Olivia Cahoon | DPS Magazine

To avoid an idle press, digital print providers are often on the lookout for print jobs that complement their existing services. Package design and prototyping is one consideration. There is great opportunity in this segment, especially for short or ultra-short runs. Demand is high and continues to grow as brand owners recognize the appeal of fresh new designs, which shorten sales cycles and require constant updates to packaging.

Above: According to Esko, WebCenter has packaging at its core. It understands all aspects of successful packaing—its shape, the importance of brand colors, and offers control of all necessary content.

Strong Demand
Gone are the days where a package with a static design can remain on a shelf for years on end without changing. Brands from every industry understand that packaging must be dynamic to generate attention.

“There is a growing trend toward shorter runs, due in part to the maturing market in digital print, which means more SKUs and therefore a greater demand for designs. Furthermore, brand owners are increasingly willing to invest in distinctive packaging design to add value to their brands and increase product sales,” says Chris Rogers, solution marketing manager, Esko.

With brands continually refreshing and reinventing designs to create new SKUs and looking for new ideas to stand out on the shelf, there is a growing need for package design and prototyping services. “They are very useful for a customer to test the market and to create products that perfectly suit users’ needs. Communication tests and market validations are easier to manage thanks to these unique tools that break down the barriers of traditional production,” explains Giuseppe Prioriello, founder/CEO, Packly.

Multiple parties including brand owners, marketing and/or creative agencies, print providers, and packaging converters play a role in this evolution. Benson Tung, product manager, Packmage Technology Co., explains that the increase of small-scale personalized consumption is commonly derived from small or entrepreneurial enterprises. These brands do not have their own packaging department. So, as it is an unfamiliar field to them, the service needs to be outsourced.

“Demand is driven mostly by the growth in local and boutique businesses that don’t have the packaging and design resources of larger consumer package goods,” agrees Ed Pierce, product marketing manager, Fujifilm North America Corporation, Graphic Systems Division. He also suggests influence from agencies looking for creative ways to take advantage of the new production abilities found on high-end production inkjet presses and digital embellishment assets.

In addition to brand owners under pressure to increase product versioning and marketing service providers or agencies looking to showcase their creativity, Sebastien Stabel, sales manager, carton packaging, EMEA, Xeikon, believes print providers wanting to meet just-in-time delivery requirements and add value by supporting clients in their desire to stand out are another piece of the puzzle.

Packaging converters are also part of the demand. “Packaging converters find these services critical to their client relationships and the implementation of digital printing is an enabling technology for prototyping and market testing. We see a cottage industry developing here, as experienced package designers fill the supply gap for services with digital print partners,” shares Rick Mazur, worldwide director, market development, packaging/labels, Eastman Kodak Company.

In-House Benefits
Initially, a service provider might want to only handle the design or printing—and not both. This is partly due to weariness over fully committing to a new venture as well as investing more time and money. While it’s a fair concern, avoiding outsourcing completely means bigger rewards in the long run for both the customer and the service provider.

For the customer, Tung explains the advantages. “In traditional business, packaging design and production are separate—customers first look for design companies, and after determining the design plan, customers look for production companies again. This increases the total cost. Integrating design and production into a comprehensive plan greatly improves efficiency and cost.”

Positives to bringing the entire service in house for the service provider include a decrease in time and cost as well. Specifically, turnaround time and especially if any rework is needed. “Increased quality and reduced rework is a large benefit to bringing this activity in house for prepress suppliers. The savvy prepress companies understand that taking control of this process reduces their production costs and turnaround downstream,” says Marc Welch, director of strategic accounts, GMG.

Control is essential. According to Brian Dollard, director, strategic planning and business development, commercial and industrial printing business group, Ricoh USA, Inc., in-house production makes both cost and quality transparent and controllable. Take for example conducting A/B testing to help optimize a company’s packaging approach. “If outsourced, the approach is cost prohibitive because it requires two separate jobs for the testing phase and then a third, larger job once a design is settled on.”

Design—and by extension, color—is well managed if kept in house. “By handling production in house the service provider not only provides the entire spectrum of services—design through end production—but can also design to the strengths of in-house production assets and own the output result,” shares Pierce.

“By offering packaging and prototyping services in house service providers ensure immediacy, responsiveness, improved communication, and streamlined technical processes. As a one-stop shop, the print provider is more tied and indispensable to its clients, which can benefit planning while also providing the customer with the reassurance of more accountability,” explains Nick Gilmore, CEO, Creative Edge Software.

It is important to foster a relationship with the customer. Indeed, if they are creating multiple versions, seasonal offers, and regular promotions, it is essential that a service provider understand and really get to know the customer, as they will be dealing with them on a regular basis.

“One of the biggest benefits is maintaining the relationship between the client and supplier. By managing the whole process internally you not only ensure the client has one point of contact, but you also get to know that client better and potentially even develop a mutual understanding,” comments Stabel.

Understanding Limits
Digital printing may be ideal for short- and ultra-short runs, but sometimes there are limits. It is important that service providers execute a cost analysis for each job prior to running it. Packaging and prototype design and production may be lucrative, but it can also offer margins for error that effect the bank account.

Dollard points out that while digitally printed packaging at short- and ultra-short runs is feasible, the finishing end of the process is important and requires additional resources. He advises that a printer conduct a careful return on investment analysis before taking on short-run work.

“When a compelling prototype is created, the typical response of the client is, ‘this looks great, I need a hundred of these for a marketing meeting next week.’ Suppliers are reluctant to tell a major client no. It is important for new prototyping suppliers to understand this and plan for it to happen—frequently. It is not uncommon for prototyping suppliers to produce hundreds and sometimes thousands of ‘prototypes.’ This blurs the lines of the definition of ultra-short runs,” adds Welch.

For this segment, the question becomes, what should the cut off be for short- or ultra-short run work? In Mazur’s experience, converters look at under 300 as ultra short and up to 5,000 as the cut off for short runs.

“In terms of production, there is no real cut off for handling ultra-short runs in house,” admits Prioriello. “However, there might be some bottleneck with the management of many short-run orders.”

When it isn’t feasible to handle an ultra-short run in house, production houses and design firms can collaborate to offer the best experience for the end user. An example would be when a short-run reorder needs to fill in a need for a longer run. To reprint a short-run length order on a conventional platform places enormous pressure on cost and profitability, according to Pierce.

Mazur says converters are building client-focused, cross-functional work teams with their design and trade shop partners to combine skills with structure design, substrate knowledge, data management, graphic, and digital production. The idea is to move projects efficiently through development, costing, and presentation to their clients.

With the constant reduction of turnaround times, effective collaboration is key. “Short runs often mean a job needs to be designed, approved, produced, and shipped in a matter of days rather than weeks. Therefore, efficient communication and project management is imperative,” explains Rogers.

“By installing the same systems for continuity and integrity of data, production houses and design firms can ensure they’re speaking the same language and there is no risk of design and specification misinterpretation,” shares Gilmore.

Supplementing Success
Tools that those looking to offer design and prototyping should consider include package design tools, production workflow tools, and on demand printing and cutting tools.

Self-service online packaging customization systems are helpful when it comes to improving efficiency, particularly in the communication between buyer and seller, according to Tung. These types of solutions should include a box type/material/process library, 3D virtual proofing, and automatic valuation functions.

“Primary customers have little knowledge of box type, need to know what the finished product looks like, and want to know the cost immediately,” explains Tung. The aforementioned tools address these challenges and without them efficiency is lost. “If the selection and pricing of each package requires professional structural engineers, the cost will be too high and it is difficult for service providers to even establish a team of structural engineers.”

New suppliers should find a way to include all of the following prototyping tasks, according to Welch, including structural, 3D software, prepress, cutting and scoring, laminating, finishing, and floor space. “Prototypes require folding, gluing, shrinking, and other complicated finishing operations. Most of this is done by hand and requires skilled labor to produce with the desired attention to detail,” he continues.

“For short-run productions, it is also necessary to have an effective digital printing and finishing plant. For instance, digital cutting tables or laser cutting tools are strongly suggested to deal with this type of production,” adds Prioriello.

“One of the biggest challenges and opportunities is in color management and building CMYK-based files from traditional flexographic/gravure files, ensuring the digital production can cost-effectively deliver projects and allow for production flexibility. Color management and software tools that automate job submission, preflight, job color match, and minimize job touches all contribute to streamlined production,” adds Mazur.

Packaging Welcomes Digital
Established in 1843, Zumbiel Digital’s—based in Hebron, KY—main service is paperboard packaging. Its 500,000 square foot space houses sheetfed lithography, web flexographic, and digital presses. A staff of 400 helps reach customers across Canada, Mexico, and the U.S.

