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      PostPress

      PostPress

      Print Decorating, Binding and Finishing

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        Troubleshooting

        Four Tips to Outsourcing Bindery Work

        July 13, 2018

        by Andre Palko, Technifold USA

        It’s not unusual for a print shop or bindery to encounter jobs that are outside the scope of the finishing equipment on their floor. Maybe the job is a favor for a good customer or perhaps it’s part of a package of jobs. Whatever the reason – once the decision is made to handle the job through outsourcing – there are a few things you can do to make sure it’s a trouble-free event.

        1. Work backwards.

        The first step in an outsourced job (or any job for that matter) is to work backwards. Talk to the bindery or finishing shop first. For example – one reader researching a map folding job found it a little tough to find a local shop that could handle the 36″ width on the folder. Printing the job is a breeze but finishing is another story, since the majority of popular folding machines in the field are less than 30″ wide. With a couple inquiries we found several trade binderies that have the necessary expertise, experience and equipment for such specialty folding.

        But now that you’ve found your possible vendor, the real work begins. If you talk to five trade binderies you might get five slightly different suggestions on paper weight, scoring, grain direction, panel size, guide and gripper location and more, even though we’re talking about the same map job. Each shop will have very specific reasons for their particular suggestions. Thus it’s vitally important to speak with the bindery first. It’s not because we bindery types get hurt feelings if you don’t; it’s simply because if you neglect to work backwards, your print job could become a salvage expedition.

        2. Keep all the cutting, scoring and folding under one roof.

        For that matter, any closely related, critical operations should be kept together. Most of us who have done any type of complex bindery work find ourselves constantly communicating with our co-workers in different departments. When I’d cut a complicated folding job, I would always discuss it with a folder operator. If I had to die score a job prior to folding and there was some question about how it would perform, we would test scored samples on the folder before scoring the entire job. When a complex stitched book was in the works, the entire crew would discuss each operation before laying the job out for printing.

        When these operations are separated by outsourcing to multiple vendors, you lose this critical communication. If, for instance, you decide to cut a job yourself before shipping to the bindery, simply because you can and because you’ll save a few bucks, you may get a phone call from the bindery advising that you cut off 1/16″ too much. So much for savings. If Shop A scores a job and then ships to Shop B for folding, there’s not much you can do if one of the scores needed to be moved to facilitate machine folding. Each shop will say they did their job and probably will be correct. The behind-the-scenes communication that would have prevented such a disaster was missing.

        3. Prepare for the unexpected.

        Another factor to consider: every time you ship the job, you are exposed to possible damage or loss. Every shipment also takes valuable time that would be better spent in production.

        4. Vendors are not mind readers.

        Lastly, communicate everything with your vendor and give them everything they need to complete the job. You can’t really get mad at vendors for their failure to read your mind.

        Outsourcing with the right partners will add tremendous value, will help you beat deadlines and can be delightfully easy with a common-sense approach and a little planning.

        Reprinted with permission.
        Andre Palko is president and founder of Technifold USA in Lafayette, NJ. He writes a Bindery Succes Blog in which he offers insights on bindery and postpress strategies, techniques and tips. He can be reached at 973.383.7920.

         

        Grain Direction – The Long and Short of It

        March 19, 2018

        by Brian Cowie, CEO, The Paper Mill Store
        The direction of the grain plays a key role in how the paper will react when it comes to folding, scoring and binding.

        Will you fold, score and bind your paper, or will you crush, break and warp your paper? That is the question.

        Proper folding, scoring and binding of paper are mostly a matter of understanding the major properties of paper fiber. One of the most important properties to understand about paper fiber is grain direction – the direction in which the fibers align on a specific sheet of paper. Yes, that pesky little grain direction issue – which is stated in so many swatch books, printing guides and all over paper mill literature – really means something and should be understood by everyone from graphic designers, printers, finishers and binders to home hobbyists. When working with paper, it is vital to know which way the grain flows.

        Grain direction unraveled

        A quick “Paper 101” on grain direction.

        As paper is made, all the fibers within the pulp stew begin to line up in the direction in which the paper machine is moving. The cellulose fibers align, side by side, much like logs floating down a river during turn-of-the-century logging. The end result is that many more fibers than not are pointed in the same direction along a sheet of paper, forming a “grain direction.”

        Typically, when using an 8.5×11-inch sheet of paper, the grain is in the 11-inch, or the “grain long,” direction, meaning that the vast majority of fibers are aligned parallel to the 11-inch length of the paper. In contrast, if the sheet was cut “grain short,” then most of the fibers would be pointing across the short side of the sheet in the 8.5-inch direction, or what is called the “grain short” direction.

        Now you know

        Paper has a grain direction. So, what? We all have our issues, right? Now hold on; it’s not that easy. Grain direction is very important and makes a huge difference as to how the paper will react when attempting to fold, score and bind it. Therefore, knowing the grain direction and how it will affect the layout of a project makes a big difference in the quality of the finished piece. A few minutes spent learning about and understanding grain direction will help for years to come.

        Folding and scoring with the grain direction

        Knowing why grain direction is important will be helpful as well. As a visual aid to the grain direction concept, think of paper fibers as a dozen wooden pencils lying side by side on a table, forming an imaginary sheet of paper. If this imaginary sheet of paper were to be folded, it can easily be imagined that folding in the parallel direction to the pencils is easiest. Fold across the parallel direction of the pencils, and the pencils will all snap in two.

        While it is not exactly the same in paper as with pencils, the concept does illustrate that the best way to fold and score paper is with the grain direction parallel to your fold and score. Folding and scoring parallel to the grain will break fewer fibers and have a stronger and cleaner fold or score.

        This can easily be demonstrated by taking a light cover stock, perhaps a 65 lb. cover, and folding it the length of the sheet and then folding it the width of the sheet. Examine both folds, and it can be seen that one fold is decisively cleaner and smoother than the other. The cleaner, smoother fold is parallel to the grain, and this illustrates how the paper fibers react more favorably when folded in the parallel direction.

        Binding with the grain direction

        Binding with the grain direction is very important for all methods of binding. Whether doing a simple saddlestitch or a more complex perfect binding, binding parallel to the grain is vital. The reason that grain direction is so important to successful binding is different from when folding and scoring; it is not a matter of breaking fibers. It is a matter of how paper fibers expand and contract in the open air. While this is a much less understood concept in the industry, it is an extremely important one to understand to avoid disastrous binding episodes.

        Paper fibers constantly expand and contract, mainly due to ambient conditions as well as glues and moisture associated with many binding processes. Most likely, the expansion and contraction of unbound paper won’t be seen or noticed, but it is happening. Paper fibers expand and contract as much as 400 percent more across the grain direction of the paper fiber than with the grain direction.

        This means that if paper is bound into the spine across its grain direction, as the paper expands and contracts, there will be as much as 400 percent more movement of the paper fighting against the anchor of the binding. This can result in very unpleasant consequences, including gusseting of the spine of the finished piece. Gusseting is the extreme warping of the spine due to the expansion and/or contraction of the bound paper. There is almost no way to repair a gusseted book once it is bound, but this issue can be avoided by using proper binding techniques.

