few inches of extra film as the weight will not allow the static to pull the film back into the rolls.

    Question: What causes repeating marks?

    Answer: Repeating marks occur when there is something on the roll, usually a piece of paper or a scrap of film. If the defect is adhesive residues, simply clean the rolls.

    MACtac is a global company that always has been driven by innovation, discovering future customer needs and developing new products. MACtac offers a wide array of products used in various fields, including graphics and decoration, the self-adhesive label industry and fixing and mounting solutions in several industries. On top of a high level of in-house manufacturing and R&D excellence, MACtac has been working on developing a strong partnership with its customers and a solid sustainable development policy. For additional information on laminating and MACtac, contact Helene Gobry at [email protected] or visit www.mactac.com.

    Fall Protection and Hazard Communication Top OSHA’s List of Common Citations

    by Jen Clark, PostPress

    According to a recent Occupational Safety and Health Administration (OSHA) report, “Adding Inequality to Injury: The Costs of Failing to Protect Workers on the Job,” the Bureau of Labor Statistics (BLS) found “approximately 4,500 workers are killed on the job each year … and that employers record nearly three million serious occupational injuries and illnesses annually.” These records are mandated by a nearly 40-year-old legal obligation to provide safe workplaces.

    The Occupational Safety and Health Act of 1970 required employers to provide workplaces “free from recognized hazards that are causing or likely to cause death or serious physical harm.” OSHA inspectors cite thousands of companies for unsafe working conditions every year, usually resulting in costly fines. OSHA annually provides a list of the Top 10 violations for the fiscal year during the National Safety Council Congress and Expo, which took place in San Diego, California, last September. For the fourth year in a row, OSHA’s Fall Protection Standard (1926.501) was the agency’s most frequently cited violation (6,143 violations), followed by hazard communication (5,161 violations) and scaffolding (4,029 violations).

    For owners and managers, knowing about these violations can help them assess their companies’ risk potential, which could help avoid business disruption, citations and/or fines.

    1. Fall Protection

    OSHA requires that fall protection be provided at elevations of 4′ in general industry workplaces, 5′ in shipyards, 6′ in the construction industry and 8′ in longshoring operations. In addition, fall protection should be provided when working over dangerous equipment and machinery, regardless of the fall distance. Appropriate fall protection gear can include railings, personal fall arrest systems or warning lines.

    2. Hazard Communication

    In 2012, OSHA revised its Hazard Communication Standard, aligning it with the United Nations’ global chemical labeling system. It will be fully implemented in 2016, with the goals of reducing confusion about chemical hazards in the workplace, facilitating safety training and improving understanding of hazards. Employers should identify and evaluate all chemical hazards in the workplace and then make that information readily available to all employees through safety data sheets. Keeping an up-to-date list is just as important as having one. Training also is a key component of the HazCom standard (see sidebar for more information).

    3. Scaffolding

    Established guidelines help protect employees who are working on or near elevated, temporary work platforms at heights of 10′ or more. OSHA noted that a big problem is people using scaffolding as ladders and ladders as scaffolding, assuming one could work for the other. Other problems include holes in platforms, not having an adequate point of access, lack of fall protection and not having a competent person assigned to select and direct employees, asses the weather, train employees, inspect scaffolding and determine if scaffolding is structurally sound.

    4. Respiratory Protection

    Air quality or breathing hazards – such as dust, fumes, gases, mist, sprays and vapors – may require the use of respiratory protection either with a respirator or dusk mask. Respirators protect the user in one of two basic ways – by removing contaminants from the air or supplying clean air from another source. Employers must have a written program to show how they are implementing various parts of the standard.

    5. Powered Industrial Trucks

    Powered industrial trucks, commonly called forklifts or lift trucks, are used in many industries, primarily to move materials. Employers must ensure that each powered industrial truck operator is trained and competent to operate a powered industrial truck safely. No one under the age of 18 is allowed to operate a forklift. Training must be provided for each type of equipment the company operates.