In 2017 it added digital printing to its repertoire with the goal of minimizing the cost of producing folding cartons digitally. “We wanted to install a production digital line for large-volume, low-cost digital folding cartons. In doing so, we configured our digital press as a web-fed, continuous inkjet with inline die cutting and numerous analog flexographic print units for spot colors, overprint varnishes, and backside printing,” explains Ed Zumbiel, president, Zumbiel Digital.

It chose a Kodak Prosper 6000S as its introduction into digital. Several features enticed Zumbiel and his staff to pick this particular press. For example its speed—650 feet per minute in high-resolution mode, its web format, compatibility with coated paperboard, quality, achievable color gamut, economic ink cost, and 24.5-inch width.

Since the press was added primarily to satisfy high runs of folding cartons, Zumbiel Digital did not have prototyping services top of mind. However, once the Kodak Prosper 6000S was up and running, it was evident just how easy and economical shorter runs could be.

In response, its sales force started offering ultra-short run digital cartons to customers. These same customers were already utilizing Zumbiel Digital’s carton design services, so they were well suited for prototypes and sales samples. “Our equipment is ideal for ultra-short runs of a couple thousand cartons because we manufacture die tooling in house and stock most of the popular paperboards,” shares Zumbiel. He adds that its current cut off for handling ultra-short runs in house is 50 cartons.

Nestle Waters is a regular customer of Zumbiel Digital. It often requests small quantities of folding cartons with identical specifications to production cartons. Using the Kodak Prosper 6000S the output is a near match for the production cartons. For finishing, die cutting is generally used for small quantities, as it is more cost effective to build a die than cut prototypes on a plotter table, according to Zumbiel.

The machined samples perform exactly as the production cartons, particularly in terms of coefficient of friction and score bends. “This is ideal for new product launches involving automated carton filling equipment,” he continues.

Zumbiel Printing continues to experience success with its digital acquisition of the Kodak Prosper 6000S. The challenge, admits Zumbiel, is getting the word out about this new service.

Focus on Short Run
The Mid-York Press, Inc. is known for printing and producing folding cartons. In business since 1946, the Sherburne, NY-based company supplies products nationally to pharmaceutical, cosmetic, and food industries as well commercial printing services to local establishments.

In addition to several Heidelberg presses, the company works with an iGen 150 digital press from Xerox Corporation, which is equipped with an inline aqueous or UV coating unit. “A digital press is the number one tool for offering packaging design and prototyping. The Xerox iGen 150 delivers best-in-class packaging design and prototyping to our customers. With digital technology, we are able to speed customers’ time to market,” shares Thomas Revoir, digital packaging specialist, Mid-York Press.

Everything conducted digitally is considered short run at Mid-York Press. 5,000 sheets is the maximum for running through the machine, so it considers anything up to 10,000 cartons a short run. In Revoir’s opinion, some of the biggest demand for these short runs derives from boutique businesses with strong local roots.

“These companies are looking for local design and prototyping counterparts who can help them reach their specific delivery goals. The boutique businesses we’ve seen looking for these types of services include everything from specialty food companies and coffee shops to even distilleries and cosmetic companies,” he explains.

Attracting these types of companies to Mid-York Press is the business’ end-to-end capabilities. Offering packaging and prototyping services from design to production all in house is a huge allure to the end user because it saves the customer money, according to Revoir.

“By providing your customers with that cost savings you’re also giving them a competitive advantage and increasing the likelihood of their returning business. By decreasing the cost of production and the time it takes to produce it, we’re able to deliver true value to our customers,” he continues.

Extensive Opportunity
Packaging and prototype services are in demand for a number of reasons. Various interested parties from brand owners to print providers and even traditional packaging converters understand that dynamic packaging is here to stay. It extensively increases the need for design and production services for packaging and prototyping. dps

Oct2018, DPS Magazine

Design
Digital Print
Packaging
Prototypes

You’ve Got an Integrated Campaign

September 21, 2018September 21, 2018 by Olivia Cahoon

By Olivia Cahoon

Facing competition from electronic solutions, direct mail evolves by embracing new technologies like omni-channel marketing, augmented reality (AR), and reporting and analytics.

Print providers and direct mail houses are moving into the era of digital transformation by investing in new technology trends and leveraging the value of digital color printing.

Innovative mailers merge their experience in creating printed output that is physical and tactile with virtual solutions to ensure print remains relevant and desired.

Above: Kodak offers a range of digital printing solutions to support a variety of digitally printed applications, including direct mail.

The Mailing Evolution
Direct mail evolves as new innovations in print emerge such as the continued development of hardware including production inkjet technology, advancements in electrophotographic (EP) printing, and embellishment tools; software solutions like omni-channel communications, variable data, AR, and real-time reporting; as well as initiatives from the USPS. With this onset of technology, direct mail expands into new markets including luxury products, loyalty programs, and mag-a-logs.

Great strides in print quality, speed, and flexibility allow inkjet to complete more jobs for direct mail houses at faster speeds and lower costs, says Brian Dollard, director, strategic planning and business development, commercial & industrial printing business group, Ricoh USA, Inc. In fact, the savings inkjet provides is increasingly important.

“Postal costs continue to go up, cutting into mail’s margins. Direct mail houses need to seize on cost savings where they can to mitigate those rising costs,” adds Dollard. From his experience, customers in the direct mail space monitor rising postal costs and what it means for direct mail’s future.

Technology improves to make a variety of print types formerly associated with only high-end presses more accessible, such as full-color items. “Today’s inkjet presses are incredible at printing on a variety of media, giving marketers true creative flexibility along with operating costs they can afford,” comments Dollard.

Digital print technology’s impact also extends into the ability to utilize variable data for personalized direct mail. From a variety of sources, businesses can track and utilize information, says Susan Corwin, marketing manager, Rollem International. “Although these runs may be shorter compared to traditional mass mailings, they still require automation to be cost effective.”

According to Corwin, mail finishing equipment must not only operate at high-volume production speeds but since most materials are time sensitive, the equipment should be dependable and maintain uptimes of 99 percent with no room for downtime during the final phase of the production process. In addition, equipment changeovers should be easy to accommodate add-on features including card tip-ons, re-moist glue lines, BRM postcards, and perforations.

New Markets
Advancements in digital printing technology attract new verticals to the direct mail space, including luxury products and services. This segment is currently increasing the use of print for both acquisition and retention direct mail programs. “These high-end mailings are designed to support their brand individuality and may feature unique papers, soft-touch lamination, exquisite product photography, and booklets or mini catalogs that seem to be begging to be displayed on your coffee table. When done properly, the experience is like receiving a gift in your mailbox,” says Will Mansfield, worldwide product marketing & category management, enterprise inkjet systems, Eastman Kodak Company.

Loyalty programs take advantage of personalized printed direct mail as well. With these programs, retailers, financial institutions, and nonprofit groups collect and acquire massive amounts of customer data. According to Mansfield, personalized direct mail is on the rise with practically every firm that maintains a customer loyalty program as a means of customer retention.

Additionally, mag-a-logs, which blend educational and marketing materials into a single printed piece to create a mini magazine or multi-page flyer, are more common. “Think of it as a magazine, plus a catalog, plus a personalized direct mail offer,” explains Mansfield. By providing helpful, timely information in an attractive printed piece, he believes marketers learn they can deliver marketing messages more effectively. Mag-a-logs are also used for both retention and acquisition.

Digital print technology enables the creation of new programs and features from mailing delivery companies as well. For example, the USPS makes significant strides with the Informed Delivery program, which combines digital communications with a printed mail piece. According to Scott Eganhouse, VP, TEC Mailing Solutions, Informed Delivery is a free service that sends a daily email with a grayscale image of each mail piece coming that day for people enrolled in the service. Through a USPS portal, mail producers can swap out the grayscale image with a color image of the mail piece, including a call to action. “The open rate is 72.5 percent with a click through of 4.92 percent that compares to a 0.6 percent open rate for email campaigns,” says Eganhouse.

Traditional Mail
Common challenges faced by direct mailers focus on quality and time to market, whereas more modern challenges are complex and include data mining and capital investment.

Traditionally, direct mailers were concerned about pre-printed stocks, data quality, and quick turn jobs. While digital printing addressed pre-printed stocks, data quality and time to market are still challenges. Direct mailers also have to worry about getting the right content and targeting rules to make each piece as effective as can be, says Patrick Kehoe, EVP product management, Messagepoint.

“With digital printing, it is much easier to create champion/challenger models for each campaign and to extend A/B testing to multi-variant testing,” he continues. Additionally, it’s important that personalization tools are coordinated between the creative, production, and measurement teams, which Kehoe says can be challenging. When executed correctly, it allows a direct mailer to be a valued partner with the customer.

Tony Hodgson, head of marketing, locr, believes that in the past, a successful direct mail campaign was largely based on a company’s contact list and offer. “You created one generic message and sent it to as many qualified people as possible,” he explains.