        When trying to visualize what happens in gusseting, imagine a pair of hands making a “time-out” sign – the fingertips of the right hand pressing into the palm of the left hand. The fingertips of the right hand represent paper fibers bound perpendicular to the spine of the book, which is represented by the left palm. Now, imagine the right-hand fingers spreading representing the paper fibers expanding. The right-hand fingers move across the left palm, which represents the spine as it stays stable. What results, in this scenario, is severe warping of the sheets as they try to move within the bound spine. The strength paper has to pull a spine into funky shapes with just the small expansion and contraction movements of cross direction paper fibers is amazing.

        How to determine the grain direction

        From graphic designers to home hobbyists, anyone who works with paper should be knowledgeable about grain direction.

        The easiest and best way to determine the grain direction of paper is to order it in the direction required, whether grain short or grain long. Grain direction is noted on most paper packaging, swatch books and paper mill stock sheets in one of a few different formats. Most commonly, grain direction will be noted as the last dimension of the sheet.

        As an example, 11×17-inch would be grain long (fibers run in the 17-inch direction), 17×11-inch would be grain short (fibers run in the 11-inch direction). Sometimes the side of the sheet with the grain direction is bolded, so 11x17-inch would be grain long or 11x17-inch would be grain short. The grain direction may be underlined, 11×17-inch would be grain long, or 11×17-inch would be grain short.

        Often there will be multiple indications of the grain direction on the label of a ream of paper. Whichever format is used, paper mills make a big effort to indicate the grain direction of every sheet of paper.

        There are few things worse than experiencing an avoidable problem. By paying attention to grain direction, it is possible to avoid some of the all too common production errors that occur due to incorrectly formatting projects with respect to paper’s grain direction.

        Professionals and hobbyists alike have trusted The Paper Mill Store, www.thepapermillstore.com, since 2004 to provide great papers at great prices. Thousands of brand-name papers, envelopes, card stocks, swatch books, samples and other products are available with an array of custom services including paper cutting, perforating, scoring, drilling, envelope printing and custom watermarking. The Paper Mill Store is located in Sun Prairie, Wisconsin.


        Simple Tests to Determine Grain Direction

        Paper, like wood, has a grain. Adhesive binding on paper with the wrong grain direction can produce disastrous results. Here are some simple tests to determine paper grain direction:

        • Folding Test – When folding a small sheet of paper, notice that it folds more easily and smoothly when the fold is parallel to the grain. If folded against the grain, the small fiber particles break and make an unsatisfactory fold.
        • Moisture Test – If moisture is applied to one side of a sheet of paper, it immediately starts to curl in one direction. The expansion is on the cross-grain edge, the curl indicating the paper grain direction.
        • Bending Test – Thicker papers are best tested by bending them in both directions. One direction offers considerably more resistance than the other. Parallel to the grain direction, the resistance is far less than against the grain.
        • Tearing Test – A sheet is torn in longitudinal and transverse directions. The tear pattern will be straight when parallel to the grain and jagged across the grain.

        Thank you to Kater-Crafts Bookbinders for this information – www.katercrafts.com.

        Creasing Solutions – Keeping Up with Digital Printing

        December 18, 2017

        by Brittany Willes, editor, PostPress
        A fully automated solution, the Duplo DC-446 Creaser was specifically designed to prevent toner cracking and unattractive fold lines on digital stock.

        The devil is in the details, as the saying goes. While this has always been true of the printing industry, it’s become even more important with the advent of digital technology. When it comes to printing on digital stock, strict attention to the smallest details is what transforms a good print job into an amazing one. Working with digital stock presents its own unique challenges – ones that experienced operators didn’t necessarily have to worry about in the old world of offset printing.

        For instance, when it comes to creasing and folding digital stock, printers are bumping up against increasing instances of cracking and/or flaking along the fold. “Although it was not a problem in the past, a surefire way to guarantee a dissatisfied customer today is to present them with a completed folded project that has cracking along the paper folds,” read a blog post from Whitaker Brothers, a company of self-described office supply nerds based in Rockville, Maryland, specializing in cutters, folders and shredders. The blog post, Should You Be Scoring or Creasing, went on to state, “The good news is that while your competitors may tell their customers it is a necessary evil, there are solutions available to prevent this damaged final appearance.”

        So, how can printers avoid cracking – and dissatisfied customers – when it comes to creasing on digital stock? As they say, the devil is in the details.

        Creasing vs. scoring

        With digitally-printed stock, it’s important to know which method of creating a fold is best: creasing or scoring. The two terms often are used interchangeably, yet experienced binders and printers know they are actually very different processes that produce very different results.

        “Scoring machines fold paper by reducing its stiffness with the use of a rotary wheel,” explained Whitaker Brothers. “It stretches the paper and then utilizes severe pressure to create the fold in the paper.” This combination of pressure and stretching results in the top layer of paper fibers essentially being cut through. Most notably, scoring creates only a single stress point to achieve the fold.

        By contrast, creasing relies on creating two parallel folding points on either side of the fold. According to Whitaker Brothers, “Since the folding points now have doubled, the paper still folds 180 degrees, but the stress disperses to two different points on the paper.”

        Noting the differences between scoring and creasing is especially important when it comes to digitally-printed stock. Because the digital print process consists of pressing a layer of toner only upon the paper’s surface, scoring – which tears through the top layer of paper fibers – can ruin the printed piece. Furthermore, because scoring produces heat that fuses the toner to the paper, “this causes the paper to dry out, causing intensified cracking along the fold,” stated Whitaker Brothers.

        Thus, when it comes to digital stock, creasing over scoring is the recommended process. However, creasing is not without its challenges.

        Creasing on digital stock

        Tech-Ni-Fold’s Tri-Creaser solution helps reduce or eliminate the inside flaking problems that can occur when using recycled/poorly produced stocks.

        While excess heat is a pitfall when it comes to scoring digital stocks, it also has proven to be a challenge when it comes to creasing. Digital stock itself is heat treated and therefore is, “much more prone to the defect of cracking than traditional offset materials,” explained Graham Harris, managing director for Tech-ni-Fold, which specializes in creasing and print finishing. Headquartered in the United Kingdom, Tech-ni-Fold has spent more than 15 years addressing common finishing problems – such as the increased rate of cracking along folds that has occurred due to the rise of digital printing.

        Kevin Chen, product manager for Duplo USA, Santa Ana, California, confirmed Harris’ assessment of the difficulty of creasing digital stock. According to Chen, “Creasing on digital stock is extremely difficult because of the different variations of toners and inks being used in the digital age right now. Each toner/ink reacts differently to certain creasing mechanisms.” Back in the days of traditional offset printing, the printing process was universal all around. Those days have mostly passed.

