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      Print Decorating, Binding and Finishing

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        Enews August 2023

        Mohawk Now the North American Distribution Partner for Fedrigoni Papers

        August 8, 2023

        Press release submitted on behalf of Mohawk Fine Papers, Inc. and the Fedgrigoni Group

        Mohawk Fine Papers, Inc. and the Fedrigoni Group are pleased to announce that effective today August 01, 2023, Mohawk will be the distributor of Fedrigoni’s Specialty Fine Papers for North America.

        Mohawk is North America’s largest privately owned manufacturer of fine papers and envelopes, and Fedrigoni is the leading global player in the manufacture of high-added-value specialty papers for luxury packaging and other creative applications.

        Mohawk’s distribution partners and community of creatives and printers will have full access to the Fedrigoni creative portfolio (with the exception of Fedrigoni digital papers, distributed by GPA). Mohawk and Fedrigoni have committed to bringing both inventory support and marketing focus to bolster the growing luxury packaging and creative solutions print segments.

        Fedrigoni’s collection of beautifully crafted, responsible, and innovative papers are the perfect complement to Mohawk’s legacy of paper brands. Fedrigoni Materica, Woodstock, Freelife Cento, and Sirio Pearl are just a curated sampling of what is possible to create with Fedrigoni specialty papers. Fedrigoni Paper offers tailor-made solutions for print and packaging customers, alongside a collection of more than 3,000 items available from stock.

        “We are delighted to evolve our strategic partnership agreement by bringing together Mohawk’s trusted and valued relationship with the North American market to expand Fedrigoni’s capability to promote its specialty papers in the creative community and better meet all needs of image-conscious clients for all the ways they print, says Melissa Stevens, Chief Revenue Officer of Mohawk.

        “The alliance with Mohawk will accelerate our geographic expansion in the US in the increasingly promising sector of specialty papers for luxury packaging and other creative and technical solutions,” states Ilan Schinazi, Chief Commercial Officer of Fedrigoni Paper. “We are determined to grow our market-leading position by leveraging the reshoring trend in the US and our deep customer partnerships with top luxury brands in Europe, and developing our relationships with US brands.”

        Shared core values of craftsmanship, innovation, and sustainability make this distribution partnership both a natural extension of their existing agreements and a valuable opportunity for our mutual customers to strengthen their brand identity and ESG strategies for all their specialty print. Mohawk and Fedrigoni will be actively working together in the market to promote the value of specialty papers and the unique and creative solutions paper-based materials can bring to a brand.

        drupa next age: Platform for networking and new business

        July 25, 2023

        Press release submitted on behalf of Messe Düsseldorf North America

        The special area drupa next age (dna) sets the scene for newcomers and young talents from the print and packaging sector in a targeted manner. With Deborah Corn and Frank Tueckmantel, drupa has enlisted two strong partners with longstanding industry expertise for organizing and designing this show-in-show for cross-sectional technologies. 

        Big ideas, small budgets – many young companies find it hard to make the right contacts and establish their exciting and forward-looking solutions on the market. For this target group, drupa has created a special platform: drupa next age (dna). Here, newcomers, young talents, start-ups and long-established companies can network on a level playing field, find matching cooperation partners and exchange innovative business ideas. For some participants, this is the opportunity to present themselves to an international professional audience for the first time ever.

        “In today’s digital age, there is one thing technology can’t replace: personal communication,” explains Frank Tueckmantel, who, together with Deborah Corn, is responsible for designing the dna program. “Here’s why Face-to-Face marketing matters: no Tweet, Snap, or chat can ever replace a real human connection. Face-to-face marketing is all about visibility and trust. Moreover, in-person interaction fosters engagement. For this reason I’m honored and excited to work together with drupa on the 2024 drupa dna program, hopefully engaging with many of the attendees that will participate in the largest get together our industry has to offer.”

        Participation made easy thanks to Plug-and-Play
        To make participation easy, drupa focuses on a transparent stand concept with flexible modules and Plug-and-Play at drupa dna. Presentations, panel discussions and interviews on the dna Stage complement the exhibition area in Hall 7.0, providing the ideal forum for attracting  investors with new business models, product solutions and technologies. The focal themes at dna will include: Additive Manufacturing, Artificial Intelligence, Business Intelligence, New Materials, Platform Economy, Predictive Maintenance, Printed Electronics, Remote Services, New Business Models and Process Design. At present, interested companies can still register for participation at the dna Forum – and there are even several ways to get involved: as an exhibitor, sponsor or speaker.