Rising postage costs and other factors are eliminating the days of mass mailings. According to Hodgson, direct mail today needs to be more precisely targeted, personalized, and relevant to grab the attention of recipients.

While data analytics present an opportunity for direct mailers, it can also be a threat for those sitting on the sidelines. According to Eganhouse, data processing departments will go through a dramatic shift in how data is processed and consumed from on-premise software to cloud-based data analytics platforms that can prepare data for mailing. “Since data processing departments tend to be from the ‘this is the way we’ve always done it camp,’ it will take the right change agents in your organization to take the leap,” he explains. Organizations that have a native growth mindset and are adaptable to change will be rewarded.

Traditional challenges for direct mailers also include shorter runs. This remains today, but with greater intensity. “Today, the runs are becoming shorter due to the specificity of the audience receiving the mail piece,” explains Nick Gerovac, director of sales & marketing, VITS International. In the past, a direct mailer would print enough pieces to blanket a market with their message. Today, direct mailers print specifically for each individual recipient—reducing overall distribution.

According to Gerovac, other modern challenges faced today but not seen in traditional direct mailers include capital investment and data mining. To take advantage of specific direct mail pieces, he believes the printer needs to invest in new technology. This includes inkjet imaging to enable personalization or full digital presses to fully implement complete variability and message specialization. Additionally, Gerovac says data mining enables the ability to collect and interpret the data so that a relevant, targeted direct mail piece can be created.

Print Remains Relevant
As direct mail faces competition from electronic solutions, print remains relevant due to its tangible, value-added, and customizable features.

Unlike electronic solutions, print is a tangible product that requires physical handling. “Customers can leave a printed piece on their counter or desk, refer to it multiple times throughout a week, and show it to other people. The person becomes an ambassador for the product because of the printed piece,” comments Gerovac. On the other hand, digital advertising is temporary, and according to Gerovac, easily deleted or ignored. “Customers are inundated with electronic messaging leaving the customer feeling like they are barraged with spam.”

Corry Casler, executive director, PressWise by Smartsoft, believes marketers shouldn’t feel the need to choose between electronic solutions or print. “If marketers are clever in their direct mail piece design, for example using unique papers, tactile coatings, and providing meaningful content, they will enhance their campaign,” she comments. Furthermore, working with electronic and print solutions simultaneously reinforces the message and makes marketing efforts more active and attractive.

“Print remains not only one of the most relevant marketing mediums, but the most powerful,” says Chris Lien, president, BCC Software. According to the DMA, Lien says direct mail sees a 5.1 percent response rate for house lists and 2.9 percent for prospect lists, while all digital counterparts combined only have a two percent response rate. “Plus, print is tangible, personal, and secure—the USPS remains a highly trusted agency,” he adds.

Andrew Schipke, VP sales and marketing, W+D North America, agrees and notes the DMA and many other research organizations find that direct mail’s response rates are actually anywhere from ten to 30 times higher than that of digital. He says studies also show that consumers, overwhelmed by inboxes cluttered with unsolicited marketing emails, are more receptive to direct mail, which arrives on a much less clustered marketing channel.

Technology Trends Affect Direct Mail
Trends like AR, omni-channel marketing support, and analytics affect the direct mail segment of print.

While direct mail generally has a higher response rate than digital campaigns, it doesn’t mean that marketers who utilize direct mail are ignoring digital. In fact, it’s the exact opposite. “Omni-channel marketing is essential for effective campaigns, and you can’t have omni-channel marketing without print,” says Lien. Thanks to advancements in the industry, direct mail is now strategically tied to compliment digital messaging.

Industry trends allow omni-channel marketing to be compelling, generating high response rates. And, the USPS follows suite with Informed Visibility, says Lien. Similar to the previously mentioned Informed Delivery offering, USPS’ Informed Visibility is a mail tracking platform designed for mailers that provides essential data needed for strategically timed direct messaging by giving users enhanced insight into the delivery of their mail paces.

Scott Draeger, VP, Quadient, finds that the combination of multiple technology skills—AR, omni-channel marketing, and analytics—will ultimately create leaders in the market. He believes AR increases the direct mail piece’s lifespan and the way people show it to others—increasing outreach. Additionally, analytics show that the printed piece is the dominant performer in segments and omni-channel marketing adds extra value by making it easy to convert a print-based direct mail piece to a digital order. “When combined, the direct mail company that plays well with the emerging technologies will win a larger share of wallet from their client by becoming a communication vendor that happens to provide direct mail,” adds Draeger.

“Omni-channel, targeted data, and great analytics increase response rates significantly,” agrees John Barber, president, Summit Direct Mail. “By tying direct mail to the internet via marketing automation, our clients are increasing overall response rates and lowering their cost of acquisition of customers.” In fact, he says mail houses started embracing SMS text, email, ringless voicemail, and marketing automation to create multi-channel marketing campaigns.

Additionally, haptic marketing is now playing a large role in new direct mail developments for converting and finishing machinery. According to Schipke, the ability to add the sense of touch to direct mail changes direct mail marketing with more paper embossing and special UV coatings to enhance brand logos and how images feel. “Touch is much stronger than sight or smell and this is where we see shape-based envelope mail, embossing, as well as UV coating playing a strong role in direct mail as we move forward,” he explains. “Marketers are just beginning to realize the power of haptics for direct mail as this is not something that you can get with electronic communications.”

Direct Mail Houses Adapt
Today’s direct mail houses adapt to the era of digital transformation.

They do so by feeding personalized data in their mainframe while combining customization with graphically enriched files, allowing them to go white paper in and finished-product-out in one pass, even for complex and data intensive applications, says Dollard. He believes adoption for many letter houses includes recognizing the value of digital color printing and learning how to implement it into their work, while commercial printers embrace data-driven digital workflows. “That sort of cultural diffusion process has been going on for some 20 years.”

To embrace digital, direct mailers look at workflow. When direct mail is printed exclusively with offset, Mansfield says every piece off the press is identical, with addressing typically completed as a separate offline process. When a direct mail printer implements a production inkjet process—webfed, hybrid, or sheetfed—he says they must also invest in variable data authoring software, a RIP architecture that keeps pace with the press’ speed, and an inspection system to ensure the direct mail piece is received by the appropriate recipient.

Additionally, direct mail houses adapt to digital transformation by investing in modern finishing equipment. “If the printing company intends to offer direct mail documents that vary in page count based on the recipient, it may also be necessary to invest in one of the new breeds of finishing lines that dynamically adjust for this—dynamic perf/punch or variable page count booklet making,” comments Mansfield.

Other direct mail houses take a different approach to digital transformation and consolidate to perform the same work on a larger scale. “This is where print innovations can make some amazing applications at incredible speeds,” comments Draeger. In addition to consolidation, direct mail houses focus on one segment or communication type. This can be a horizontal application, like loyalty programs, or vertical, like automotive.

The A/B Test
Another way direct mail houses adapt is by using digital inkjet solutions to do more testing of what offers, messages, and designs work best for their list.

Before investing in large print volumes, designers and marketers conduct A/B testing. According to Maureen Brock, VP, Memjet, these tests involve running a small campaign that compares two versions of a direct mail campaign to see which version performs best.

“Inkjet printing solutions provide an ideal way to support these tests,” comments Brock. Designers are able to produce a small run test campaign to see how well it performs in the field. If it does well, they can produce the campaign at a higher volume on the same digital press.

Direct Mailers Advance
United Printing & Mailing is a direct mail provider that evolved with modern demands. Established in 1965, the print provider started in Phoenix, AZ with 12 employees.

From the start, the company focused on direct mail. It originally produced the majority of its work with litho-based technology. In 2004, the direct mailer saw a spike in digital printing needs and adapted by investing in the technology, says Ashley Jorgensen, marketing director, United Printing & Mailing.

Today, the company operates with 70 team members as a high-volume direct mail partner that specializes in servicing high-volume accounts and agencies. 100 percent of its work involves direct mail campaigns. Everything is printed and mailed in house with on-site USPS verification.

Over the last ten years, direct mail campaigns evolved immensely. “We have seen a massive spike in digital-based printing because consumers these days want personalized pieces addressed to them with offers and information that speak to their direct interests. Personalization goes a long way,” admits Jorgensen.

For all its digital needs, United Printing & Mailing uses a variety of presses including the Océ VarioPrint 6160 from Canon, Ricoh Pro C9100, and a Ricoh 8200 B&W press. “We love both of these brands and machine types because they are high-quality workhorses for an affordable price,” says Jorgensen.

In addition to digital printers, United Printing & Mailing uses targeted direct mail software from BCC Software. According to Jorgensen, the company chose this brand for its powerful expressions tool and ease of training. “BCC’s features and flexibility are amazing,” she adds.