        “It’s a vicious cycle that often repeats,” explained Harris. “Creasing machine manufacturers develop their latest super solution to solve a production headache, only to have the rules change all together.” As a result, creasing has become a critical application.

        While the technology for creasing paper stocks has come a long way over the last several years, digital stock continues to present problems. For instance, the digital printing process can help cause brittleness to the stock and, in some cases, a static charge can make feeding/separation and finishing more difficult, Harris explained.

        In addition to increased cracking along folded edges, another problem that is becoming apparent is the added threat of flaking on the inner side of the crease, meaning each side of the bead. “In other words,” Harris explained, “cracking on the outside of the fold used to be the only problem, but suddenly it was the other side of the sheet that posed threats. Quite literally, right now the folded sheet can easily hide a new surprise for those that pay for perfect creasing results.”

        According to Harris, this new flaking problem is the result of increased numbers of recycled and poorly produced paper stocks. While this issue is hardly the fault of creasing machine manufacturers, it still is an issue that needs to be addressed in order to achieve the desired fold – and a happy customer. As Harris stated, “Creasing machine manufacturers are beginning to realize that stopping the cracking on the outside of the fold isn’t enough anymore, and therein lies the challenge for those who create creasing solutions.”

        Along with increased flaking due to inferior stock, the slow speed of output versus the need for faster digital press speeds also can pose problems for printers. “One of the most critical areas with creasing digital stock is in the speed of output,” said Harris. “Cylinder methods may average 4,000 creased sheets per hour, but multiple crease applications significantly reduce this ratio as the same creasing blade is needed again. Furthermore, it isn’t uncommon for fewer than 1,000 sheets to be completed (per hour) in such cases.” All in all, this doesn’t bode well, especially as digital copiers and printers are getting faster.

        So, how can binderies and printers avoid problems with cracking and flaking while getting more from their overall production process? For starters, they can help themselves by identifying higher quality stocks whenever possible. This will allow for better finishing results. “Really, just some forethought to the whole process is sensible,” remarked Harris. Next, binders and printers can turn to creasing solution experts for the latest in digital creasing technology, which can aid in turning a good print project into a great one.

        Digital creasing solutions

        Standard Horizon’s automatic creaser offers an automated feeding function that allows for high-quality creasing.

        When it comes to creasing solutions, Tech-ni-Fold’s CreaseStream technology has made great strides in reducing cracking and flaking for digital stock. CreaseStream consists of a range of three creasing and micro-perforating machines, from manual and semi-automatic versions through to the fully-automatic solution.

        “The newly patented Tri-Creaser tools used in all CreaseStream models reduce or eliminate the inside flaking problems that can occur when using recycled or poorly produced stocks,” stated Harris. This is achieved with a special double scoring tool in the female channel that irons out those fibers that are prone to such defects.

        “As well as giving customers the quality crease they expect, the CreaseStream solutions significantly increase output ratio,” said Harris. “All machines have the same tooling shaft specifications and can combine creasing, cutting and micro-perforating in one easy operation, if required.”

        Other options in the marketplace for creasing digital stocks include Duplo’s DC-446 Creaser, which was specifically designed to prevent toner cracking and unattractive fold lines on digital stock. A fully automated solution that creases up to 60 sheets per minute, the DC-446 comes with Duplo’s patented creasing mechanism, which prevents toner cracking and unattractive fold lines on digitally printed documents.

        “A number of options are available on the DC-446 to suit the demands of digital printers,” remarked Chen. “For instance, a double-feed detector sensor stops the machine when two or more sheets are fed, preventing misfeeds and paper jams.” In keeping with the idea that printers desire more from the their creasing machines, slitting and perforating tools also can be added to eliminate white borders and/or create perforated pieces.

        With greater amounts of recycled and/or poorly produced stocks introduced to the market, increases in cracking and flaking are almost unavoidable. Synthetic materials likewise pose a problem for creasing. “Synthetic material attracts a lot of static,” stated Chen, “which makes it hard to feed into the machine. When customers start using synthetic material, it is hard for machines like the DC-446 to process.” Luckily, Duplo has found a way of helping to combat the static problem. One of the options available on the DC-446 is an air knife, which provides additional air to reduce static problems. While this may not eliminate all static problems associated with synthetic materials, it’s a step in the right direction.

        The Standard Horizon CRA-36 Auto Creaser also is designed to eliminate the cracking that is so common with digital print, cross grain and UV coating. Producing high-quality creasing through an automated feeding function, the CRA-36 is capable of creasing up to 10 lines per sheet. “Designed for digital and offset printed sheets, the CRA-36 offers rotary perforation, edge trim and gutter cut in a single pass, while impact creasing helps to prepare high-quality perfect bound book covers,” stated Marketing Specialist Will Frank.

        The ability to crease in a single pass can be particularly important. “When creasing on digitally imaged stock, operators should be aware that one size does not fit all,” noted Frank. “In other words, based on the weight of the stock and the direction of the folds, operators will need to choose the right width and proper direction (up or down) of the creasing line. A general rule of thumb is that a lighter line is required for lighter weight stock, and a heavier line is best for heavier stock. On heavier stocks, it is best for the crease line to be opposite the direction of the fold, while a crease in the same direction of the fold may yield better results with lighter stocks. When looking at equipment, it is best to consider a solution that will provide up and down creasing in a single pass to avoid the need for multiple passes through the machine.”

        Conclusion

        The rules are changing – quickly – when it comes to digital printing and overall production processes. The tried and true solutions that once prevailed in the traditional world of offset printing no longer apply in the digital age. Binders, finishers and printers are looking for new and better solutions to ever-evolving issues, and suppliers of creasing technology are doing their best to combat those issues by addressing the challenges of digital printing head on. The devil may be in the details, but so is the solution that helps transform a digital print job from good to great.

        Finishing First: Changing Mindsets to Ensure Greater ROI

        September 8, 2017

        by Lance Martin, vice president of national accounts, MBO America

        One of the things that end users can do for themselves is to think about finishing first. The printing part of the process is undeniably sexy – the vivid colors are beautiful and watching the print process is just cool – but as finishers like to say, you can’t sell a roll or a sheet until you actually do something to make it into what you want.

        Having the mindset of “finishing first” will enable businesses to capitalize on greater return on investment (ROI) while making sure they are best able to serve their customers. Many times, the end user will go down the path of the press without fully considering the job they are doing or how that job will be finished. This often results in missed ROI opportunities and is not an infrequent occurrence. It’s partially a flexibility issue, and making sure end users educate themselves properly in the buying process is one of the most important things they can do. You have to go outside the box when you look at finishing.

        From afterthought to forethought

        Flexibility and education are key issues in today’s fast-paced and ever-evolving market. End users run the risk of putting themselves in a box – and out of business – when they fall into the rut of producing products in certain ways without opening themselves up to new ideas and new ways of doing things. Education can play a significant role in helping to avoid such instances, and it can begin with something as simple as learning to ask the right questions. If end users just ask more open and general questions of their suppliers, they might get different answers from a finishing expert than they would from non-experts. That can make all the difference.