    6. Lockout/Tagout

    According to OSHA, nearly 200 workplace deaths occur each year because hazardous energy hasn’t been controlled during routine maintenance or machine servicing. Proper lockout procedures help prevent the accidental startup of machinery. There are nine steps to a general lockout/tagout procedure.

    1. Prepare for shutdown
    2. Notify others
    3. Shut down the equipment
    4. Isolate the equipment
    5. Lockout/tagout the equipment
    6. Release stored energy
    7. Verify isolation
    8. Perform service
    9. Release from lockout/tagout

    7. Ladders

    Similar to the fall protection standard, ladders only should be used for what they are designed for and must extend 3′ above the upper landing surface. OSHA prohibits ladder use as a walking platform or lifting device. Ladders also must be in good shape.

    8. Electrical: Wiring

    Dangers such as electric shock, arc flash, electrocution, fires and explosions are possible. To help avoid potential violations, inspect wiring and insulation, plus take steps to ensure proper grounding of electrical equipment.

    9. Machine Guarding

    Guard the machinery to help protect operators and others from hazards, such as rotating parts, flying chips, sparks and other dangers. OSHA uses the 1910.212 standard to cite employers for lack of guarding on several types of equipment.

    10. Electrical: Systems Design

    Stay in compliance and avoid workplace injuries by following factory instructions when designing, installing and using electrical equipment. Using equipment in the workplace that only has been labeled or listed for home use is an OSHA violation.

    Full Implementation of Hazard Communication Standards Expected in 2016

    Three years ago, the Occupational Safety and Health Administration (OSHA) aligned its Hazard Communication Standard (HCS) with the United Nations’ Globally Harmonized System of Classification and Labeling of Chemicals (GHS). Once fully implemented in 2016, OSHA expects the changes will impact over five million facilities and over 40 million workers.

    HazCom 2012 provides a common approach to classifying chemicals and communicating hazard information on labels and safety data sheets (SDS). The definitions of hazard were changed to provide specific criteria for classification of health and physical hazards and for the classification of mixtures. Chemical manufacturers and importers now are required to provide a harmonized label that has six standardized elements for classified hazards, including product identifier, manufacturer contact information, hazard pictograms, signal word (DANGER or WARNING), hazard statements and precautionary statements.

    SDSs, previously known as Material Safety Data Sheets, remain the backbone of HCS. Employers must ensure they are readily accessible to employees. The major change here is a required, standardized 16-section format, which include identification; hazard(s) identification; composition/ingredient information; first-aid measures; firefighting measures; accidental release measures; handling and storage; exposure control/personal protection; physical and chemical properties; stability and reactivity; toxicological information; ecological information; disposal considerations; transport information; regulatory information; and other information. To be compliant, an SDS needs all 16 sections; however, OSHA will not enforce sections 12-15, which fall outside of its jurisdiction.

    For more information on complying with the standards, visit www.osha.gov/dsg/hazcom.

    A Walkthrough in the Four Steps of Kaizen

    by Kara McPipe, Artistic Finishes, Inc.

    Imagine that you are a manager of a manufacturing plant. The production reports are studied every day, and it is discovered that one of the lines continually is getting worse. You walk out to the line and ask the operator why the numbers are dropping. The operator immediately states, “The machine is old and doesn’t work the way it used to.” Is your first thought, “We need to buy a new piece of equipment to replace this outdated thing?”

    New equipment or technology often is our first choice. Kaizen often is a better choice, because even with new equipment, if the process has waste in it, will the new equipment help? The Japanese word Kaizen means “change for the better.” Kaizen focuses on looking at a process and removing waste from it.

    Let’s look at the example above again. If a few minutes would have been taken to observe the process, there might have been observations like the operator leaving his machine to collect job materials, making the same adjustment multiple times or searching for a missing tool. All of these observations are forms of waste and prevent the machine from running. If you take a few minutes to look around your own plant, you will notice the same type of waste everywhere. Problems get in our way every day, and they decrease our efficiency. Remove these problems (waste) and think of the positive impact it will have to the equipment efficiency.