        “drupa dna is the ‘Big Bang’ for new companies, new ideas and fresh perspectives that will form and define the future of print,” confirms Deborah Corn. “Our curated program is designed to provide a global stage for global conversations focused on the technology, tools and people who are pushing the industry forward and enabling unique business opportunities for the graphic communication value chain. I encourage everyone to stop by Hall 7.0 during their time at drupa and get a head start on creating a profitable future.”

        Companies interested in exhibiting or taking part as sponsors at the trend forum dna will be assisted by Benedikt Salmen from the drupa team (SalmenB@messe-duesseldorf.de). Companies interested in taking part as speakers can obtain more information from Deborah Corn (deborah@printmediacentr.com) and Frank Tueckmantel (tuecki@mac.com).

        About Deborah Corn:
        Deborah Corn is the Intergalactic Ambassador to The Printerverse, providing printspiration, education and resources to print and marketing professionals around the world, helping them achieve creative and business success through their printed materials. She is the host of Podcasts from The Printerverse playing in 146 countries, producer of ProjectPeacock.TV, founder of International Print Day, Print Across America and Girl #1 at Girls Who Print – the largest independent, global organization for women in the industry. Through her website PrintMediaCentr.com, content endeavors and social channels, Deborah engages with more than 250,000 printing professionals, print buyers, marketers and students worldwide.

        About Frank Tueckmantel:
        Frank Tueckmantel, Ambassador of Face-To-Face Marketing, spent his entire career in the print industry. In his last role at EFI he served as the VP of Corporate Marketing. In this role he and his team oversaw all worldwide face-to-face marketing activities, like trade show and customer events activities.

        About drupa:
        Under the umbrella of the megatrends sustainability and digitalization, the  international print and packaging sector will meet at the drupa from May 28 May – June 7, 2024, at the fairgrounds in Düsseldorf, Germany. The world’s leading trade fair for print technologies is synonymous with inspiration, innovations, high-caliber knowledge transfer and intensive networking. This is where the international top decision-makers of the industry meet and exchange ideas on current technology trends and ground-breaking developments. For more information: www.drupa.com

        BOBST reveals its Innovation Award winners for 2023

        July 23, 2023

        Press release submitted on behalf of BOBST

        BOBST has presented its annual Inventor Awards, given to innovators and their patents within the business that have pushed the boundaries of technology to enhance print and packaging workflows for customers.

        For 2023, BOBST has issued two awards for the first time. The main Inventor Award has been presented to Patrice Chatry and Maude Steiner, inventors of the Non-Stop with Automatic Swords Selection innovation, while a Special Jury Award has been presented to Rene Heinze, inventor of an intermediate dryer in particular for rotary printing presses.

        “We believe in expanding the boundaries of converting & printing efficiency, and each year we see BOBST engineers going above and beyond.” said Leonard Badet, Chief Technology Officer at BOBST. “Around the globe, our business is home to some of the industry’s most experienced and forward-thinking minds, making our customers production workflow more effective. This year we are thrilled to award 2 inventions supporting our Automation & Sustainability pillars. .

        The Non-Stop with Automatic Swords Selection, created by Inventor Award winners Patrice Chatry and Maude Steiner, is a sheet pile supporting assembly. The device automatically selects which swords are used to temporarily sustain the pile of blanks in the separation station. With efficiency central to printing success, the key advantage of this patent is that job-dependent blank separation structures can be avoided, meaning a replacement pallet of blanks can be swapped in without stopping the machine and disrupting productivity. The innovation offers packaging converters a valuable time saving of six minutes per job, creating valuable gains throughout the workflow.

        Presented with the Special Jury Award, Rene Heinze’s Dryer is a new geometry of intermediate rotary printing press dryer. The design features areas of both high and low pressure and comprises a novel system of nozzles and openings for the discharging of heated gas in exchange for cooled gas. In judging, the dryer was noted for presenting a 15% performance increase over conventional dryer designs, improving the yield of the overall drying process and making efficient use of hot air.