        Current end users are not the only ones we would like to see increasing their knowledge about the finishing side of the equation. Today’s college training programs are not typically geared toward finishing and focus more on the printing side. So, a great way to educate young people is for suppliers of finishing and binding equipment and supplies to get involved with local and regional colleges and technology schools. With this type of outreach, companies can get an idea of what’s going on, what students are learning about the industry and what that will mean for the printing/finishing business in the future. It is going to be very important to get programs like this in the education system involved with the finishing/binding side of graphic arts to help grow and educate the industry.

        That doesn’t mean it will be easy, however. Many of those in the industry currently come from an environment that has long been characterized by self-maintenance and self-training. It’s still an offset world, and there are a lot of conventional printers out there. As a result, we have to do things differently than we used to. We’ve had to change to keep up with the times. Part of keeping up involves initiating new training programs.

        Training programs that are closely tailored to the hands-on finishing experience are the most effective. When working with a customer, it is recommended that operators have the opportunity to work on the new equipment first-hand in a training facility or showroom. This will provide the best environment for pre-installation training, where operators can set up a few jobs with educated trainers to help.

        This is especially useful for facilities looking to move from offset to the digital world since digital is a very different animal. You have to do things differently, so approaching customers differently is the best answer. The more flexibility you can build into the system, the more you can do what your customer needs you to do.

        One size does not fit all

        When flexibility is not built in, businesses have little choice but to drive their customers to existing solutions, which may or may not be the best fit for all customers. In my experience, the most successful businesses do it the other way around. Thriving businesses not only ask what the customer needs to be successful, they also are able to produce it for the customer. Relying on this premise, offering finishing/binding systems that are built to provide customers not just with what they need now, but also with the ability to change as the industry changes, is of utmost importance.

        Building flexibility into a finishing system means decreasing the number of times pieces need to be touched during the finishing process. Fewer touches means fewer opportunities for error. In the old offset world, you would print the piece and sheet it, then take the sheet over to X unit to perform one function before going to another unit to do the next thing. Given the increase in customer demand for short lead times and cost reductions typical of digital inkjet printing and finishing, that approach is just not practical anymore. You have to touch the piece as little as possible.

        The pressure to increase efficiency and reduce costs can be a compelling argument for printing and finishing in one pass wherever possible, especially where finishing requirements are relatively simple and straightforward. However, problems can arise when you put a series of complex finishing processes inline with a press that is able to run at 95 percent efficiency and above. In that case, what you’ve actually done is reduced the efficiency of the entire system by increasing the chance for error due to makeready delays, jams and other issues.

        For example, if your finishing system applies glue, folds the piece four times, adds a Post-it note to the outside and then perforates and folds it over into a direct mail piece, the chance of something going wrong increases greatly. The resulting shutdown and cleanup – even if it takes only a few minutes – can dramatically reduce both productivity and profit.

        That’s when you do the math and realize you’ve just taken a $2 million production inkjet web capable of running at peak efficiency and turned it into a 70 percent production machine. Given the dynamic nature and progression of inkjet technologies, therefore, printers are often well-advised to choose fast, efficient offline finishing systems to complement their high-speed production inkjet webs.

        When considering a finishing system, printers and finishers owe it to themselves to ask questions. How flexible is the equipment relative to the demands of the market? Can it be adapted to meet those demands if the printer’s product mix changes? Can it handle a wide range of substrates and formats? Questions like these are why MBO takes a modular approach to finishing, where every digital finishing unit is compatible with any other unit. This means that finishers can add onto existing systems as requirements change and new opportunities come along. Each unit rolls quickly and conveniently into or out of a given system so a finisher can reconfigure his finishing system at a moment’s notice.

        Finishing first

        In either an inline or offline finishing environment, the need for a skilled finishing operator cannot be overstated. When the finishing process is simple (incorporating few or no extra functions), all the finishing operator may need to know is how to cut a sheet. On the other hand, when the finishing process is more complex, as in the example above, an operator must learn both how to print and how to be a good finisher. However, the talent pool for finishers is not especially large, and it can be difficult to find knowledgeable, experienced operators. Among other things, the “finishing first” mindset requires a practical understanding that finishing is not a matter of simply pushing a button and being able to guarantee that a beautiful, complex piece comes out the other end.

        Again, this is where training programs come into play. Providing customers with the opportunity to train on new machines – even before those machines have been installed in their individual facilities – and encouraging end users to educate themselves in the buying process, are necessary steps toward encouraging a shift in mindset whereby finishing becomes a primary consideration instead of an afterthought.

        As noted earlier, quality finishing requires thinking outside the box. Printers and finishers have to do things very differently now. Conventional practitioners already know what it means to go from prepress to the final product. As the industry has evolved, however, printers and finishers have had to change their mindsets and learn how to incorporate more flexibility into their systems to achieve greater efficiency.

        Lance Martin is the vice president of national accounts for MBO America. MBO America, Marlton, New Jersey, offers a broad array of cutting-edge, high-performance finishing solutions for conventional, digital and hybrid print operations and fulfills specialized needs upon request for pharmaceutical, commercial finishing, packaging, diecutting and digital finishing sectors in the Americas. From intricate folds and diecuts to niche packaging with special standards, MBO gives printers the edge over the competition with next-generation achievements in digital finishing, high-speed systems and workflow flexibility. For more information, visit www.mboamerica.com> or call 800.336.1164.

        Avoiding Bindery Bottlenecks

        September 8, 2017

        by Melissa Larson, contributing writer
        Rollem’s Jetstream 8-up postcard sheet runs at speeds up to 4,000 sph and eliminates the needs for guillotine cutting, allowing for increased efficiency in production.

        Most experienced printing professionals are accustomed to thinking that printing bottlenecks occur in the prepress department. That’s the black hole, right?

        Bottlenecks can occur anywhere in the workflow, and these holdups in the bindery or finishing area are rarely examined and poorly understood. This has become even more relevant with the growth of digital printing technologies and working with digitally printed output.

        We’ve talked to postpress professionals to get their best practices in avoiding bottlenecks, whether through making the most of the equipment a printer or binder already has or investing in new technology.

        Think “Finishing First”

        Si Nguyen, vice president of sales at Duplo USA, was quoted at the recent Dscoop 11 event in San Antonio, Texas, as saying, “If print service providers want to be profitable, they need to think Finishing First. Eliminating postpress bottlenecks will create a smoother workflow, generating efficiency and profits. In addition, when print service providers use finishing techniques to add value to their products, they can become one of the top profit-makers in the printing marketplace.”

        Doug Sherwood, national sales manager at finishing machinery builder Rollem Corp. International, put it succinctly: “Make sure you have the right finishing equipment. So many times I go into facilities that have invested heavily in the latest press technology, only to have finishing technology that is outdated, hard to use and in need of specialized operators. Equipment that is user-friendly, easy to maintain and versatile, with the ability to run multiple substrates with high-quality, will go a long way toward efficient production.”