    Every plant strives for perfection out of every piece of equipment it owns, but often forgets to look at the simple things which can cause the machine not to run. This is where a Kaizen event can help. A Kaizen event has four key phases: Selecting, Planning, Implementing and Follow Up. Kaizen events will cause minimal disruption to your current daily production output when planned well, but they can yield a significant increase in efficiency once completed.

    Selecting a Kaizen event

    There are several areas where a company can look for Kaizen opportunities. One of the easiest ways to identify a Kaizen event is by creating a Value Stream Map for the production workflow. This tool can help to identify bottlenecks or slowdowns in the overall process so you can see what areas should be improved first. The book Learning to See by Mike Rother and John Shook can help anyone effectively create a Value Stream Map for his or her organization. A corrective action system or any other error-tracking system also can be used to determine where opportunities are for improvement. Utilize an idea system to pinpoint ideas that are larger in scope and may warrant putting a team together to solve the issue. Ultimately, it is important to listen to the data and the operators on where the biggest issues are within the organization.

    Planning a Kaizen event

    A scope and goals document clearly laying out the problem, scope of the event, goals the team should focus on, team members and schedule must be created. To start, take the time to research and understand the issues. Often, we want to jump to improvements because we think that we already know the solution, but just like the example above, this potentially could lead us down a path that may be costly for the company and, potentially, a waste of time. Conduct interviews with leaders and subject matter experts in the affected area. Collect data where appropriate. Once you have gained a better understanding of the problems, write an issues statement to help the team look for them and address them in the discovery and improvement phases.

    Next, create a scope that is specific and attainable within the given Kaizen event time frame. A well-written scope helps to keep the team on track throughout the event and can prevent team members from looking at areas outside of the defined scope. Consider goals the team must tackle and base these on a realistic time frame (typically two to three months). Well-defined goals can assist the team members in staying focused if they are struggling.

    When developing the team, it is key to gather subject matter experts from upstream and downstream functions, along with people with fresh eyes (those who know nothing about the process). Six to eight people are ideal in larger companies, while in smaller companies, four to five people on the team is typical. In most situations, using the area leader as a sponsor of the event instead of a member allows the team to not feel confined to what the leader wants. A poorly defined team may make it difficult to reach the Kaizen goals.

    Finally, schedule the event based on the size of the scope and the resources needed. Kaizen events can run anywhere from three to five days. In smaller companies, it may work better to break the scope into smaller chunks and allot three- to four-hour increments to complete the Kaizen event. Proper planning is the key to a successful Kaizen event, so don’t rush past this step.

    Implementing a Kaizen event

    Implementation of a Kaizen event starts with a facilitator. The facilitator has key responsibilities, including training the team on Lean tools, keeping the team on track and helping the team to visualize what the future could be.

    The most critical responsibility of the facilitator is getting the team to see the current process. Returning to the example at the beginning of the article, we instinctively want to go to the improvement phase, but if the team doesn’t take the time to understand the current process, real improvements could be missed. It is the job of the facilitator to help the team to see the waste, so the team can come up with ways to reduce it. Taking videos, using a spaghetti diagram and gathering forms used in the process are a few ways to help the team to “see” the waste. Once the waste has been identified, the team will spend the remaining time of the event brainstorming improvement ideas and beginning to get them implemented.

    Follow up on a Kaizen event

    In almost every case, there is not enough time during the event to implement all improvements, so following up after the event becomes the next critical step. Follow up often is the most difficult part, so staying organized and maintaining a consistent leadership message is imperative.

    Use a Kaizen newspaper to keep track of the improvements identified during the Kaizen event and the status of completion of each item. The Kaizen sponsor (area leader) should own and drive the Kaizen newspaper. Communicate the Kaizen results to leadership and the company using storyboards to show what the team has accomplished. As the Kaizen event is being implemented, continue to measure the Kaizen goals against the results. Keep the metrics visible for everyone to see and readdress when results are not sustained.

    As you begin your first Kaizen event, remember to take the time to properly scope the event; understand the process; measure (you cannot improve what you cannot measure); get employees excited and involved before, during and after the Kaizen; and, most importantly, ensure there is management support and Kaizen follow-up. Over time, each Kaizen will become easier. Before you know it, efficiencies in your plant will happen that you did not expect with the current equipment.