        Christian Zeller, Head of Marketing BU Printing & Converting at BOBST, adds: “The printing and packaging supply chain is under pressure to deliver heightened quality, speed and sustainability. To meet these evolving demands, we must be bold in our innovation and find new ways to boost efficiency – and that’s what our Innovation Award platform is all about. We’re celebrating the talented minds of the BOBST team and the novel technology patents that make a real difference for our customers, which ultimately signpost the future of effective printing workflows.”

        UV Days 2023 Welcomes Around 1000 Participants from 32 Countries

        July 20, 2023

        Press release submitted on behalf of IST METZ

        At the UV Days, which took place from July 4 to 6 in Nürtingen, organizer IST METZ welcomed around 1,000 guests and 40 exhibitors from a total of 32 countries.

        More than 30 impulse and short lectures,18 company tours as well as 21 live demonstrations at the in-house excimer laboratory system and simulations of the UV measuring device UV Analyzer, a multifunctional in-house developed champagne packaging and a Swabian wine village – these were the eleventh UV Days of IST METZ, market leader in the field of UV and LED curing systems. “We are pleased about the great success of the eleventh edition of our in-house exhibition – especially after the pandemic-related break of several years. With around 1,000 visitors and 40 exhibitors, UV Days was nearly as well attended and as broad in terms of applications as before the break,” said Tim Sterbak, managing director of IST METZ GmbH & Co. KG.

        Premium packaging with added value presented at UV Days
        Together with PrintCity Allianz and Benz Catering, IST METZ has developed an outer packaging for the sparkling wine bottles from Germany’s oldest sparkling wine producer, Kessler. The high-quality produced and finished packaging experiences a double benefit in that it can be further used as a bottle cooler. The outer packaging was designed as a container for the transport and presentation of sparkling wine from Kessler in Esslingen am Neckar. The packaging is designed as a two-part box, so that after transporting it can also be used for attractive presentation of the bottle at the table. The special feature here is an integrated cooling system consisting of a cardboard container that can be filled with ice and is made of water-repellent coated material. This means that the bottle can remain at the table and is cooled at the same time.

        Industry partners enrich UV Days
        With ten industry partners, industrial applications were particularly well represented at this year’s UV Days. Even outside the printing industry, the possible applications of optical systems are almost limitless. Therefore, IST METZ offers customized systems and solutions as well as professional support and laboratory services with UV, LED and excimer systems for industrial applications. IST METZ systems are used in the processing of materials such as glass, plastic or wood and wood-based materials.

        Scodix Achieves Sustainability Credentials with Landmark Repulpability, Recyclability Certification

        July 20, 2023

        Press release submitted on behalf of Scodix

        Scodix, the leading provider of digital embellishment solutions for the graphic arts industry, announces the successful completion of its latest recyclability tests, further reinforcing the company’s commitment to sustainability. The results demonstrate that Scodix embellishments can be repulped during the recycling process, allowing products enhanced with Scodix embellishments to carry the recyclable symbol.

        Scodix EVP Global Sales & Marketing, Mark Nixon, comments, “Sustainability is a core pillar of our business operations. As such, we are thrilled to share our latest test results which underscore the positive impact Scodix products can have on building a more sustainable future.  With our repulpability and recyclability certification coupled with our Life Cycle Assessment (LCA) findings, Scodix users can confidently embrace data-driven sustainability practices.

        FTC guidelines require third party independent testing to allow manufacturers to use a recyclable symbol. Scodix worked with Western Michigan University (WMU) to implement the SBS Equivalency (WMU SBS-E) testing protocol, which models the Fiber Boxboard Associations (FBA) wax coating replacement protocol.

        The testing was performed on 16pt SBS Printkote C1S paper with a fifteen percent coverage. Sheets were taken through the process of repulping, screening and cleaning to ensure that the digital embellishment would not inhibit the recycling process.

        The tests produced positive results showcasing the recyclability of Scodix digitally embellished sheets. Passing the WMU SBS-E protocol proved that sheets with Scodix embellishment would qualify for recycling and could be repulped during the process. Brands and manufacturers using Scodix embellishment under this control protocol are able to use the FTC recycling symbol as long as the substrate used is also certified as recyclable.

        “Today is a momentous day for Scodix, but our journey towards sustainability doesn’t end here,” affirms Nixon. ” Coupled with the commissioned LCA that clearly states that Scodix is over 7 times less harmful to the environment than the traditional foiling process, we believe the time is now to remain steadfast in our commitment to driving continuous improvements in sustainability – equipping manufacturers with the necessary data to accurately measure their processes.”