        Start with a flowchart

        Crafting a flowchart of the work moving through a printing or binding/finishing shop can help determine where the bottlenecks lie.

        An essential component of this exercise is to put down the number of minutes each machine or operation takes to process an order. Work-in-progress areas normally will be spaced between the operations. When the flowchart is complete, walk out to the production floor and look at the real-time workflow.

        Think the bottleneck must be the operation with the most inventory in front of it? You may have to think again. It could be the job down further in the workflow after digital or offset printing, including older and slower binding or finishing equipment, that is causing the problem. The old adage about the weakest link is true: your workflow is only as fast as the slowest operation.

        The key is to look at the underlying reasons for the bottleneck and not just address the symptoms. This means gaining a whole new understanding of your overall workflow and hopefully getting input from production staff about the reasons the blockage is occurring.

        Look at the layout

        According to Brad Emerson, general manager at FixYourOwnBindery.com, “Layout is paramount. If you can move smaller finishing machines, if only to save one footstep, you should consider doing it. In this feast-or-famine sales world we live in today, a layout should be friendly to inline and near-line production, where minimal staffing can make one box of books with minimal footsteps, as well as max production, with max personnel stacking materials on and off pallets if needed, again with minimum footsteps.”

        Be on the lookout for new bottlenecks

        Digital press technology offers greater flexibility in how jobs are printed and arranged. Valuable sheet space can be maximized by laying out multiple-up images, which can then be trimmed, scored, slit and even perforated in one process.

        Eventually, you probably will conclude that you need to increase the capacity of the operation causing the bottleneck. This can be accomplished by adding team members, adding equipment or by taking advantage of new technology that speeds up a particular process – or a combination. And, asking if the equipment or new technology is something you need to have in-house or if it is best to partner with a reliable vendor for that technology – these are all questions that must be asked.

        Although many binding/finishing operations can be performed in-house, either inline or near line with a digital or offset printing operation, there are situations where the binding/finishing functions may be better suited for a trade binder or finisher that has invested in specialized equipment for such things as complicated folds, special diecuts or specialty decorating techniques, such as foil or embossing. So, planning and avoiding bottlenecks with jobs that are outsourced to a binder/finisher also is very important to an operation.

        As you improve one bottleneck, you may find the bottleneck now has moved to a different operation or different portion of the job. It is vital that you continually monitor the effects of your process changes to identify when the bottleneck does indeed change – then change your focus accordingly.

        Make software your ally

        Combatting bottlenecks increasingly includes the use of software – from MIS and enterprise resource programs (ERP) that have existed in some form for decades, to programs that are specifically designed for print production, from prepress through post-printing.

        One commercial printer has made a seven-figure investment in an ERP system that allows for finite scheduling. It tells production what jobs should run on a machine and in what order and moves an operation to the next day when that day’s hours have been filled, synchronizing all work centers. Despite the expense and the fact that it involves numerous data points, the system has made identifying and avoiding bottlenecks easier.

        A recent white paper from Kodak and Epicor, however, emphasizes that printers should “choose ERP that is designed and built to accommodate the specific needs of the printing and packaging industry.” And, the authors don’t accept that modified, adapted or enhanced ERP software will work for most printers.

        “The differences and needs of printing and packaging are so fundamental to the basic structure of how ERP works that modification and work-arounds will not suffice,” stated the piece, titled “Five Reasons Why Generic ERP Doesn’t Work for Printing and Packaging”.

        “Printing and packaging companies should look for an ERP system that is designed specifically for their industry, with estimating, product and job structuring, scheduling and material control capabilities that are properly attuned to the specifics of their world,” stated the piece. “These fundamental capabilities, however, should be tightly integrated with industry-leading customer relationship management (CRM), workflow, quality and supply chain management applications for a comprehensive enterprise solution.”

        Epicor and Kodak have partnered to offer the Epicor solution for printing and packaging, which includes Kodak UpFront production planning software, Kodak Preps imposition software and Kodak Prinergy workflow integrated to Epicor CRM, lean manufacturing and supply chain solutions. Epicor solutions comply 100 percent with service-oriented architecture and include service connect and business link for connectivity with other systems.

        Muller Martini’s Connex software is designed for digital production planning. It simplifies complex workflows by tracking, monitoring and analyzing a job’s data and its variability throughout the entire production process, from file to finished product, thus significantly reducing bottlenecks on the production line.

        Software systems are important for trade binding/finishing operations as well. Having an efficient way to track a job from start to finish and keep the customer up-to-date on the progress is crucial. “There is more pressure on printers to have binding and finishing all done in-house, so today’s trade binderies and finishers must be more efficient than ever when they are called upon by the printer for help,” states Dienamic MIS Software President Mark Porter. Dienamic has developed a software platform that is specifically designed for the special and unique needs of the binding and finishing businesses. Dienamic offers a fully integrated system, including estimating, management information system, customer service software and E-commerce solutions. Porter tells PostPress that the Dienamic software platform is designed to strengthen the bonds and communications between staff and customers. This is a key aspect for trade binders and finishers.

        Search for the right equipment, in the right configuration

        Rollem’s Sherwood urged customers to value versatility. “Automating the process has been a key focus of Rollem for some time,” he said. “Having the ability to perform multiple functions to complete a product, or run inline with other equipment, eliminates the bottleneck aspect, as well as improving quality and minimizing labor.

        “The goal is to take a job from printed sheet to finished product in a single process that keeps up with, and in most cases exceeds, the output of the digital press,” Sherwood continued. “By eliminating the need to take a job to multiple stations, the job is completed in the most efficient and cost effective way possible. For example, many customers’ products require UV coating, which is a popular configuration of a UV system coating the sheet and feeding it directly to the slitter. This eliminates the need for moving the stock and instead delivers the coated, cut products at rapid speeds, greatly increasing turnaround.”

        Again, not all jobs will be able to be completed in-house by the printer, so printers must seek out competent and reliable partners for binding and finishing as well. Those binders/finishers that have the right equipment for handling digitally printed output, as well as more traditional offset printed material, will be in the choices printers will make. So, having binding/finishing equipment that is flexible and can complete multiple types of bindery functions will be very important.

        Embrace new technology

        Andy Fetherman, vice president of sales and technology at Muller Martini Corp., extolled the benefits of what he called touchless workflow, stating, “Touchless workflow combines both automation and connectivity and is critical to achieving not only smooth production, but a quality end product.” He went on to explain that, “A touchless workflow starts with either simple barcodes or more sophisticated JDF integration. This enables our equipment to achieve uninterrupted finishing, oftentimes without any manual intervention.”

        “Another advancement is hybrid systems. Our bindery equipment processes both offset and digitally printed products, either separately or concurrently, thus avoiding the need to utilize separate machines and resulting in reduced makeready during production and a more balanced quality of the finished product,” said Fetherman.