    This article was reprinted with permission from PIA’s The Magazine. The author, Kara McPipe, is the continuous improvement manager for Artistic Finishes, Inc. Founded in 1985, Artistic Finishes specializes in finishing hardwood moldings, vents and treads that complement over 13,000 manufacturers’ hardwood and laminate flooring lines.

     

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    FSEA Tastes “Sweet Finishes” with its Sourcebook

    by Brittany Willes, PostPress
    The finishing process for the Foil and Specialty Effects Association’s annual Sourcebook employed a 3D UV coating, making the cover image appear good enough to eat while compelling viewers to reach out and touch.

    Long before the Foil and Specialty Effects Association’s annual Sourcebook begins making appearances at tradeshows and conferences, the association’s directors are hard at work designing each year’s cover. Every year, a new theme is selected, highlighting various aspects of the foil industry. Previous years have included such memorable themes as the 2014 award-winning “Add Bite” Sourcebook, which featured an engraving of a great white shark that literally jumped off of the page with the help of detailed embossing.

    For the 2015 Sourcebook, Executive Director Jeff Peterson and Associate Director Kym Conis decided on the theme of “Sweet Finishes,” with the cover displaying a decadent cupcake, drizzled with chocolate and sprinkles and topped with a tantalizing cherry. Thanks to the finishing process, which employed a 3D UV coating, the cover image appears good enough to eat while compelling viewers to reach out and touch. “We knew early on we wanted to use the Sweet Finishes theme,” said Peterson. “With that, it made sense to look at images and graphics that conveyed sweetness. We liked the idea of something that had a cherry on top because finishing is the ‘cherry on top’ of the printing process.” According to Peterson, the cupcake image was the perfect fit once it was determined the cover would utilize Sipe, Inc.’s Touch Me 3D UV coating process in conjunction with a combination (foil and embossed) headline and FSEA logo.

    Utilizing Sipe’s Touch Me coating, the cover first was offset printed in 4-color process on a 15pt. C1S Carolina Cover. Specific inks were applied that were able to easily accept both the special UV coating and hot stamping foil. From there, several steps were necessary in order to create the touchable look of the cupcake. Lisa Hill, vice president of sales and marketing for Sipe, explained, “Technically speaking, our designer started by creating a 3D-UV layer mask over the image provided by the printer. He selected the areas of the image that would receive the extra ‘pop’ or ‘texture’ from the 3D-UV and determined how high the build should be.” For the Sweet Finishes cupcake, the cherries and the chocolate sauce were done at 100Micron level, while the sprinkles were at 200Micron. The watermark (blind application, meaning there is no print underneath it) was done at 20Micron and the cup at 60Micron. The file then was sent to Sipe’s MGI JetVarnish 3D digital machine, where sheets were fed through and the coating was applied via MGI’s inkjet varnish technology.

    The finishing touch to the final cover image, which included the text, “Sweet Finishes,” embossed and hot foil stamped using red 45-Red foil by Infinity Foils. The red FSEA logo likewise was embossed and stamped with 45-Red foil and offset next to the cupcake. The combination foil and embossing brass engravings were produced by h+m USA for both the headline and logo. Due to the “digital stock” utilized for the sourcebook cover, special attention was needed to ensure the correct depth was used in the making of the combination dies. This was important to make certain there would not be any stress cracks between the letters of “Sweet Finishes” or around the FSEA logo. “We were excited to see the finished covers when they arrived,” explained Peterson. “It always is so gratifying to see a project start from a simple theme and grow into a beautiful finished product.”

    The “simple theme” was not without its obstacles, however. “We did have some challenges to overcome on the FSEA cover,” reported Craig Kotzenmoyer, Sipe’s process quality manger. “We realized the digital stock and print did not react the same to the combo as conventional paper and print does.” According to Kotzenmoyer, the designers had a difficult time finding a foil that would adhere fully and cleanly to the digital paper and print before they found the MH 45 foil from Infinity.