        For more information about the testing process or to learn more about Western Michigan University standards, visit their website at http://wmupilotplant.com. The verifying documents for Scodix can be requested for download at www.scodix.com/sustainability.

        Fujifilm Announces Supplier Partnership with Kongsberg Precision Cutting Systems

        July 20, 2023

        Press release submitted on behalf of FUJIFILM North America

        FUJIFILM North America Corporation, Graphic Communication Division, announces Miamisburg, Ohio-based Kongsberg Precision Cutting Systems (Kongsberg PCS), as its supplier of digital cutting table solutions for the sign and display, packaging production, and manufacturing markets. Through this partnership, Fujifilm will distribute and sell all Kongsberg PCS digital cutting systems across the United States and Canada.

        “Kongsberg PCS is highly regarded as one of the most reliable, innovative finishing/cutter device manufacturers in the wide format market,” said Toyoyuki (Tommy) Katagiri, division president, FUJIFILM North America Corporation, Graphic Communication Division. “This partnership demonstrates Fujifilm’s commitment to a ‘whole solution’ approach; we are with our customers from start to finish, offering complete printing and finishing solutions in one easy-to-implement package.”

        By partnering with Kongsberg PCS, Fujifilm customers will have direct access during the purchase process to Kongsberg cutting system solutions for multiple materials, including folding cartons and packaging, labels and decals, POP displays, banners, wall graphics, aluminum signs and flexo plates.  By integrating Kongsberg’s precision cutting solutions with Fujifilm’s graphic printing technologies, print service providers can maximize efficiency by streamlining their production processes, resulting in fast turnaround times, high output, and low costs. Additionally, Kongsberg PCS’s commitment to research, development, and listening to customer needs will keep Fujifilm customers at the forefront of cutting system technology.

        As part of this partnership, Kongsberg PCS will not only provide Fujifilm and its customers with sales, service, and support for the Kongsberg precision cutting platforms, but also will offer ongoing training and technical support to Fujifilm customers throughout the lifecycle of their cutting system.

        “Kongsberg digital finishing solutions are designed to meet the increasing demands of the packaging, sign and display, graphics, and corrugated industries,” said Matt Thackray, vice president & general manager – Americas, Kongsberg Precision Cutting Systems. “With their advanced features and capabilities, Kongsberg’s digital finishing/cutting platforms will help provide Fujifilm customers with elevated accuracy and versatility while maximizing productivity.”

        Kongsberg Precision Cutting Systems are now available for FUJIFILM Graphic Communication Division customers. For additional information, visit www.print-us.fujifilm.com.

        Print Across America: A Unified Celebration of Print for Industry Professionals, Printing Enthusiasts

        June 28, 2023

        Print Media Centr announces the launch of Print Across America. Join us on October 25, 2023, to create a unified celebration of print by facilitating, fostering, and supporting open house events at print and sign shops and in-plants from coast to coast.

        The Print Across America mission is to share the power of print as a viable and effective sales, marketing and communication channel at the local level by inviting customers and prospects, university, high school and technical program students and faculty to open house events. This initiative creates community engagement, provides education about printed products, cultivates new business opportunities, and contributes to workforce development.

        Participation in Print Across America is free! The official Print Across America logo, icons, and files for marketing materials, social media and electronic communications, apparel production, signage templates and more are posted at printacrossamerica.com and are available to download. A store to purchase swag and open house materials is in development.

        “Print Across America gives print, sign shops, and in-plants a unique opportunity to open their doors and show guests the cool and amazing things we can create with print, the printing technology that makes it possible, and meet the people who make it all happen,” said Deborah Corn, intergalactic ambassador to the Printerverse at Print Media Centr, and the founder of Print Across America.

        “Participants can host an event for an hour or host an all-day event that includes design classes, a career fair, presentations about what is new in print… and more. I will share ideas for the open house events and help promote all of them – I may even attend a few!”

        Printers who are members of our industry organization partners will be included in the “Find an Open House by You” directory, enabling interested attendees to locate their local open house events easily. Nonmembers can pay a small fee to be listed on the open house directory.

        “The National Print and Sign Owners Association (NPSOA) is encouraging our 400+ members to open their doors and participate in this unique national event,” said Nathaniel Grant, chairman of NPSOA and president of GAM Graphics and Marketing.