According to Jorgensen the main benefit of offering digital mail campaigns with digital technology is personalization. “Today’s consumer craves personalization at almost every stage of the buyer’s journey. The limits and options are endless for the direct mail customer, it just requires creativity and to step outside the norm of today’s standard direct mail customization.”

Despite success with its direct mail campaigns, the company has seen slight decreases with direct mail competing against electronic solutions. But overall, the direct mailer experienced an increase in direct mail usage due to the influx of digital advertising. “People have adapted and learned how to ignore digital advertising while using their favorite websites, applications, etc. We have found that the most successful marketers pair direct mail with digital efforts and/or email campaigns. The tangibility of direct mail is unbeatable,” concludes Jorgensen.

Mail Away
Advancements in direct mail continue to expand in the printing industry as new trends like USPS’ Informed Delivery and Informed Visibility grant customers and direct mail houses more control.

Additionally trends like AR, omni-channel marketing support, and analytics help advance the direct mail segment of print, keeping it fresh and relevant. dps

Oct2018, DPS Magazine

Digital Print
Direct Mail

Quality and Consciousness

September 21, 2018September 21, 2018 by Olivia Cahoon

By Cassandra Balentine

Print is powerful. Photo-inspired printing products represent a great niche for companies that want to leverage the capabilities of digitally printed products. However, to avoid becoming a commodity provider that competes on price alone, many successful photo printing businesses offer unique, high-quality products that stand out from the competition.

Founded in 2012, Artifact Uprising is a Denver, CO-based lifestyle brand, which the company says is driven by the belief that everyone has a story. What better way to tell these tales than through photographs. It aims to honor the meaningful moments of life through printed, photo-based gifts and books. “With a focus on high quality and elevated design, we help make permanence of what matters most,” shares Melanie Robertz, product marketing, Artifact Uprising.

Starting as a basement operation, today a team of 40 employees work out of offices in downtown Denver. The company produces a variety of photo products including photobooks, wall art, prints, and photo-inspired gifts. The company’s heirloom-quality Layflat Photo Album and its Hardcover Photo Book are staples within its photobook line.

Design, marketing, customer service, engineering, and production expertise are performed in house, while also working with partners across the U.S. to help bring its products to life.

Above: Artifact Uprising utilizes digital printing equipment to produce its photographic output, primarily using production printing technology from HP Inc.

Positive Vibes Only
Artifact Uprising is heavily influenced by the environmental elements that go into its offerings. A very ecocentric company, these values drive its mission and products. It uses recycled paper as well as reclaimed wood.

“We care greatly about both the quality and environmental impact of the papers we offer,” shares Robertz. Because of this core business value, it intentionally selects paper composed of recycled fibers for the interior pages of its hardcover and softcover photobooks. The current paper selection is Mohawk Options Paper.

Robertz explains that from the start, Artifact Uprising recognized the narrative that could be rewritten in its own backyard, the story of mountain beetle pine. Finding beauty in reclaimed wood, it teamed up with a local woodworking company, Azure Furniture Company that manufactures furniture built from trees affected by mountain pine beetles in the Rocky Mountain Forest. Using pieces that would otherwise be discarded in furniture production, they are used to manufacture products like its Wood Calendar and Wood Block + Prints.

The wood features a uniquely grayish-blue color, which serves as reminder of new purpose in an otherwise storied past. “Occasionally you’ll find a storied spec of this paper’s past from the recycled fiber within—we see these as beauty marks of a better choice for the environment,” shares Robertz.

She describes these marks as reminders of individuality throughout every piece. Four years in, Robertz says it has helped support Azure Furniture Company in reclaiming 250,000 feet of fallen pine in the Rocky Mountain Forest. “And this is only the beginning.”

Production Quality
Artifact Uprising utilizes digital printing equipment to produce its photographic output, primarily using production printing technology from HP Inc.

“Our choice of production equipment is driven by what is best in the industry to accommodate our high-quality standards,” says Robertz. “Having been founded by professional photographers with an eye for color, it’s a combination of the materials we choose and our custom print profiles that make up that quality, so we select equipment that can give us the most flexibility while delivering the most consistent product at the same time.”

Turnaround times vary. To maintain its quality standards, production times differ between products. Photobooks generally range from three to eight business days, while prints and cards are about two to three business days, and wall art between two and five business days. Shipment times for orders begin after production.

Robertz says the biggest challenge with digital printing has been consistency, which is why it has several quality assurance check points throughout the production process to ensure products look their best. That said, the great thing about digital print is that it’s ever improving. “New solutions are developing every day to reduce those inconsistencies, and we’ll always strive to be early adopters of these methods.”

Binding
In terms of finishing, the photo printers tend to use flush mount materials. The Artifact Uprising’s website explains the process, noting that each page has a glue sheet inserted to make the page extra thick. The pages are secured around the spine and placed into the cover, which is then adhered to the outer side of the end sheets.

In its layflat photo albums, each page is approximately .04 inches thick. The minimum book is 20 pages and .625 inches in thickness. The maximum book is 70 pages and 1.625 inches in thickness. Because the photo paper has an easy sheet inserted to create a flush mount photo album, the pages are not measured in gsm.

Its softcover and hardcover book products use PUR binding due to its durability and compatibility with digitally printed output.

Mission Accomplished
Artifact Uprising offers unique products driven by its core values and intertwined with some of the newest technology and materials. Its story is one worth paying attention to, as it stands out in a competitive marketplace with high-quality, ecocentric products that make a lasting impression in homes, its community, and the environment. dps

Oct2018, DPS Magazine

Digital Print

Label Finishing Trends

January 8, 2019September 21, 2018 by Olivia Cahoon

By Cassandra Balentine

Labels represent a big opportunity for digital print technologies. The inherent benefits of digital print technology—cost-effective, short-run work and customization—are attractive to marketers looking for testing opportunities and startups that don’t need a large stock of labels at once.

Aside from the printing technology used to produce digital labels, finishing is essential to these applications. Inline, nearline, and offline—a variety of finishing options are available. Functions include, but are not limited to, lamination or varnish, foiling/embossing, cutting, and unwinding and rewinding.

There are benefits to both inline and offline solutions, but print engine manufacturers are incorporating more finishing functions inline.

Above: Dantex offers modular press solutions that can be upgraded in the field.

Recommended Finishing
Finishing functions required for digitally printed labels vary from UV varnish and lamination to hot stamping/cold foiling and corona treatment systems.

For Michael Panzeri, VP, D.P.R. Labeling LLC (DPR), necessary finishing comes back to what the end user is trying to accomplish. There are many questions that need to be answered. Do they need only one size label, or one size roll, or the ability to do many? Do they want the equipment to slit larger rolls down to smaller sizes? How will the rolls be used—hand applied or placed on an applicator? What quantity of labels is typically needed—will there be a lot of turnover with smaller volumes, or will larger rolls be needed?

The ability for label and packaging converters to differentiate themselves from the competition is important to the success of today’s digital printing environments. Tony Bell, sales director, A B Graphic International Ltd. (abg), notes that traditionally it was easier to do. “Digital print can mean more of a ‘me too’ situation where output from machine A is the same as machine B. Finishing and embellishment can make the difference and provides the opportunity to stand out,” says Bell.

Basic label converting requires unwinding, flexographic printing, die cutting, matrix stripping, slitting, and rewinding. In terms of embellishments, Bell believes it is more synonymous with beverage labels. “Converters need to consider offering lamination, screen printing, hot foil, and embossing for a high build, tactile feel.”

Embellishments—while not a requirement—are an attractive option. “Our experience in the market is that customers require a simple-to-operate system for both print and finishing. Embellishments are talked about, but in reality 90 percent of our Picocolour customers are running short-run jobs and die cut, slitting, and rewinding inline so that the rolls are ready to ship straight off the press,” shares Simon Cosh, business development manager, UK, Dantex Group.

Regulations also play a role, as multi-layer labels are necessary on some products due to legislation requirements. To produce these, converters need a delamination/relamination and crossover modules on their finishing line. “If more than three-ply labels are required, a specialist booklet machine is needed,” shares Bell.

“For users looking to protect labels from fingerprints, smudges, abrasion, and the outdoor elements, there are two options—lamination or UV/aqueous coating,” says Sabrina Reed, product solutions, Kompac. Each method has its own benefits and it’s important to consider the end application and use.

With lamination, Reed explains there is a thicker layer of protection, which is better suited for applications where the label will face moisture, heavy abrasion, and outdoor weather conditions. “A vast majority of labels don’t require such a robust finish, and coating is often used for those that have a shorter lifecycle, less handling, and for added visual appeal. It not only enhances the appearance and durability of the label, but can also be used to increase the product’s value.”

Reed says UV coatings provide a super glossy sheen after finishing, and are commonly used to add depth and make printed colors more vibrant. Aqueous coatings are water-based and provide a neutral semigloss finish to the label substrate.