    Furthermore, the depth of the dies initially proved too great for the digital paper and print, causing stress cracks between the letters of the words “Sweet Finishes.” Kotzenmoyer explained that when then designers first used the dies on conventional paper and print, they looked great; however, when they moved to digital paper and print, it resulted in stress cracks. Sipe immediately contacted h+m, which remade the dies with less depth. “We received the second set of dies and experienced the same issue with stress cracks. It wasn’t as bad as the first set, but it still wasn’t good enough,” he explained. h+m remade the dies once more, and the third time proved to be the charm. The dies were “perfect!” according to Kotzenmoyer. “We learned that the digital paper and print we worked with on this project had its limitations on how much depth can be successfully achieved with a combo. Just as with conventional paper and print, die relief and depth are crucial for producing a quality product. I believe it is even more so when using digital paper and print. Sipe learned a great deal about digital paper and print through this project that will help us in the future.”

    Digital Printing Enhances Award-Winner from Innovative Labeling Solutions

    by Brittany Willes, PostPress
    Innovative Labeling Solutions (ILS), Hamilton, Ohio, picked up the Bronze Award for Difficult Sheet/Rotary Labels in the FSEA’s 22nd annual Gold Leaf Awards competition.

    The Terressentia Corporation was founded on the belief that technology dramatically can improve both the quality and taste of its premium spirits. When a unique and innovative label was needed for the company’s Winchester Rye Whiskey, Innovative Labeling Solutions (ILS), Hamilton, Ohio, befittingly opted to use digital print technology to create the award-winning label.

    “We believe that digital printing is the wave of the future,” explained Vicki Hausmann, ILS’ marketing director. “Our mission is to provide our clients with opportunities to engage with their customers on a more personal level, and digital technology allows for more flexibility than conventional printing. Digital technology offers our clients the opportunity to better engage with consumers at the shelf, to provide high-end looking and feeling labels to accentuate the product and also can increase the speed to market.”

    Creating the high-end look and feel of the Winchester label required a great deal of collaboration between the designers, the processers and manufacturers. Once ILS received the initial design from Terressentia, a heavy eggshell paper stock with matte UV varnish was selected for the label base. When it came to printing, ILS turned to its Hewlett-Packard Indigo WS6600 digital printing press. The base stock was hot stamped with copper-colored foil provided by Kurz Transfer Products. The Winchester brand name was embossed and printed with black ink. A faded grey image of a Wild West era cowboy astride a galloping horse takes up part of the background, filling in some of the white space between the layers of text. The labels were printed 6-across and 9-round using ILS’ special I-Mark settings.

    “All the printing was done in a single pass,” explained Director of Technology Brian Smallwood. The label was hot stamped, varnished, embossed and diecut in one pass utilizing an AB Graphics Digicon press. “Having the label finished in one pass can increase the complexity of the process,” Smallwood went on to explain. “However, some accuracy can be gained by processing everything together. With a single pass, everything is running through the printer with the same tensions, the press is running through the entire operations at semi-rotary and everything is firing off the same I-Mark and semi-rotary re-insertion.”

    Despite the intricacy of the Winchester design, the label was not an overly difficult project. “It might have been more difficult or challenging at one time,” said Smallwood, “but this is something we do all the time now. We have the advantage of having the latest technology to work with. We run all HP printing equipment, and HP has been very supportive of any challenge we bring them. They trust us enough to give us the first opportunities using their new technology.” That’s not to say the label presented no challenge whatsoever. Smallwood admitted the complexity of the Winchester label was slightly above average for the company. “We did send this hot stamp out,” said Smallwood. “The logo is very intricate and some of the finer details had to be moved. We sent it to our die manufacturer, and they were able to put their own spin on it.”

    With its sophisticated foiling and embossing, the Winchester label involved a partnership with the prepress side “pulling everything, all the resources, together in order to create a production item that was very simple to run,” said Smallwood. “For someone like myself or Vicki, when we see something of this level and intricacy, it’s very rewarding.”

    “The way we go to market, we view everyone as partners,” Hausmann stated. “Our vendors, our manufacturers, we’re all in this as a way to grow our client’s brand. We partner with you, you partner with us. In the end, we all benefit and the customer is the ultimate winner. That’s the way it should be.”