        Additional associations committed to promoting and participating in Print Across America include The Print and Graphic Communications Association (PGCA), Printing Industries of New England (PINE), the Graphic Media Alliance (GMA), the Florida Graphics Alliance (FGA), Printing Industries of MidWest (PiM), Printing Graphics Association of MidAtlantic (PGAMA), the Printing Industry of the Carolinas (PICA), In-Plant Printing and Mailing Association (IPMA), International Sign Association (ISA), and the Graphics Communications Education Association (GCEA) with more joining every day.

        In conjunction with Print Across America, Print Media Centr will produce a 10-hour online conference celebrating International Print Day on October 25, 2023, from 10 a.m. to 8 p.m. ET. The free conference will feature industry experts from around the world and is open for everyone to join.

        America’s Print Show, in partnership with the Graphic Media Alliance, is planning an exclusive event at the Rock and Roll Hall of Fame in Cleveland, Ohio to celebrate Print Across America, International Print Day, and kick off the countdown to APS2024 on May 8 and 9 in Cleveland.

        “APS shares the vision of industry unity with Print Across America. We are pleased to support this initiative and participate in the online conference for International Print Day” said Jim Cunningham, president of Americas Print Show. “We will join the online broadcast live from our APS2024 launch event with Graphics Media Alliance at the Rock and Roll Hall of Fame and provide an exciting preview of our upcoming show in May. Anyone who wishes to join us in Cleveland on October 25th can reach out to me, or to Andrew Schall, president of GMA. We look forward to this unique celebration of print and celebrating the printing community that makes it all possible.”

        To stay informed about Print Across America and the International Print Day Conference, please join the mailing list at printacrossamerica.com.

        For International Print Day Conference speaking opportunities and inquiries about conference sponsorship packages, don’t hesitate to get in touch with Deborah Corn at deborah@printmediacentr.com.

        Print Across America promises to be an exhilarating celebration of print, connecting industry professionals, enthusiasts, and communities nationwide. Join us on October 25, 2023, and be a part of this momentous occasion!

        CNC Engraving Improves Embossing, Stamping Dies

        June 5, 2023

        Machine technology maximizes detail, eliminates chemicals.

        By Hallie Forcinio, writer, PostPress

        Computer numerical control (CNC) engraving is a process where a computer-controlled cutting tool is used to remove material from a workpiece to create a desired shape or pattern. This process has been around for several decades and has been widely used in the automotive, aerospace and manufacturing industries.

        Advancements in technology have led to significant improvements in CNC machines and software, increasing the precision of the engraving process and helping to expand use of the technology for engraving sculpted embossing, combination foil embossing and foiling dies. The CNC machine can perform 100% of the engraving, although some dies still may be produced in a hybrid process that combines CNC engraving with hand finishing.

        “The precision of modern CNC machines is measured in microns, allowing for extremely fine detail and accurate reproduction of designs,” said Christopher Arns, director of sales at H+M USA, a KURZ company, a supplier of hot-stamping and coating technology located in Charlotte, North Carolina. He explained, “This precision results in sharper and more accurate images with less ‘bridging’ or ‘flaking.’ This is particularly important in the decorating industry, where high-quality images and intricate designs are essential.”

        Precise reproduction plus the sustainable nature of the technology will boost adoption of CNC engraving for the production of foil stamping and embossing dies, predicted Robert Murphy, vice president of sales and marketing at DATRON Dynamics, Inc., a supplier of CNC machines located in Milford, New Hampshire. The supplier is working with companies that want to bring engraving capability in-house.

        Successful CNC engraving

        Successful engraving depends on properly prepared artwork. “The three most important items needed for a quality CNC die are artwork, artwork and artwork! High-quality, 100% black and white vector art is crucial to creating a great die,” stated Doug Pendergast, national account director at Owosso Graphic Arts, Inc. Based in Owosso, Michigan, the photoengraver has been in business since 1949 and offers magnesium, brass and copper dies.

        Engravers need to know all facets of a project, but first, and perhaps foremost, they must understand what substrate the die will encounter. “This will help ensure the correct depth and design is achieved for the specific application,” explained Arns.

        In addition, “… clear communication with your engraver is critical,” said Ross Hutchison, president of Universal Engraving, Inc. and national sales manager of Infinity Foils, Inc., both part of the UEI® Group Companies, a supplier of foil stamping and embossing products in Overland Park, Kansas.

