Printing, pre-press, publishing and photography services – yesterday, today and tomorrow

Contents:

1. DELIVERING HIGH-QUALITY GRAPHICS REQUIRES PROPER EQUIPMENT
2. WAYS TO IMPROVE
3. CONVERTING MANAGEMENT PRINCIPLES

There's a widespread trend toward increased graphics in the corrugated business. In the past the corrugated box was used to protect products during distribution. Today through the use of higher quality graphics, it is being used to sell the product.

This trend requires a new perspective in designing the package to fit the equipment capabilities, operating practices and the understanding in:

• The care of plates;
• Preparation and use of inks;
• Proper registration techniques;
• Viscosity control;
• Anilox roll care;
• Proper durometer of plates and wiper rolls;
• Substrate impact.
• Importance of good housekeeping at press;
• How to troubleshoot.

And the lists goes on. It requires a commitment throughout the organization and a creative attitude toward designing, selling and production techniques. There will be an increased emphasis on improved graphics and design to meet retailers' demands.

The Food Marketing Institute and Grocery Manufacturers of America is implementing a concept called "Direct Product Profitability," which measures the profitability of grocery items by including all of the variable costs of handling a product through the warehouse and store. It allows grocers to arrive at the product contribution, or DPP, of each product by looking at an item's gross margin dollars, plus discounts and allowances, less direct handling, selling and inventory holding costs.

Retailers want packages that are descriptive and eye catching. This is where graphics plays a vital role.

In the past, the corrugated box was synonymous with a heavy-duty shipping container. Spot and full labeling were the dominant methods for adding high-quality printing. E- and B-flute became the substrate for special printing on corrugated containers, as well as the recently introduced F-flute.

Other printing processes include: Preprint or roll to roll web printing on corrugated liner using photopolymer printing plates with reverse angle doctor blade ink metering systems; gravure preprint or web printing using etched metal cylinders and solvent-based inks, printing on solid bleached or clay-coated substrates; screen process printing or silkscreen printing; and metallic and fluorescent inks.

Flexographic direct printing on corrugated has taken off because of the new technology being developed for plates, presses, anilox rolls, and inks. Today, the printer is able to use plates with improved caliper uniformity, durometer, ink transfer, and durability; less distortion and cupping around the cylinder; and thinner plates. You will see more of the soft-backed or cushioned photopolymer printing plates in order to compensate for combined corrugated board, which has peaks and valleys for a printed surface.

Equipment manufacturers are also providing environmentally-controlled machines with enclosed printing units, dust collector systems and accelerated drying capabilities. They are developing improved feeding systems, registration systems, plate mounting systems, ink metering systems with both roll to roll and blade metering capabilities, and improved dimensional stability or sheet transfer capabilities.

Today, the anilox roll manufacturers are able to give the printer laser-engraved cells, allowing for more precision and finer screens and greater volumetric capacities. The shape and depth of the anilox cells can be tailored to suit the graphic needs or requirements of customers.

Inks, which often were purchased based on price and not on enhancement capabilities, are today being provided by ink companies with higher intensity, allowing the printer to carry a thinner ink film with greater color intensity while providing for improved drying capabilities.

Graphic designers are playing an even more intimate role in producing something that will catch the consumer's eye in the retail store. Success in graphics depends on commitment to:

• Improve graphic capabilities;
• Forming partnerships with suppliers;
• Establishing and enforcing in-house standards;
• Providing training and practicing for experience;
• Supporting cost increases for setups, materials, training, and practice.