    In the case of the Winchester label, both ILS and Terressentia Corporation have come out winners. Hausmann reported their client was very happy and excited about the label. ILS recently submitted the Winchester label to the FSEA’s 22nd annual Gold Leaf Awards. When Terressentia was informed that ILS would be entering the Winchester label into the Gold Leaf competition, “they were thrilled.” The label was awarded Bronze for Difficult Sheet/Rotary Labels.

    2015 Narrow Web Supplement

    Top 5 Ways to Keep Your Customers Happy

    by Brittany Willes, PostPress

    Your customers are the lifeline of your business. Their satisfaction with your products and services determines your revenue stream. Happy, satisfied customers mean a more profitable business. How can you make sure your clients are happy, and remain that way, to boost your bottom line? Here are five ways to show your clients that you value their business.

    1. Pay Attention

    Your customers need to feel that you are listening to them, which involves much more than simply waiting to hear that they are satisfied with your products and services. Paying attention means learning to anticipate your clients’ needs, knowing their expectations and being able to interpret those needs in a way that ensures all parties are satisfied with the end goal. Pay special attention to any concerns your client has expressed. Few things are more frustrating than feeling as though apprehensions are falling upon deaf ears. By paying close attention to your customers, you demonstrate that they are valuable to you, reinforcing their trust and confidence in your business.

    2. Don’t Believe the Multi-Tasking Myth

    We live in a society where attention deficit is common place – expected even. Multi-tasking is considered one of the most valuable jobs skills and perceived as a necessary business practice. It’s no surprise then when businesses take on more work that is wise, encouraging employees to multi-task projects in the misguided belief that it will save valuable time and resources. As a result, full and complete focus goes out the window. Juggling multiple projects means no one project will receive the concentrated attention it deserves. This can lead to reduced quality and dissatisfied customers. So, slow down. Don’t take on more projects than is reasonable to ensure customers receive the best quality you can offer.

    3. Don’t Play the Blame Game

    No one likes to admit when they’re wrong. Your first reaction is usually to cringe, deny and look around for the nearest scapegoat. If you make a mistake, don’t try to slough the blame off onto someone else – especially the customer. Acknowledge your error and reassure your customer that you will do everything you can to rectify the situation. Most clients understand that mistakes happen and no one is perfect. Trying to stop looking bad by avoiding responsibility actually makes you look worse in the end. Customers are less likely to trust your word or your professional abilities. As a result, they will be less likely to seek you out in the future.

    4. Remind Your Customers You Value Them – And, They Should Value You

    Like you, your customers get busy and may not always remember everything you do, or have done, for them. There’s nothing wrong with a friendly reminder that they have one less thing to worry about because of your customer service. This can take the form of a quick phone call, a friendly email or even a monthly newsletter. Keep your customers happy by reminding them that while you do value their business, they also should value yours in return.

    5. Don’t Forget the Personal Touch

    Technology has made it easier and more convenient to communicate with anyone, anywhere, at practically any time. Yet, how often do we become frustrated when reaching a voicemail or automated recording instead of an actual person? Or while waiting for a response to an email sent a week ago? Keep your customers happy by keeping it personal. When possible, arrange to talk to your customers in person. Make use of emerging video messaging technologies so that your customers always have a face to put with your name/voice. While it may seem old fashioned, don’t discount the value of a handwritten note or thank you card sent to your most valued customers. Let them know how much you continue to appreciate their business by adding a personal touch to your business relationship.

    Some items on this list may seem obvious, but that doesn’t make them any less valuable or that you’ve been practicing them effectively. The best time to determine if you’re keeping your customers happy is now. So, take stock. Have you established a personal connection with your clients? Do you devote your full focus to each project you undertake? Are you hearing clients when they express their concerns, as well as their satisfaction? If not, it’s time to devote more of your efforts to keeping your customers happy to keep your company growing.