        “Important details include the type of engraved die or tool needed, registration requirements, heat comp, press information, the number of dies needed, turnaround time, expectations, engraving perspective and finished intent, to name a few,” Hutchison continued.

        When implementing CNC engraving, another consideration is identifying the right people to process the digital artwork and learning the best practices associated with operating the machine. “When purchasing CNC engraving equipment, it’s important to make sure it comes with proper training so die production can begin right away,” Murphy said.

        Growth of CNC Technology

        Brass, copper and magnesium can be engraved on a CNC machine. Photo courtesy of DATRON Dynamics, Inc.

        CNC-engraved dies offer a sustainability benefit by eliminating the need for chemical etching and related environmental issues. “Engraving dies on a CNC machine is a cleaner process,” commented Murphy.

        However, companies that decide to transition to CNC engraving should be aware they may need to install multiple CNC machines to achieve the same output as their chem-etch lines, which typically offer high-volume production.

        The type of engraving and number of dies will help determine if CNC is the correct choice. There are many benefits to CNC, but the costs involved with the machinery, software and trained operators also must be a part of the equation. It is not the answer for all engraving applications.

        Today’s CNC machines are more accurate and rigid and sometimes include integrated vacuum tables to hold stock material. In addition, cycle times are faster and, in many instances, CNC machines occupy a smaller footprint as well.

        “The use of high-speed spindles, more powerful motors, advanced cutting tools and improved milling programs/strategies have significantly increased the speed of the engraving process,” Arns said. He added, “This increased speed reduces lead times and production costs significantly, which is particularly important in the graphic industry, where turnaround times are critical. With the ability to program and store designs digitally, CNC machines quickly can reproduce designs with a high degree of accuracy and consistency, reducing the likelihood of errors and ensuring that each product meets the same high-quality standards.”

        “These features are vitally important to efficient production of quality dies,” agreed Murphy. Automated processes like an operator interface, which works like a smartphone, and control improvements using software simplify operation and provide step-by-step instructions for job setup and machine operation. Built-in safety features make the systems safe for virtually anyone to run.

        “It takes three days of training to learn how to set up and run dies. Skilled machinists, who are difficult to find, are no longer required,” Murphy said.

        At the front end, CAD/CAM systems used to process artwork and generate “tool paths” for a CNC engraver have become more powerful and easier to use, another time and cost saver. An array of engraving bits is available to achieve different effects. Bits can be resharpened multiple times and are inexpensive to replace when worn out.

        Die materials and designs

        Brass, copper and magnesium can be engraved on a CNC machine. However, brass is the most common metal for most engraving applications.

        “Brass is a durable material and very easy to engrave. Brass can be engraved ‘dry,’ which means no coolant or lubricant is required,” Murphy said. “The brass chips generated by the engraving process can be vacuumed out of the machine using a shop vac and then recycled.”

        Magnesium can withstand high temperatures and is impact resistant, which yields a long-lasting die. “Magnesium is used for embossing and combination dies instead of brass in some situations,” said Pendergast.

        “CNCs can be used with any type of engraved die,” said Hutchison. “It is an operational decision that each engraver has to make – some engravers use only CNC equipment, and others don’t use it at all. We are a hybrid and have developed operational procedures that help us to determine which method of manufacturing is best for each order.”

        Recent developments that rely on CNC engraving include new refractive MicroEmboss and NanoEmboss technology, which creates extremely fine patterns on the stamping die surface. Capable of adding a unique landscape of reflections, depth and dimension to the design, this technology is particularly well-suited for high-end packaging, luxury goods, cosmetic products and security applications. NanoEmboss and MicroEmboss dies do not require a fiberglass counter die and can be combined with emboss and combination dies. “The latest advancements allow MicroEmboss and NanoEmboss technology to be applied on cold foil,” noted Arns.

        New technology advances have moved the art of CNC engraving forward, working with traditional engraving processes to offer more choice for those using dies to decorate print. Historically utilized in automotive, aerospace and manufacturing applications, it’s making itself known in die production for print and packaging.