        Conclusion

        “We know that the finishing process is more complex than ever before. The ability to seamlessly adapt to variability is of paramount importance, not only for the efficiency (i.e. profitability) of the press run but the quality of the end product,” said Fetherman. “The nature of variability is its unpredictability and that can cause bottlenecks within every phase of the process, from prepress to printing to finishing to distribution. That’s why a higher, centralized level of intelligence needs to drive the workflow and oversee, troubleshoot and validate the integrity of the entire run…The system only delivers complete, verified, good books at the end of the process.”

        Sherwood concluded, “Many times adjusting workflow or product orientation to accommodate the finishing technology can be a huge asset to improving overall production and eliminating bottlenecks. The big advantage of the digital press technology is the flexibility in how jobs are printed and arranged. The better communication we have as to how the product goes ‘downstream’ the better the flow of production will be.”

        Yes, It’s Beautiful…But, Will It Mail?

        September 4, 2015

        by Mike Porter, Print/Mail Consultants

        Many consider the hurdles for direct mail advertising to be capturing the recipient’s attention, enticing them to open the mail piece and persuading them to take the intended action. Those all are important aspects of the campaign design phase. Just as important, however, is making sure the piece can be delivered to the intended recipient intact, on time and within budget. If those things don’t happen, the copy, graphics and offer won’t matter much.

        Dozens of factors can affect the deliverability of mail pieces through postal systems. Some design characteristics essentially can switch a mail piece from one postal class to another. Others can trigger extra fees and charges. And, a few design miscues can cause the USPS to reject a mailing in its entirety.

        Material size, shape, weight and format can determine the speed, quality and accuracy of handling by print and document finishing providers before the job ever gets to the Post Office. Mail piece designers – and printer finishers and binders that work with clients to add specialty folds or effects – should consult with all the organizations involved in distributing the pieces before locking themselves into a design that results in unexpected costs and delays. For the US Postal Service, the people to contact are called Mailpiece Design Analysts (MDAs).

        MDA approval not a free pass, but can save the day

        MDAs can answer mail piece design questions or evaluate prototypes and provide guidance about improving the design to meet USPS standards. MDAs can save mailers time and money and offer some protection against accepting and running a job that may turn out to be an expensive disappointment.

        Many readers of this publication likely are highly skilled and experienced mail professionals. They are certainly qualified to evaluate mail piece designs on their own. But, keeping up on all the guidelines and regulations can be a chore. MDAs can be a second-level defense against bad mail that slips through an internal evaluation process. Or, they can serve as an outside authority on those occasions when customers push back against recommended mail piece modifications. MDA services are free. Mailers might as well take advantage of the resource.

        Getting the blessing from a Mailpiece Design Analyst isn’t a guarantee a mailing job will proceed through the postal system flawlessly. Final mail preparation methods or last-minute modifications in piece design, address location or other factors still can cause problems in the mail stream. But, having a favorable MDA opinion could provide some leverage should it be necessary to challenge a USPS ruling about the design of a piece.

        I can recall personal experiences where consulting with an MDA saved my customer thousands of dollars or prevented a mistake that would have rendered the mailing useless. In one instance, the customer had engaged a graphic artist to create a folded self-mailer. It hadn’t been printed yet, but the customer supplied a drawing that showed the layout, the location of the folds and the finished dimensions. As it turned out, the MDA noticed the aspect ratio was outside USPS specifications. If we’d printed and mailed the piece as designed, every one of them would have incurred a non-machineable surcharge – a budget-busting $20,000 of unexpected expense. In another case, the MDA pointed out tabs placed in required locations would obscure some important information on the document. We would have unknowingly reduced the response rate to practically zero. Advanced consultation with the MDA really saved the day on both those occasions.

        Recognizing the value of the mail piece design analysts, the USPS has launched a help desk application to streamline connectivity between customers and Mailpiece Design Analysts. Customers can get connected with an MDA by calling 855.593.6093 or sending an email to [email protected]. The MDA customer service help desk is available Monday through Friday from 7 a.m. to 5 p.m. Central Time.

        Mailers can find additional information about getting help from MDAs by clicking on the MDA Customer Service Help Desk tab found at https://ribbs.usps.gov.

        Creativity within boundaries

        Coming up with creative designs can be a struggle. One can do only so many things with a jumbo postcard before it becomes clear a different approach is necessary to make a mail piece stand out. A folded self-mailer, unusual windows, embossing or dimensional mail pieces might be aspects of a campaign designers decide to explore. When they do, it is best for finishing and mailing operations to get the specifications in advance and compare the piece to the mailing requirements and regulations.

        Here are a few areas mailers always should consider before approving designs for direct mail pieces.

        Size and Shape – Size restrictions differ among mail classes. As a result, mis-sized mail pieces can become ineligible for the intended mail class. A postcard too big for First Class may have to be sent via Standard Mail instead. That might be a problem. Among other things, delivery standards are different between the two mail classes, affecting the timing of the promotion.

        Aspect Ratio – The aspect ratio is calculated by dividing the length of a mail piece by the height. The resulting ratio must fall between 1.3 and 2.5. A mail piece with an aspect ratio beyond the approved range can trigger a surcharge assessed to every piece in the mailing. On a batch of 25,000 First Class pieces, the surcharge alone would be over $5,000! Note the USPS considers the dimension of the mail piece parallel to the mailing address to be the length. Printing the address parallel to the short side always will result in an aspect ratio less than 1. The piece may stand out as different, but expect the Postal Service to add that nasty surcharge to the postage bill.

        Odd-Shaped Items in Envelopes – Special rules exist for mailing bulky items in envelopes. Flash drives or pens, for example, can damage postal equipment, cause jams or injure postal employees. Mailers may be required to wrap such items. In some cases, it may be necessary to add material to the piece to achieve the uniform thickness required for the mail to run through postal sorting machinery.

        Tabs – If using tabs or wafers on folded self-mailers, the mail must meet certain specifications regarding the placement, size and number of tabs required by the Postal Service. Obscured information will negatively affect the performance of the piece, so be sure designers do not place important text or graphics where they will be covered by the tabs. Alternatively, mailers may decide to use transparent wafers or glue, which could increase the cost or cause a delay while waiting for delivery of substitute sealing materials.

        Response Devices – The design of any response devices mail recipients will utilize to return information back to the mailer is just as important as the outbound mail. Aspect ratios (see above) apply to response pieces, too. If using a return envelope, make sure the response piece fits in the envelope without requiring the mail recipient to fold or modify the response device. Using window envelopes for reply mail is a great idea, but be sure the response piece inside does not shift such that the return address falls outside of USPS address placement specifications.

        Plenty of variables in any mailing contribute to the total project cost. Any time a mail piece design seems unusual, it pays to have it evaluated by the print/mail production team and possibly the Mail Piece Design Analysts. In today’s environment of multi-channel communications, rejected mail or delayed delivery encountered at the last minute can have effects far beyond an individual mailing job. A direct mail piece may be integrated with timed emails, web ads, social media campaigns or events. Failure of a mail piece to meet expectations can ripple throughout an entire campaign.