Automation is recommended for digital label production. Laminators provide an opportunity to produce durable digital labels with added protection and other visual enhancements. “In addition to creating a gloss, matte, or textured finish, laminating films help protect against scratches/abrasions and fading caused by UV light,” says Brian Biegel, marketing communications specialist, D&K Group.

Finishing Configurations
Depending on the requirements of the print provider or converter, finishing needs vary. Inline, nearline, and offline configurations each offer advantages and disadvantages.

Mike Bacon, director of sales, Grafotronic Inc., says the type of finishing setup is always up for debate. “Traditional flexographic finishing units print and finish inline, so most print providers/converters feel like digital printing and finishing must be the same way. The issue is digital converting equipment is still a conventional form of finishing unless laser die cutting is used as part of the system.”

James Thomas, business development and marketing manager, Focus Label Machinery Ltd., lists a variety of benefits to inline finishing for label production, including shorter production and turnaround times, greater flexibility and modularity, blank reel to fully finished product capability, reduced footprint, single person operation, multi-skilled, and reduced power consumption.

Olaf Walter, president, mprint llc., adds faster throughput, reduced operator costs, and precise run length as benefits to inline finishing for label production.

For label finishing, print providers look for maximum flexibility. Matthias Marx, head of marketing, Gallus Group, says a majority of finishing is done after digital printing, but print providers should also have the ability to use certain functions in front of the digital printing unit. For example, users should be able to make use of the high opacity of screen printed white on transparent substrates before starting digital printing to reach the utmost print quality on the transparent substrate. He says the most common configuration is a digital-only printing machine followed by a separate converting line.

If a customer wants to finish inline, Bacon says they coach them on several factors. “Do you need to track your jobs through the plant? If yes, then inline keeps all of the jobs in order from printing to finishing. Do you utilize lean manufacturing practices? If the answer is yes, then inline should be considered. What does your plant floor look like? Is there enough room? Inline systems can be very long. Does the speed of your press and finishing solution match up? It is always better to have the finishing system perform at a higher speed than your digital printer. Do you want to reduce labor? If so, many customers utilize one operator for inline solutions. Do you run a lot of longer runs without many material or die changeovers, concentrating on a particular business sector? If so, inline works best.”

On the other hand, if a customer wants to finish offline, Bacon offers a similar checklist. “Do you have a lot of job changeovers for very short-run jobs—100 feet of material—where you are changing materials and dies? Do you want to funnel more work from other printing presses into your converting department? Do you need to hot stamp, screen print, or emboss on short-run jobs? If so, you may need the flexibility of offline because the changeover will be much greater for these conventional functions than the digital printer.”

Selecting inline or offline depends on the type of label and finishing you want, suggests Bell. For inline finishing he says using a buffer of 18 meters, enabling the print engine to synchronize without affecting the finishing unit, is great for minimizing set up times and increasing efficiencies by saving on expensive work in progress areas.

Bell points to two types of cutting available for inline finishing solutions, one uses a conventional die, suitable for cutting at very high speeds. “This is more suited to digitally printed jobs cutting the same shape,” he shares.

The other type makes use of laser cutting, which negates the need to wait for dies to be ordered and delivered, as well as the need for storage. Bell says the other advantage to laser cutting is the range of label shapes and sizes that can be cut.

Lamination systems are also available for nearly every type of label manufacturing process, suggests Biegel. “Inline lamination systems attach directly to the back of a digital printer for an automated finishing solution. This type of system reduces labor requirements, offers the most efficient label production, and helps minimize scrap rates. An inline laminator can also feed directly into a die cutting system for a fully automated process.”

Nearline lamination systems are also available with feeder options. A roll of printed label stock can be taken from the backend of a digital printer and placed onto a roll unwinder in front of the laminator. “The benefit of this system is that there is no bottleneck at the lamination station. Some digital printers can run faster than laminating systems and can cause a production backup in that area,” explains Biegel.

Offline lamination is another consideration. Biegel comments that a standalone laminating system allows for a great deal of flexibility. “If a laminator isn’t able to match print speeds, many organizations purchase multiple lamination systems to keep up with the output. It’s also possible to manufacture labels with different finishes or characteristics at the same time.”

Inline Advantages
Many digital label printing systems integrate finishing inline for an end to end label process.

Inline finishing allows for labels to be completed in a one step process, reducing waste, time, and labor costs, says Mike Barry, product marketing manager, Fujifilm North America, Graphic Systems Division.

Danny Mertens, corporate communications, manager, Xeikon, adds that inline finishing removes human touch points for streamlined job management. “Xeikon’s solutions run inline with Xeikon presses, ensuring production time is matched to achieve optimum productivity.”

Martin van Waeyenberge, marketing and sales manager, labels, Mouvent, adds shorter time to market as an advantage. “Most die cutting systems are semi-rotary modules and the die cut plates must be changed each time the shape changes. Alternatively, a laser die cut could be used but this is—due to the limited speed and the high purchase price—only valid for short-run, high value-added applications.”

Bacon agrees that laser die cutting is a good technology for very short-run, industrial, or pharmaceutical labels where multiple job changeovers on a single roll of material is required. “Laser die cutting is a great solution for inline or offline production, however, speed fluctuation from job to job needs to be considered. When considering inline production, you always want to make sure that the laser finisher can keep up with the slowest possible speed of the printing press.”

R. Keith Nagle, North East senior sales associate and digital product manager, Nilpeter, says the primary focus of digital label printing is to offer a unit to print the label and let someone else worry about finishing it. “The industry temporarily adapted because that is how it was offered, but quickly saw the shortcomings of a multi-step process. The advantages traditional flexography had over a previously predominate print process was that it was a one-step/one machine process. A fully printed, decorated, and die cut label came off the end of the press. This is the same benefit to a digital process with inline finishing. One step, one machine means a quicker turnaround with less scrap, fewer machines, and reduced overhead—all in all, more profit.”

Producing labels with inline finishing saves the user time and money by taking a multi-step process and completing it in a single pass. “Digital printing already eliminates downtime due to plate and ink color changes. By incorporating accurately planned job changing, downtime on an inline digital press can be almost eliminated. This time savings results in increased throughput on the equipment, more jobs run per shift, and faster return on the capital investment. Plus, only one operator is needed to run jobs from start to finish versus a separate operator for the printing press and each finishing machine,” says Katelyn Bohr, marketing manager, Colordyne Technologies.

Brian Cleary, North America category manger, Indigo Label Solutions, HP Inc., says the advantage of inline finishing is creating finished roll labels in one operation. The tradeoff is extending job setup time, which can diminish the key advantage of digital printing. “Dual Mode inline finishing gives HP Indigo customers the option to maximize productivity. If the converter is going to run 20 jobs in a shift on four different substrates using ten different die shapes, it is probably more efficient to print the jobs and set them aside for offline finishing. This maximizes printing time by minimizing setup time. If a converter is going to run four jobs in a shift, all on the same substrate and die cut, it may be more productive to have the press operator setup with inline finishing. Finishing flexibility is one of the keys to maximizing productivity.”

Finishing Trends
As digital label production continues to grow, finishing needs evolve.

Biegel sees a recent trend towards using thermal—or heat activated—laminating films in place of pressure sensitive—cold—laminating films on top of digitally printed labels. He says thermal laminating films do not contain a disposable release liner and generally cost at least a third less than pressure-sensitive films. These thermal laminating films offer comparable label performance at a reduced price and with less scrap. However, he points out that many standard laminating films are not compatible with new digital print technologies. “As new digital printer models enter the market, we can expect to see more specialty laminating films and adhesives designed for specific print engines,” he offers.

Several finishing options are coming to market. Bacon says hybrid is more popular, where there is a digital print engine integrated in with the traditional flexographic line. “As speeds of UV inkjet printing systems increase to over 200 feet per minute (fpm), the need to finish at those speeds with full rotary die cutting systems is becoming more popular.” This is ideal for longer runs with fewer job changes or variable printing.

Additionally, automatic slitting reduces operator intervention and setup time and reduces movement in the plant when considering lean manufacturing practices, shares Bacon.

Another trend involves the ability to add UV inkjet printheads to finishing lines for variable printing, sequential numbers, and barcodes. This allows a flexographic printed job with static information to be customized during the finishing process. Or have multiple UV inkjet colors to provide all types of printing embellishments, points out Bacon.

Manufacturers and print producers are always looking for new solutions to everyday problems. “With the ongoing changes to the digital label market space, customers demand more and manufacturers respond. Machines are getting smaller, quicker, and are streamlined for compatibility with printers of all shapes and sizes. The number of primers and coatings is increasing as new substrates and technology come on the market,” adds Reed.