        ‘Willy’ Print Pushes Boundaries, Engages Imaginations

        June 5, 2023

        by Erin La Row, editor, PostPress

        If there is one movie character who has helped shape childhood imaginations for decades, perhaps it’s the eccentric and mysterious Willy Wonka – founder and proprietor of the Wonka Chocolate Factory. Roald Dahl’s 1964 novel Charlie and the Chocolate Factory first came to life on the big screen in the 1971 musical fantasy film adaptation Willy Wonka and the Chocolate Factory, with Willy Wonka immortalized by the late Gene Wilder. The movie ignited imaginations, leaving many children dreaming of dipping their hands in a river of chocolate or dancing through a park of lollipop flowers and gummy bear trees. Others were shaken by the ominous undercurrent of Wilder’s character (let’s not forget the tunnel scene). Regardless, Wilder delivered a Golden-Globe-nominated performance – veering from charming to mildly sadistic candy maker – that still is captivating more than 50 years later.

        When the team at Post Press Specialties in Independence, Missouri, needed to design a piece to demonstrate the company’s overall capabilities and how fine of a dot could be foiled on its digital embellishment machine, the titular candy man became the inspiration.

        “I first asked for a duotone photo and, after a few days of playing around, Willy Wonka was targeted and we went above the two colors originally planned,” said Andy Humble, president of Post Press. The graphics were created in Adobe Illustrator. The challenge, Humble said, was to intermingle small dots of opaque foil to create an image resembling a lithographic photo. The team was surprised it could produce foil halftone dots in different foil colors in a way none of the team members had ever seen before. The result: a striking image of Wilder’s Willy Wonka in his signature top hat and purple jacket, simply called “Willy.”

        The process

        “Willy” was a piece of whimsy from the start, created on a leftover scrap piece of board that the team laminated. The project was done, design to finish, in an afternoon, with fewer than 10 copies made. It was produced as a sample to show customers.

        “We showed the print to people as we did plant tours and a few samples were given away over time,” Humble said.

        When asked if the company had anything to enter into the FSEA Gold Leaf Awards, Humble said the team found the last two copies and made frames out of paper in the shop. The team then added a black soft-touch laminate they had been given to try and added a quote from Willy Wonka himself: “A little nonsense now and then is relished by the wisest men.”

        The piece was produced on a Konica Minolta JetVarnish EVO 3D using foils made by Crown Roll Leaf. On the MGI, inkjet heads print the image based on the foil pattern and the Willy photo was adjusted to create layers of foil. The UV coating on the sheet then cures under a UV lamp before being re-heated under a hot foil stamp roller, which allows foil to transfer to the areas printed previously with UV. The paper stock used was 24-point CIS with 1.5 mil FeatherTOUCH matte laminate from Leading Edge.

        Inspired by a “world of pure imagination,” Post Press Specialties moved quickly to create the project. “We have a special machine – we have great operators. Let’s make something to show the limits to engage customers’ imaginations,” Humble said. “We have different foil colors and the guidance of, ‘We are the music makers and we are the dreamers of the dreams’ [a Wonka quote lifted from the poem, Ode by Arthur O’Shaughnessy], and – the next day – 10 samples of this were shared.”

        Now, the team at Post Press Specialties is celebrating “Willy” for winning Gold in the category Best Use of Digital Foil (Self Promo) in the 30th annual FSEA Gold Leaf Awards competition. It then took the Best of Show award from among all gold award winners for Digital Embellishments.

        “The ‘Willy’ poster is an amazing demonstration of what can be accomplished with digital embellishments,” said FSEA Executive Director Jeff Peterson. “Even with having a record number of entries this year in the FSEA Gold Leaf Awards, it really stood out and was awarded Best of Show.”

        Humble said he couldn’t be happier about the win: “We enjoy pushing the limits of equipment and operators in an effort to create something never done before. Thanks for the selection of Best of Show!”

        The magic will live on, immortalized in film and print. Humble added that one customer asked for his own copy of “Willy.”

        “He took it and had it matted and framed, and it’s now hanging in his house,” Humble said. “That very much surprised me!”

        In the years since the movie’s debut in 1971, Johnny Depp has added his spin to the quirky character. Later this year, Timothée Chalamet is expected to bring Willy Wonka back to the big screen in the “Wonka” prequel.

        Industry Influencer: Emilio Corti

        March 15, 2023

        Emilio Corti is the region business director, Americas for BOBST.