    MPS Helps Video Game Packaging Evolve to the Next Level

    by Brittany Willes, PostPress
    Multi Packaging Solutions, New York, New York, pushed designs to the next level by turning the standard o-sleeve into a work of art on the packaging for Evolve, the latest video game from Take-Two Interactive Software.

    The video game industry has evolved dramatically since iconic plumbers Mario and Luigi first battled their way through the sewers of New York. Just as the games themselves have become more complex and detailed, so have their packaging. When it came to creating the packaging for Evolve, the latest video game from Take-Two Interactive Software, the creative team for Multi Packaging Solutions, New York, New York, knew it would need to push designs to the next level by turning the standard o-sleeve into a work of art.

    Led by Bob Kelly, MPS’ art director, the creative team presented several design options with a footprint theme. In the end, Impressions™ brand packaging was selected. The unique packaging technology allows designers to add deep embossing to graphics in order to create sculpted effects. “With our Impressions technology, we’ve crated many distinctive new shapes that simply are not possible using conventional board, achieving depths in the range of eight to 10 times that of standard embossing,” said Kelly. “In addition to more dramatic depth, we also can hold more detail than normally possible.”

    Kelly went on to explain, “The final result depends in part on the contours and complexity of the artwork, with smooth shapes more conducive to deeper embossing. To achieve the best results, we work with customers to test the artwork to assess how to best combine graphics and embossing.”

    According to Erin Willigan, vice president of global marketing for MPS, “As competition for the consumer’s attention intensifies across markets, packaging increasingly plays a central role.” As a result, MSP consistently strives to “help customers gain a competitive edge with materials, structures and decorative technologies that make lasting brand impressions.”

    Appropriately named, Impressions™ packaging made its US debut when Paramount Studios approached MPS to create the Transformers: Age of Extinction packaging. Paramount wanted a package that pushed the boundaries of technology, simultaneously creating a lasting impression and appealing to its science fiction fan base. The concept for the Transformers’ franchise called for dramatically sculpted artwork in order to accentuate the engineering complexity of the Transformer’s Bots.

    With the success of the Transformers: Age of Extinction packaging, the Evolve packaging had a lot to live up to. “We’re currently developing uniquely shaped styles where previously plastics would have been the only packaging option,” Kelly stated. With a more moldable substrate than the standard embossing, developing and maintaining a greater depth during Evolve’s manufacturing process proved to be challenge during production. Luckily, the Impressions™ packaging technology allows for design flexibility. “Impressions can be formed into a pod to hold a liquid, granules or past and impregnated with barrier coatings,” said Kelly. MPS spent numerous hours in the Dallas, Texas, facility, re-engineering production lines and reorganizing to create a more efficient workflow. Additionally, experienced technicians pushed their abilities to the max. The final result is a ruggedly embossed footprint motif in shades of steely grey contrasted with the bright red of the boxy title pattern.

    According to MSP, curiosity starts with the packaging. Utilizing the Impressions™ technology, the company was able to create the striking footprint design. With its eccentric embossing, Evolve is sure to catch – and hold – consumer attention.

    Long before the Foil and Specialty Effects Association’s annual Sourcebook begins making appearances at tradeshows and conferences, the association’s directors are hard at work designing each year’s cover. Every year, a new theme is selected, highlighting various aspects of the foil industry. Previous years have included such memorable themes as the 2014 award-winning “Add Bite” Sourcebook, which featured an engraving of a great white shark that literally jumped off of the page with the help of detailed embossing.

    Q&A: A Look Inside the Narrow Web Decorating/Finishing Marketplace

    Foil products and the adhesives used with the cold foil process have improved significantly over the past few years.

    PostPress asked two industry veterans in the narrow web decorating/finishing arena (Tom Kirtz, president, Telstar Engineering, and Michael Rivera, vice president, K Laser Technology) to provide some insights on the current landscape and what we can expect to see changing in the foreseeable future.

    What were the turning points in hot foiling inline that helped it grow into a feasible option for flexographic printers? Is there still room for growth in the hot foil side of the business?

    Although inline foil with narrow web flexo had been around for quite some time, flexographic printers were not willing to slow their presses down to the speeds they would have to run at to effectively apply foil inline. Improvements in the release of the foils by foil manufacturers began changing this, along with more flexible and cost-effective solutions for hot stamping tooling.