Panzeri says as time progresses, so do technologies and customers. “Demands are changing, quantities are getting lower, and users are looking for higher levels of customization. In recent years technology in the print industry has been adapting and there is a better pairing between digital label printing and digital label finishing equipment—making it easier for seamless production—whether the user is looking to create ten or 10,000 labels.”

Finishing Devices
Many finishing providers target the label industry. As digital print continues to gain popularity, label finishing vendors adapt to meet new demands.

abg launches the Jetfx digital embellishment module at LabelExpo, which is an offline, fully digital system that creates varnish and foil effects. This adds to the company’s digital label portfolio, which includes its flagship Digicon Series 3, a digital finishing solution available in both inline and offline configurations. The company also offers an inline Digilase laser cutting finishing machine, which is an exclusive digital solution.

D&K manufactures a range of offline and inline laminating systems suitable for digital label production. It partners with printer manufacturers, including Xeikon, to configure inline laminating systems that work in tandem with digital print engines.

DPR offers digital finishing systems suitable for all levels of production—from entry-level users looking to cut small quantity sheet labels up to full roll-to-roll production level for converters and commercial printers. Its finishing lineup includes the Gemini digital die cutter; Virgo cutting and finishing for label rolls from 4.3 to 8.86 inches; Scorpio roll-to-roll digital finishing system that includes cutting, lamination, matrix removal, and slitting; and Taurus label finishing system, including laminator, waste matrix removal, and slitting and rewinding preprinted labels for larger production printers.

Grafotronic offers entry-level SCF, mid-level VF2, and fully modular DCL2 digital finishing equipment with full rotary or semi-rotary capabilities. The company also offers the slitter rewinder SR2 and HI2 inspection units for label production. Its mid-level and fully modular systems can run inline, offline, or nearline. All Grafotronic machines include flexographic varnish, lamination, die cutting, slitting, and rewinding. Grafotronic demonstrates its GigaFast, 525 fpm, semi-rotary die cutting system at LabelExpo.

Kompac offers UV/aqueous coating solutions that can be used both inline and offline for sheets and web, compatible with most digital, inkjet, offset, and flexographic printers on the market.

Inline Functions
A variety of digital label systems offer inline finishing functions. Here we highlight some of these systems.

Colordyne offers a range of solutions with different finishing options. The 1600 Series bench top unit can utilize pre die-cut material, while the Commercial Class and Production Class solutions have inline and offline finishing available. The company’s newest Commercial Class solution, the Colordyne 2800 Series Mini Laser Pro, offers inline printing, laminating, laser die cutting, and matrix removal. Further, Colordyne’s Production Class—or 3600 Series—offers two retrofit engines and custom inline finishing solutions. The retrofits are digital print engines that can be mounted into a new or existing flexographic press, which allows the press to become a digital hybrid work center.

Dantex provides modular, upgradable press solutions. The company offers two digital press solutions that can be configured with or without finishing. The mid-range Picocolour press prints up to 35 meters per minute. Online full rotary die cutting allows the press to run at full speed. The Picocolour has additional finishing options such as digital varnish and inline lamination.

The Epson SurePress L-6034UV UV digital label press offers digital varnish ink—a gloss or matte finish that can be selected for the overall label, and partial accents can be added using glossy or matte spot finish. The digital varnish enables users to save time and cost by applying matte, gloss, and even a combination of both in patterned or selective spot varnish effects.

Focus Label Machinery Ltd. designs and builds inline capabilities such as rotary die stations, die adaptors, de lam/re lam, cold foil, peel and reveal, sheeting/stacking station, slitting, and roll to roll or roll to sheet. The company also partners with Stork for Rotary Screen inline, LundbergTech for matrix/edge trim removal, and tooling supplied by Rotometrics.

Fujifilm offers options for inline rotary and semi-rotary die cutting, slitting, laminating, foiling, and more.

The Gallus Labelfire 340 is a hybrid digital press featuring an end-to-end logical operating concept that integrates digital printing with conventional printing and further processing. Labels are produced inline in a single production operation—from the unprinted roll and die cut and matrix-stripped end product. The conventional modules support the use of primer, spot color, security, or cold foil features; varnish; or lamination without interrupting production—regardless of the complexity of the label. The latest innovation from Gallus is a digital embellishment unit, which can produce gloss and matte spot coatings and tactile relief effects in a single pass, all using atmospheric UV inkjet coatings.

At LabelExpo, HP showcased the HP Indigo 6900 running inline with HP Indigo GEM, a digital label embellishment machine. Also, the HP Indigo 8000 will run dual mode inline finishing with the abg Digicon Series 3.

Mouvent’s LB-701-UV features an optional module for die cutting and slitting. Mouvent is part of the Bobst group, which affords them the experience from one of its companies—Bobst Firenze, having an extended offering in the label market from printing to finishing.

mprint offers a variety of finishing functions inline to its digital label printers, including rotary, semi-rotary die cutting, and laminating. While the systems are integrated entirely by mprint, they partner with Kocher + Beck for tooling.

Nilpeter provides a flexible digital platform. Of three base configurations, two offer inline finishing with unlimited configurations to support the business needs. Inline, Nilpeter is able to incorporate the typical value-adding embellishments that flexography offers.

Xeikon features a number of finishing solutions designed to work inline and nearline with its broad digital press portfolio.

The Xeikon Dcoat post press unit is available in a range of widths from nearly 13 inches up to approximately 20 inches. Standard features include flood UV varnishing, lamination, semi-rotary die cutting, length slitting, and a dual spindle rewinder. They can be installed inline or offline to a range of presses from the Xeikon CX3 and Xeikon CX500 to the entry level Xeikon 3030.

Another offering is the Xeikon miniDcoat unit, which includes an optional laser die cut unit. It is 100 percent integrated by the Xeikon Vectorizor that generates the die cut profile.

The company also offers additional auxiliary equipment from Aura Partners to enhance the standard solution, allowing customers to further customize set up.

Finishing Labels
Digital label production is heating up. A variety of both printing and finishing solutions target this segment.

“Overall, the message is to understand what exactly you need to achieve for maximum return on investment in the whole production process,” shares Cosh.

Depending on your specific needs, printing and finishing configurations are available. Additionally, embellishments bring added value to those looking to reach high-end markets. dps

Oct2018, DPS Magazine

Digital Print
Embellishments
Finishing
Labels

Media Perspective on Production Inkjet

September 21, 2018September 21, 2018 by Olivia Cahoon

By Cassandra Balentine

Media selection plays a crucial role in the quality and performance of production inkjet. Several considerations affect the paper selection process, including how the media is treated or coated and what ink sets run on the device.

Above: Zanders offers its coated Zanjet Gloss & Silk product.

“What’s often overlooked is paper’s critical role in bringing many of the benefits of production inkjet to full fruition. Paper compatibility is often cited as the top challenge when deploying inkjet production—most of this is due to lack of investigation and testing of various paper options,” explains Ashley Maydak, brand marketing manager, Domtar. “From ensuring a consistent output to maintaining a desired production speed, selecting a paper that’s engineered for high-speed inkjet printing and a good fit for your project, priority, and budget, can make all the difference when it comes to preventing delays and disappointments.”

Tanya Pipo, director, digital sales, Verso Corporation, suggests that inkjet media compatibility is segmented and more complex than most commercial print providers are used to managing. “While a universal plug-and-play media solution is desirable, the reality is that production inkjet press technology and ink sets vary widely by the original equipment manufacturer (OEM). The variation in technology and ink sets makes providing a universal media solution challenging, especially for coated paper compatibility.”

Amy Ambos, inkjet sales manager, North America, Zanders GmbH, adds that print providers should develop a business plan that includes understanding long-term paper requirements. Preferred product should then be tested with the OEMs to confirm performance—including acceptable speeds, ink usage, and achievable densities. Paper price and availability should also be measured against performance to understand total return on investment. The final step is determining how the product performs through the finishing process.

In terms of the considerations, Scott Harman, director, digital, Appvion, suggests print providers consider print quality, runnability, and availability when reviewing substrates for production inkjet.

Application Consideration
Prior to investing in production inkjet, print providers should identify what applications they will be producing.

When working with a paper manufacturer or distributor to determine media compatibility, it is essential to provide the specific OEM press model as well as the ink set used and any plans for media pretreatment. “The paper team uses that information to discern which papers will help the printer be most successful. Inkjet media solutions are frequently specific to equipment models, ink sets, and pretreatment, so the most complete information is helpful,” says Pipo.

The ink set—dye or pigment—plays an important role in selecting the appropriate substrate. The type of ink selected should be based on the applications generally run on the press.

Not all papers work with both ink sets, however some do. “It is always best to speak with printer and paper manufacturers prior to deciding on an ink set. Both providers offer unique perspective and typically provide lists of papers that are certified on specific presses and ink sets,” adds Dorothy Fulton, manager, sales support, Mitsubishi Imaging.