        Emilio Corti is fluent in four languages – something that likely has come in handy over the course of his expansive career. Today, Corti is based in the United States, serving as region business director for BOBST, where he’s responsible for the company’s capital business throughout the Americas. PostPress magazine posed questions to Corti to tap into his expertise in folding cartons and find out what he thinks of the future of the industry.

        How did your career develop in the folding carton and packaging industry?

        I have worked in the industry since the early 1990s, specializing in initiating, restructuring and managing local sales and services branches. I joined the BOBST team in 2003 as marketing and sales manager of the folder-gluers product line.

        My earlier career with BOBST included a move to Mexico, where I became CEO of the North Latin America business. Working with outstanding teams, I was able to re-establish the company’s leading market position in Central America, Mexico and the Caribbean by building new working procedures and processes and increasing overall efficiency. From there, I moved to Switzerland, where I led capital sales worldwide for the folding carton and corrugated board industries. In January 2021, I moved back to the US to serve in my current role.

        Over the past two years, we’ve seen tremendous growth in certain segments of folding cartons, such as pharmaceuticals and food. Do you expect this to continue in 2023?

        Yes, absolutely. Demand for folding cartons is predicted to grow in several end-use segments, including “on-the-go” eating, pharmaceuticals and beverages. “On-the-go” eating growth is due to continuing urbanization, busier lifestyles, more working women and single-parent/single-person households, and time pressures.

        Growth in the pharmaceuticals sector, meanwhile, partly is due to changes in regulations, and partly because growing health awareness among consumers, especially since the pandemic, is increasing demand for cartons for pharmaceutical products.

        Folding cartons are one of the most sustainable forms of packaging. Do you see more brand owners switching to folding cartons as a more sustainable solution?

        Demand for sustainable packaging remains a main driver for growth, and many brand owners have committed to sustainability goals – such as 100% recyclable packaging by 2025. There certainly is an increased utilization of paper instead of plastic and increasing government regulations and legislation for non-recycled material.

        Sustainability covers the entire packaging spectrum, and it requires collaboration. We are in a very exciting period for sustainable packaging, and at BOBST, we believe we’ve reached a defining moment. We have introduced oneBARRIER FibreCycle, which is a full paper, mono-material, recycle-ready solution, developed in response to increasing demand in the industry for more paper-based packaging options.

        Both as an industry and as a society, we need to keep collaborating and talking. Education is a significant part of this; we need better home education for consumers on waste sorting and recycling, and improved collaboration, not only with the entire packaging spectrum but also with waste management companies, for example. It is a process, but huge steps forward have been made.

        What are the biggest challenges facing the print/packaging/folding carton industry? How should the industry respond to successfully grow and thrive?

        There have been some significant pressures on our industry in the last year or so, due to factors including global economic instability, global supply chain challenges, human resource shortages and the energy crisis.

        As we look at the year ahead, our hope is that many of these challenges settle down, but the human resource shortage is an example of a challenge that likely will be ongoing for some time. When we speak with converters, we still are hearing that many of them are struggling to find skilled machine operators or to retain or find skilled personnel.

        Companies, like BOBST, can help, whether that’s supporting the training of operators or through the automation and digitalization of the production process. This includes automating the setup of the machines and changeovers, making production for our customers easier, more reliable and therefore more efficient; or automating the machine to enable it to process a PDF file to set up the machine automatically for production – right up to the end product being ready to be shipped to the client.

        It’s a challenge but also an opportunity. We can make the process smoother and faster. This industry always has been about adapting and evolving, and we will continue to do that and help our customers to do the same.

        What other trends in folding cartons do you predict for 2023 and beyond?

        There are three key trends we foresee in 2023: zero-fault packaging, automation and digitalization.

        Zero-fault packaging will continue to be a non-negotiable factor. Zero-fault packaging puts the onus on the manufacturer to provide completely fault-free packaging in short lead times. Low quality is not sellable. It means waste and higher costs, and it lowers the converter’s profitability.

        Automation of plants will continue to be a key focus. With job runs getting shorter, automation is required for quick changeovers. The ongoing challenges around the lack of skilled manpower and increased production rates will drive further automated solutions. In the near future, companies will have to offer solutions to answer the latest market demands, including robotics and more.

        Meanwhile, the digitalization of the industry will continue throughout the complete supply chain. Cloud-based reporting integrated into the quality assurance monitoring systems of equipment enables converters to receive real-time data.

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