        Mike Porter is president of Print/Mail Consultants. Porter specializes in guiding his clients in the development and implementation of strategic and operational improvements in customer communications. Together with his consulting practice, he also generates custom informational content for document industry professionals to publish in newsletters, blogs, web sites, white papers and trade media. To keep up with Porter’s tips, trends and commentary, visit www.printmailconsultants.com and sign up for Practical Stuff – a free newsletter for customer communication professionals.

        Board Choice Sets the Stage

        March 25, 2015

        by Jen Clark, PostPress
        The Signature Access folder gluer from American International Machinery, Inc., Oak Creek, Wisconsin, is shown with paperboard blanks loaded in the feeder.

        Picking the right board for a particular application – whether for book or carton production – relies on a variety of factors, but the key to executing a flawless project is to have a production team in place, according to industry experts. While not always an option, a team approach can ensure a profitable and successful outcome for each set of circumstances.

        PostPress reached out to industry experts at American International Machinery (AIM), Bobst North America, Inc. and Eska Graphic Board for more information on the impact of board choice for book and carton production, as well as an understanding of operational issues that can arise when a holistic approach isn’t taken prior to production. Bobst North America, Roseland, New Jersey, and AIM, Oak Creek, Wisconsin, make equipment that turns board into cartons, while Eska, Chesapeake, Virginia, makes board for both books and packaging.

        Involve the team

        “Board selection is a very important process,” said Kevin Koplin, managing director at AIM, “and to have everyone involved who will work with the product (from the beginning) is very beneficial.”

        Ideally, the production team should be involved with every job from the start, said Rob McCann, process optimization manager for Bobst North America. “Yet for various reasons, not every plant has a production team. Many plants have a manager or lead person for each phase of the converting process, but not an actual team that proactively arrives at decisions together that will best suit all of the departments.”

        Koplin explained that the team should be involved as early as the estimating stage. “The production team should work with the designers and estimators to make sure the proper board is used for the job,” he said. “If they are not involved, the company could incur additional costs during the process because of increased waste due to wrong grain or thickness of board to the size and configuration of the carton.”

        According to David Senter, sales account manager for Eska, his company can be part of the production team. “We come to our customers’ sites free of charge to help with planning and production,” he said. “If problems arise, Eska is there to work with customers to evaluate and adjust the process to be successful.”

        Anticipate production issues

        When choosing a substrate and the machine on which it will run, there are certain things to consider as well, McCann said. “There are very few standard rules for any application; and, as products across the board constantly are evolving, the variables increase each day, making it even more challenging to know the best converting approach for a given job,” he said. “An operator is limited to what he can overcome on press. If a problem must be solved by the operator, it normally is too late. This is where planning and having a production team in place play an important role in early identification and prevention of potential production obstacles.”

        Issues such as choosing to run very thin material with multiple scores perpendicular to machine running direction will limit the speed and quality of the carton on a high-speed folder-gluer. Koplin said different types of board always will run differently. Board with the wrong grain direction, for example, is another problem. “You need to have the right grain direction to give the box the strength and stability for storage,” he said. “The right grain direction also allows the box to fold better, therefore increasing speeds and eliminating waste.”

        Added McCann: “Unfortunately, these are not things an operator can “fix.” These issues must be known and discussed in the initial production meeting. The same holds true for recycled board. There are some general guidelines that an experienced operator will know when dealing with this material, but the operator will have limited options once on press.”

        This is why having the production team involved from the start of a project is important, Koplin said. “They know what boards, stock, grain direction, etc. will help with the production of the product,” he said. “Virgin board always will run better and faster than recycled board, but this also can depend on the complexity of the carton to be produced. The type of machine and the experience of the operator will have a big influence on how the cartons will run. But, the main influences are the board used and the experience of the operator to overcome any problems that they run into during production.”

        Consider the board material

        Awareness of sustainability and recyclability factors is a must for book manufacturing customers and publishers, Senter said. “When selecting a board, most customers require FSC certification, COC (Chain of Custody) documentation and CPSIA (US Consumer Product Safety Improvement Act) certification,” he said. However, an eco-friendly label doesn’t necessarily equate to a higher production cost or level of difficulty. “Other than a small percentage of material that is virgin fiber, most board is made from recycled fiber. Eco-friendly inks and glues will work with recycled board and generally don’t carry a higher cost than non-eco-friendly materials.”

        Senter noted a few common mistakes to watch for when choosing the type of board. “Proper caliper of board should be taken into consideration based on the size and weight of book being produced,” he said. “Consideration should be given to the smoothness of the board. After being covered with a costly material, no one wants to be surprised with a surface that looks like an orange peel. For decoration, the board must be able to withstand and hold up to die designs. The board should work well with cover material, foil type and required detail of the die image.”

        The type of material obviously plays a key role in the entire converting process, McCann said. “There can be structural issues with a carton that must be taken into consideration. These issues may not effect production, but the end user performance of the product.” Knowing what finishing techniques will take place also is an important factor, he added. “Other issues to consider are making sure that a particular UV coating will be compatible for hot foil stamping later down the line or that a varnish will not crack if the job calls for embossing,” he said. “Again, these variables must be known and addressed prior to starting production in order to reach the highest profit margins.”

        Koplin suggested choosing the best quality board affordable to do foiling. “You would need a good coated stock so that the adhesive for the foil is not absorbed too much into the grain of the board, causing flaking or disfiguring of the foil,” he said.

        Understand outside factors

        Senter said factors that contribute to problems in production range from process control and environment to equipment specs being out of control. “Process control is necessary in delivering a quality product every time,” he said. “Most issues found are traced to conditions such as inconsistent glue application or fluctuations in relative humidity, temperature and moisture content of materials. Machine settings and calibration, along with craftsmanship, are keys to successful production.”

        Koplin said an experienced operator can overcome many, but not all, obstacles. “Weather can have a big influence on the board,” he said. “If it is humid and the board is damp, or if it is very dry and the board dries out, it will change the way the board reacts on the machine. A good operator plays a big role in overcoming these obstacles.”

        It isn’t uncommon for machine manufacturers to get calls about equipment problems when, in reality, the issue turns out to be a board issue or even a workflow issue. “Regardless of the process – printing, converting or finishing – today’s modern equipment is very sophisticated,” McCann said. “This means that the equipment sensors, lasers, encoders and more all are feeding information to the software running the machine. This software often requires an operator to set the parameters for that particular run. If a board weight or thickness is entered incorrectly, the machine automatically may set the speeds and feeds of certain operations at different rates, resulting in misfeeds or jams. Another example is if a color or varnish is not input properly, a camera registration system may inaccurately reject a product due to non-conformity when, in reality, the machine was given the wrong information to follow.” An understanding of all factors affecting carton and book productions can ensure a smoother process.

        PostPress would like to thank Rob McCann, Bobst North America; Kevin Koplin, American International Machinery; and David Senter, Eska Graphic Board, for their input on this article. Koplin’s European counterpart, Clive Robshaw, also contributed to this article. For more information, visit www.americanintl.com, www.bobst.com or www.eskagraphicboard.com.