Pipo says the type of press and ink set to invest in is an important conversation between client and OEM that happens in early discussions of deciding which platform best fits the business. “Among the factors for consideration will be the type of business applications the printer serves, expected quality levels, durability, and mailing and finishing considerations.

“Dye-based inks are best suited for short lived, color vibrant work—applications such as direct mail, transactional, and newsletters, which are often read and then discarded,” says Fulton. Dye-based inks contain various optical compounds that increase color brilliance and saturation and capture fine line detail. They can however fade or shift in color after long exposure to direct sunlight and smudging is a possibility when exposed to excessive moisture or humidity.

Pigment inks offer better color stability and longevity because of the way they bond to the paper. “Although pigment inks tend to resist water and UV light better, they are more expensive and lack the color range that can be achieved with dye-based ink systems,” says Fulton.

“Chose the ink set that allows you to achieve the quality and performance acceptable to your clients. Acceptable print quality is achievable using all ink sets, however, results per substrate will vary,” shares Ambos.

Primers and Coated Stocks
Inkjet media is available as coated, uncoated, and treated. Primers and treatments are designed to provide a uniform surface and can be added to uncoated paper inline to improve media performance. Coated media options are specifically designed for inkjet production for optimal performance.

Fulton says papers specifically designed for high-speed production inkjet equipment will sometimes include special coatings that trap ink before it can penetrate the fibers of the paper. “These coated inkjet papers provide the benefit of lower ink consumption and faster dry times, enabling jobs to move directly to inline finishing. Although these papers can be more expensive than standard offset papers, the price differential is less than the associated cost savings gained through efficiencies—quicker production speeds and lowered ink consumption. However, new trends are emerging and expanding media options for high-speed presses.”

Alternatively, inline primer treatments pre-coat paper before the printing begins. Fulton says the primer creates a uniform print surface to uncoated paper, slows ink penetration, and helps to create “better” color and quality than if not applied. She says there are costs associated with this method, and production speed is affected as there is another step in the process.

Primerless inks are also emerging. “They allow printing on diverse media types without pretreatment. Benefits include an expanded color gamut, reduced dot wicking, and flat sheets on exit,” says Fulton. “The high viscosity inks do slow down jet speeds, take longer to cure, and can crack on folding if not properly scored. Additionally, a pretreatment is needed for any pot coating application.”

While there are several options to choose from, Fulton says it is important to keep in mind that offset papers are optimized for offset printing, a transfer system using high viscoelastic inks; and inkjet papers are optimized for inkjet printing a direct discharge system using lower viscous inks. “Papers specifically engineered for a process typically perform better. Even as systems continue to develop, it is most likely that offset papers suitable for inkjet printing will continue to be narrow in range if optimized resolution and maximized production speeds remain driving factors,” offers Fulton.

Quality Considerations
All of the factors that go into choosing a media affect the quality that comes off press. Depending on the application, quality demands may differ drastically.

Maydak says it’s true that paper plays a critical role in the image quality and color reproduction of a print job. She says that while OEMs are constantly improving printing technologies and inks to achieve the vivid color and crisp imagery demanded by the market, paper manufacturers work alongside them to ensure they perform well.

A key takeaway for print providers is maximizing resources available from their OEM, paper partner, coating, and finishing support teams.

Media Highlights
A variety of paper manufacturers and suppliers offer products recommended for production inkjet. Here we profile a few of the selections. Visit the Target Chart for a more comprehensive look at available media selections.

Appvion offers both coated and treated media options for production inkjet. Harman says the company works closely with OEMs for constant testing and trials.

Domtar provides a variety of inkjet papers to meet the needs of various print markets.

The company has a team of inkjet industry professionals that work with the OEMs to engineer and qualify paper. Maydak says the team also works with the OEM and customer during the onboarding process of a new install to recommend and test various Domtar papers until a proper solution is discovered. “We like to test not only on OEM inkjet hardware, but also on feeding and finishing equipment to ensure folding and inserting are efficient. If a problem does arise, we collaboratively work with the customer and OEM to resolve the issue and get the customer back to full production.”

Mitsubishi Paper Mills (MPM) manufactures coated inkjet papers in a range of basis weights and surfaces, including high gloss, gloss, and satin for both dye and pigment ink systems. The paper manufacturer offers five distinct lines in its portfolio. SWORD iJET is a premium line of inkjet coated papers in high gloss, gloss, satin, or matte that is suitable for a variety of applications including direct mail. Premier IJ Form and Premier IJ book are a bright white, lightweight matte coated grade of papers suitable for a range of publishing applications. Value IJ is a lightly coated matte paper typically used for transactional and transpromotional work. JETSCRIPT is a premium coated matte paper for high-resolution graphics.

The U.S. sales subsidiary for MPM works closely with its OEM partners in the Americas to test and evaluate papers and pre-certify them if applicable. “We typically send sample rolls and/or sheets for these purposes and in return we get a test report/performance checklist and imaged samples, which we then send back to MPM for review. Through the mill’s R&D and extensive coating assets, modifications or fine tuning can be achieved to improve compatibility of existing grades, or develop new ones. Often, these modified or in-development grades are used for proof of concept by the OEMs targeting new market applications for their hardware and our papers. It’s a mutually beneficial relationship,” shares Fulton.

Verso produces coated inkjet papers that enable offset-like quality on production color inkjet presses without any pretreatment or bonding agent. Sterling Ultra TrueJet comes in gloss and matte finish, and is designed to meet the needs of commercial printers. The patented offering provides a range of text and cover weights including a 7 pt. gloss and 9 pt. matte product for direct mail applications. TrueJet Book is designed for high-speed, book publication print runs. It features a specially designed patented matte coating, which enables full-color variable inkjet printing to meet the needs of the book publishing market. Both Sterling Ultra TrueJet and TrueJet Book are optimized for performance on HP PageWide and Kodak Prosper Presses.

Additionally, Verso manufactures coated web offset papers, folio sheet papers, as well as media for electrophotographic equipment.

The Verso Digital team maintains relationships with OEMs to create successful solutions for the mutual customer base.

As a U.S. paper manufacturer committed to producing high-quality coated papers for digital printing for over two decades, Verso has a knowledgeable digital team well equipped to answer media compatibility questions across the gamut of OEM inkjet presses.

Zanders offers its coated Zanjet Gloss & Silk product. Zanjet is qualified with pigment inks on the HP PageWide and Kodak Prosper and dye inks on the Screen TruePress Jet520ZZ and NX.

Zanders’ products are thoroughly tested by the OEMs during the qualification process to determine optimal profiles, speeds, and drying. Profiles in many cases are shared by the OEM.

Media Perspective
Print providers offering production inkjet must have knowledge of the nuances of media compatibility. Depending on the application, factors like ink set, primers, and coatings are important considerations. One thing is certain, media manufacturers are committed to ensuring success throughout the process.

OEM advancements play a big role in media compatibility. We tackle that subject in OEM Perspective on Production Inkjet Media, which appears in the next issue. dps

Oct2018, DPS Magazine

Digital Print
Inkjet
Media

Preparing for Print 18

September 21, 2018September 21, 2018 by Olivia Cahoon

By DPS Staff

The Print 18 industry event is right around the corner. Taking place from September 30 to October 2, 2018 in Chicago, IL, it features an expansive show floor for exhibitors, along with a range of educational sessions presented in a variety of formats. Print 18 is hosted by the Association for Print Technologies—formerly NPES, an organization dedicated to supporting the entire commercial printing value chain.

New to Print 18 are special exhibit floor guided tours led by teams of industry experts. These tours follow topic-specific programs in the Exhibit Hall Learning Experience Theater and run each day.

To help plan your time at the show—or inform you of what you may miss—here is a selection of vendor highlights. Check out the September issue for more, or visit us online at dpsmagazine.com. For an audio preview of Print 18, listen to our podcasts—featuring several Q&As with exhibitors about their show plans.

Above: Eagle Systems displays its 40-inch cold foil unit in booth 1142.

Absolute Printing Equipment Service, Inc., booth 1411, showcases the full line of KAMA Finishing Equipment including Die Cutter, Folder/Gluers, and Cliché Positioning Equipment as well as a Baumann/Perfecta Cutting System including D2F and S2C makereadies.

AccuraMIS, booth 349, invites attendees to learn about the new features of v.5.30. These include user-interface updates, custom tab configurations, batch account-status changes, batch web enable/disable clients, commission plans, sending holiday messages, contact-office ownership, quote collection, automated web signups, EasyPost carrier integration, CRM multi-view calendar, appointment reminders, and SMS broadcasting.