    “We saw the potential in the hot stamping market for narrow web several years ago and acquired a hot stamp equipment manufacturer to add to our converting equipment line,” stated Kirtz. “We made several engineering upgrades and believe we encouraged this growth with the availability of retrofit hot stamping equipment for all types of label presses.”

    “Another major turning point in the growth of hot stamping inline was the development of flexible rotary dies that could be utilized with magnetic cylinders,” added Rivera. “This provided a more cost-effective solution for shorter runs and faster turnaround times for the customer.”

    Rivera believes the rotary hot stamp market most likely has peaked as far as growth opportunities, but there are many customers who still are interested in the look of a hot stamped image and the opportunities will continue to be available for the flexo printers offering it.

    Cold foiling inline has continued to grow in popularity. What percentage of the market for foil decorating would you estimate is cold foil vs. hot foil?

    Cold foil inline also has been available in the marketplace for many years; however, consistency and reliability simply were not obtainable to spark significant growth. Foil products and the adhesives used with the cold foil process have improved significantly over the past few years. This has helped develop a huge increase in its acceptance and growth for label decorating. Rivera estimates that the cold foil market now holds about 80 percent of the foil decorating market for narrow web flexo printing.

    “Cold foil is an acceptable foil decorating process and now is considered an industry standard,” stated Rivera. “However, because cold foil is limited to non-porous substrates, its market share is not expected to change significantly.”

    “We have seen significant grow with cold foil and Cast & Cure™ for narrow web applications,” added Kirtz. He stated that his company currently is manufacturing more than twice as many cold foil units to hot stamp units for narrow web flexo presses.

    What label applications are more suited for hot foil, and which applications are more suited for cold foil? What factors go into an end user decision between the two processes?

    “To go hot or cold with foil isn’t always a clear choice,” stated Kirtz. He pointed out that some designs and substrates demand one or the other, and there can be issues with the quality level demanded by the job and even the press speeds required to remain profitable. “If you have been doing hot stamping and are faced with a customer demanding cold foil, you may find you can add this process to your existing press at a cost that still allows you to make a profit,” continued Kirtz. “You may even end up expanding your product lines for your sales staff.”

    “One of the major factors in the decision between utilizing cold or hot foil is the substrate being used,” added Rivera. Cold foil must have a non-porous stock to perform effectively, so labels designed to use an uncoated stock are going to be more suited for hot stamping. Cold foil works best for plastic label substrates because there is no heat involved when applying the foil, which can distort the plastic film.

    What do you see changing and growing in the label decorating/finishing marketplace?

    “There are units now available that can provide hot and cold foil, along with Cast & Cure™ decorating,” said Kirtz. “Imagine foil combined with rotary screen, metallic, glitter varnish, heat embossing or embossed-look effects… there is so much more to come!” Kirtz went on to say that there is a lot of talk about digital and digital labels. He does not look at digital as a separate technology, but rather a complimentary opportunity for label printing and decorating.

    Rivera noted that more printers are applying foil decorations to digitally printed labels. “The digital print market for labels has shifted its finishing strategy from an “inline” to an “offline” process,” he said. This shift mainly was dictated by the maximum running speed of the digital press. While digital presses run substantially lower in speed than the finishing equipment, more printers are opting to perform their decorating/finishing process offline, where one decorating/finishing press can serve two or more digital printing presses.

    Kirtz added that hot foil holographic security applications area is where he is seeing a growing demand due to increased concerns about counterfeiting. “These techniques provide an extremely difficult-to-duplicate graphic identity,” added Kirtz. “It’s like creating a virtual fingerprint, only better.”

    “I don’t believe we have tapped the potential, especially when it comes to combining various decorating effects,” concluded Kirtz. “There is such a huge demand for new and more exciting graphics, and we don’t yet know how this will all tie into digital applications, for example. Label designers are becoming more tech savvy and bring new ideas to the table. It’s our job to figure out how to achieve their visions.”

    2015 Narrow Web Supplement