        Preparing for Machine Installation

        March 25, 2015

        by John Kaverman, Pad Print Pros, LLC

        Recently, I’ve been in two different companies to install new equipment systems and to train their operators. Neither of the companies was prepared for either the installation or the training. Unfortunately, this happens all of the time.

        Many companies fail to adequately prepare to receive a new piece of equipment or schedule dedicated personnel and time for training. As a result, valuable training time is lost, and the training is not as successful as it otherwise could (and should) have been. There are simple things that can be done to help maximize installation and training time.

        Environment: The environment should be clean, organized and, ideally, climate-controlled and properly ventilated.

        At a minimum, the room or area where the machine will be installed should be cleared of clutter and swept. Paying me to come in to the plant and push a broom doesn’t make sense. As a “clean freak,” I don’t mind pushing a broom, and I certainly don’t think the task is below me. However, there are better uses of my time.

        Any process works best in a controlled environment. Even if the facility doesn’t have an air-conditioned space, the negative effects of variations in temperature and relative humidity can be minimized by keeping the machine out of thoroughfares (where dust and dirt are stirred up by constant traffic, and rubber-necking personnel cause distractions) and away from outside walls and areas where drafts are common (overhead doors, beneath heat ducts, etc.).

        Utilities: The correct power and, if necessary, compressed air need to be available.

        Even though my quotes specify the correct power requirements for the equipment being installed, many companies fail to ensure that the correct power is available until I show up. As a result, I lose half a day of training time running to the nearest Builder’s Square or Grainger store to pick up the correct plug or parts.

        Check with the equipment supplier to ensure the correct receptacle is on hand simply by taking a digital photo of the receptacle and messaging or emailing it to them. If the supplier ships without a plug installed (as some manufacturers do), coordinate ahead of time to ensure that the right plug is available to wire the machine in once it arrives.

        Tools: The correct wrenches, screwdrivers, screws, nuts, bolts, etc. should be available.

        If the installing technician is bringing his or her own tools, go out and buy whatever he or she uses while the technician is on site. That way, the installing technician can evaluate the tools on hand and point out anything that will be needed once the install is complete.

        People and Time: Dedicate the right personnel and adequate time for training.

        Too often it is unclear which personnel are supposed to be trained and when. If the facility is new to the process and/or has a manufacturer that provides training in its facility, it typically is a good idea to go to the manufacturer’s facility rather than having the technician visit for the initial training. This is true for two reasons.

        The manufacturer has all of the “stuff” necessary on hand. The tools, supplies and facilities are available to maximize training time. No time is lost running all over the shop or visiting the nearest hardware store to purchase the supplies mentioned in this article. The operators receiving training can focus on the instruction without being constantly distracted with the “normal” requirements of their jobs.

        Not everyone has to be included in training at the manufacturer’s facility. In any organization, someone has to be willing to accept responsibility for the success of the department. Someone has to “take ownership.” That person is the one who needs to attend training at the manufacturer’s facility.

        Maintenance personnel don’t need to visit the manufacturer for training unless complicated automation is being purchased. They can be trained in conjunction with the installation.

        If only in-house training is available, limit the number of people being trained to no more than four per shift. Beyond that, a trainer cannot adequately interface with the operators to give them enough one-on-one, hands-on time to become comfortable.

        If dedicated operators aren’t already in place, choose people who have exhibited the ability to follow directions and are conscientious. In initial training, personnel need to be able to focus and follow directions. Later, once they’ve gained enough machine time to become proficient, they may revise the trainer’s process to work within their own shop. That’s fine. I realize that my methodology isn’t right for everyone… and, as long as shop personnel can revise the process in a logical manner, document the revisions and teach someone else to perform them, revisions won’t result in bad habits that negatively impact efficiency and productivity.

        John Kaverman has a degree in printing technology and decades of experience in process, applications and pad printing systems engineering. He has written extensively for Plastics Decorating and other industry-related publications and organizations and has authored two books on the pad printing process. Kaverman is the head of Pad Print Pros and can be reached at 517.467.5340 or www.padprintpros.com.


        Installation and Training Checklist

        Maximize the effectiveness of machine installation and training with this checklist.

        Environment

        • __ Adequately sized
        • __ Clean
        • __ Organized
        • __ Ventilated

        Utilities

        • __ Power (voltage, phase, plug configuration)
        • __ Air (regulators, hoses, fittings)

        Tools

        • __ Allen/hex wrenches
        • __ Screwdrivers or drill
        • __ Pliers
        • __ Vice-grips

        People and Time

        • __ Initial training at manufacturer
        • __ In-house training
        • __ Ownership of the process/correct personnel
        • __ Dedicated time/distraction-free

        Sun Chemical Enhances Online Troubleshooting Guide

        January 13, 2015

        PostPress

        Sun Chemical, Parsippany, NJ, has further enhanced its online troubleshooting guide by making it available as an app for mobile devices.

        Designed to help customers resolve common technical defects that can arise during a press run, the troubleshooting app, available on Google Play and the Apple App Store, provides solutions to help customers solve any challenge they may be facing with their flexographic, sheetfed, paper packaging, gravure and/or energy curable printing issues. After choosing the printing process, the app uses both photos and defect terms to help the printer identify which technical problem they are facing. Then, they can read the solution provided by Sun Chemical to resolve their particular challenge.

        For more information on how the online troubleshooting guide works, visit Inktsa.sunchemical.com or download the app from Google Play or the Apple App Store.

         

        Level Platens Save Time, Money

        November 13, 2014

        While it typically takes about 30 minutes to level the platen on a Kluge press, far more than makeready time can be lost when pressure is uneven. Additional time preparing each job can affect a shop’s bottom line. So how do you know if it is time to re-level the platen? Ask yourself a few questions:

        • Does makeready seem to be taking longer than normal?
        • Are you spending more makeready time on one side of the platen rather than the other?

        Most press operators know this means it is time to level the platen on a Kluge press. In fact, many operators find it a good practice to do so every couple of years – or after jobs that require a lot of pressure. Brandtjen & Kluge, Inc., St. Croix Falls, WI, offers the following tips for re-leveling the platen on a Kluge press.

        Option #1

        1. Place four new bearer blocks on the corners of the honeycomb.
        2. Put masking tape on the platen where the tape will hit on impression using your 1/8″ diecut plate.
        3. Roll the press closed by hand and compare the pressure the blocks leave in the tape.
        4. Level the platen as needed until all four corners look the same in the tape.

        Option #2

        1. Lock four pieces of cutting rule in a chase – one across the top and bottom, as well as up and down on each side.
        2. Take any thin paper big enough for all four rules to hit and level the platen until it kiss cuts all four sides.

        Not only will leveling the platen cut makeready time, but it also will improve quality and make press runs more consistent.

        PostPress ENews would like to thank Brandtjen & Kluge, Inc., St. Croix Falls, WI, (www.kluge.biz) for their assistance with this article.

         

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