Artifex, booth 547, unveils next-generation embeddable PDL and scan technologies. Based on 25 years of PDF, PostScript, and PCL expertise, the new solutions provide performance enhancements for the embedded printer and scan markets. The result is a faster, smarter, leaner print engine. In addition to this cutting-edge product, discover what’s new in the latest releases of Ghostscript and MuPDF.

Avanti, booth 640, demonstrates developments and enhancements to its JDF-certified Avanti Slingshot Print MIS, including recent integrations with BCC Software Mail Manager, HP PrintOS Jobs, XMPie StoreFlow, and Enfocus Switch 2018. The company also showcases the latest add ons to Avanti Slingshot including mobile fulfillment, automated fulfillment, and contract management.

BDT Print Media, booth 4216, displays the convenience of simplicity with the reliability of its patented Tornado Technology. Together with its partners, BDT products are found further enhancing various applications on Canon’s imagePRESS C10000VP Digital Color Press Series; Kodak’s NexPress and NEXFINITY; and Rhin-O-Tuff, with the world’s first collating offline autopunch—the Tornado Autopunch EX. This year, BDT demonstrates its SIS Feeder.

Brandtjen & Kluge, booth 1603, demonstrates high-quality finishing equipment, showcasing new advancements in die cutting, foil stamping, digital foil transfer, and folding and gluing. The company was recently acquired by Mark Andy.

Cooper Enterprises, Inc., booth 3049, features end boards for web-fed printers. Produced from 60-pound high density fiberboard (HDF), the company’s custom end boards are optimally sized, unbreakable, and splinter-free. The durable end boards feature bull-nosed edges to prevent strap material failure.

Colter & Peterson, booth 1607, features a pair of new and dynamic paper cutters as well as the new PRISM jogging unit.

Crawford Technologies, booth 541, features its software solutions. Highlighted products include PRO Conductor, a solution that orchestrates every step of an end-to-end workflow; PRO Inkjet Express, which allows print and mailing service providers to easily implement automated workflows for inkjet presses and quality assurance in the cloud; and a powerful solution that automates document testing and manages continuous regression testing with on premises or secure cloud licensing options.

D&K, booth 2852, showcases its lamination systems at Print 18, including the two-sided Double Kote Junior and the new single-sided AutoKote Pro. These systems are fully automated with sheet feeders, lamination stations, and automatic cutters/separators to reduce labor costs while increasing output. D&K lamination systems and the accompanying thermal and pressure-sensitive film supplies are manufactured in the U.S.

DirectMail2.0, booth 1246, releases new and upgraded features of its cloud-based integrated marketing platform for printers and mailers. Visit the booth for demonstrations of Informed Delivery with the USPS, upgraded mail tracking features, and new call tracking features.

Eagle Systems, booth 1142, highlights its cold foil solution, the Eco-Eagle. The company’s machines are fully automatic—requiring no operator programming, and compatible with new or existing sheetfed offset presses. Visit the booth for samples of cold foil on uncoated and FoilCURE. Eagle provides cold foil certification, foiling on uncoated stock, and now FoilCure.

EMT International, booth 3811, showcases the Chameleon RFX series roll-to-sheet finishing line. The EMT International finishing line features dynamic cross web scoring for digital or conventional applications. The Chameleon RF Cross Web Scoring Module is the latest technology offered within the EMT finishing portfolio. The company features live demonstrations of its second generation Chameleon RFX Dual Head Chip-Cutting and Stacking finishing line configuration.

Harris & Bruno International (H&B), booth 3047, is a global provider of high-performance printing and coating equipment. At Print 18, the company displays the ExcelCoat series of offline/inline coaters for UV and aqueous. Fully-automated ExcelCoat sheet coaters include the ZR flood coater, as well as the ZRS spot coater, which utilizes a sophisticated optical registration system. For web, H&B features the simplex/duplex ExcelCoat Web Coater, which can be fully integrated for inline priming or over-print varnish.

HP Inc., booth 2411, is pioneering digital print technologies by creating products to allow visionaries—both businesses and creatives—to reinvent the possibilities of print and transform their business through the #WonderOfPrint. At Print 18, the company showcases ground-breaking technologies and the customers and creatives who harness HP digital press technologies and innovations to help print providers learn how to outshine competition and increase business profitability.

ImPress Systems, booth 224, designs and manufactures digital foil printers at its facility in Chelmsford, MA. The company’s printers are desktop, digital foil printing solutions that eliminate the need for printing tools. These versatile, on demand printers are used to print foil on a range of applications including invitations, greeting cards, envelopes, and other stationery products—as well as journals, calendars, and writing instruments. They are Windows compatible, so printing graphics, text, and variable data is quick and easy. Visitors to the booth find demonstrations of Foil Xpress and new Foil Direct printers.

Konica Minolta, booth 1611, features innovative solutions designed specifically for your business. Visit the booth for demonstrations of production printing, label printing, wide format printing, and decorative finishing and embellishing products.

Magnum Magnetics, booth 413, highlights its printable magnetic sheeting and magnetic rolls, magnetic strip, and extruded magnet products. The company’s flexible magnets are made in the U.S. and can be seen all over the world.

MyOrderDesk and Printer’s Plan, booth 347, showcase two industry leaders under one roof. In March, PagePath Technologies acquired Printer’s Plan, an estimating, job management, and billing system. PagePath features new additions to both products, including the connections that allow an ultra-easy-to-use website to pull out pricing and send back job data. PagePath, with its front-to-back solution, has served thousands of small and medium printers.

Nobelus, booth 1225, educates attendees on new ways to increase profits in print by providing more to existing clients. Attract new clients by offering the latest in print finishing technology. The company showcases two new holographic films for the print and packaging market. In addition to this, it demonstrates sleeking and layering techniques on a Komfi Amiga 52.

PressWise by SmartSoft, booth 549, has kept busy in 2018 responding to input that was received from customers. New developments by the company include enhancing the user interface to make information easier to find and use on a day-to-day basis, updating reports, expanding finishing calculations, and simplifying the setup process are just some of the changes. The company also added new artwork validation checks and is unveiling a new reporting platform and dashboard tool to improve data visibility.

Quadient, booth 246, showcases its leading customer communications management and data quality solutions. On display are Quadient Inspire, which enables the quick and easy repurposing of existing print-based content into high-impact digital communications; Quadient Ignite data quality software that reduces data processing time by up to 99 percent and increases mail processing capacity by more than 40 percent; and Quadient’s Data Services, which allows service providers to optimize customer data by making it actual, complete, correct, and unique.

Quantum Roll Sheeters, booth 3052, unveils full details of its newest product, the Roll Sheeter LS. The LS model roll sheeter is the industry’s first inline integrated dual roll sheeter lap splicer combination system, bringing together the benefits of a traditional roll sheeter with the continuous feed operation made possible by a lap splicer. With dual rolls and integrated lap splicer technology, the LS model’s 24/7 continuous run capabilities make production yields of up to ten milimeters more sheets per press per year possible, offering the potential for return on investment in just six to 12 months.

RISO, booth 3611, features RISO’s ComColor GD series of inkjet printers—the fifth generation of compact, durable, high-speed, high-volume print engines, delivering full-color cutsheet output at speeds of up to 160 pages per minute. RISO inkjets are affordable to own, inexpensive to run, reliable, and “green.” See the full line of RISO inkjets in action on the show floor.

Screen Americas, booth 1136B, highlights its extensive portfolio of high-speed inkjet equipment, label and packaging solutions, as well as prepress and workflow products.

Standard Finishing Systems, booth 1629, showcases a comprehensive lineup of feeding and finishing solutions set up for live demonstrations in die-cutting, perfect binding, folding, and saddlestitching. Highlights include the Horizon BQ-480 Perfect Binder, which raises the bar in variable book production; the StitchLiner Mark III Saddlestitcher, which delivers higher quality booklets in a wider range of sizes; and Hunkeler’s Generation 8, designed for the unique requirements of digital commercial printing.

Tecnau, booth 3529, highlights its flexible finishing systems, which support a broad set of applications in digital printing, developed in close cooperation with leading digital press vendors. Stop by its booth to see the unveiling of a new high-speed cut/stack system.

VITS International, booth 1800, displays some of the latest technology in high-speed finishing for the digital and inkjet market.

Xerox, booth 1621, showcases an array of digital color production print devices, including the new Xerox Iridesse Production Press, the Xerox iGen 5 Press, the Xerox Versant 3100 Press, and the Xerox Brenva HD Production Inkjet Press. Additionally, the company features a variety of workflow solutions and business development resources. XMPie, a Xerox Company highlights solutions that deliver personalized cross-media communications and web to print portals.

Meet at Print
We hope you find this compilation of vendor information useful. Find more Print 18 content in our new podcasts, featuring Q&As with exhibitors like Duplo, HP, PressWise, and more. Please visit us on the show floor, booth 4042. dps

Oct2018, DPS Magazine

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