by Cassandra Balentine
One great step towards automating and being more competitive is to implement software for production data analytics. “Collecting data forces the implementation of automated processes that can collect the data properly without requiring human input,” shares Carlos Martins, head solutions management, Muller Martini North America.
When used to consolidate data, Tom Peire, founder/CEO, Four Pees and chief evangelist, Atomyx, says automation can do far more than simply improving productivity and boosting the profitability of individual jobs. “It can make it easier to spot the points in their workflow that would benefit from improvement, investment, or reinvention. Underpinned and enabled by automation, this approach extends beyond information about a print business itself all the way to their customer’s experience, because when they understand the whole customer journey alongside their performance data it will be possible to spot opportunities to add value and sell relevant additional services.”
Ensuring the integrity of input data is also a must. “Printers must carefully manage and validate input data—including product, customer, and production data. Good data is the building block that enables workflows to take specific actions automatically,” notes Marc Raad, president, Significans Automation.
Many approach automation from the starting point of implementing closed-loop web inspection, artificial intelligence (AI), and machine learning automation applied to managing on-press print quality and color quality. “Through this process, a print provider’s reliance on the journeymen level press operator can be greatly reduced. Automation in the form of cobots and other technologies can also be applied to repetitive, lower skilled labor tasks. This minimizes time-consuming touch points for employees and lowers the training requirements,” offers Tim Bolton, manager, inkjet technology, Ricoh USA.
With shorter print runs, tighter delivery schedules, and varying printing substrates, an intelligent workflow is a must to organize and prepare jobs. “This intelligent workflow must not only affect printing but also finishing—it must be a complete closed loop,” explains Carlos Martins, head solutions management, Muller Martini North America. “The numerous benefits of a complete closed loop workflow from printing to finishing include optimizing efficiency in finishing to eliminate makeready times and reduce errors by eliminating manual interventions.”
Automation is a broad term that Waddington says encompasses many areas of improvement through revised or shortened processes. “In production print, prepress has been an early and impactful area for automation. Processes like file preparation, imposition, batching, and preflighting have all been enhanced through automation, ensuring faster turnaround times and fewer errors.”
Within printing itself, automation is most prominent in optimization steps. “Examples include auto-wash systems, auto plate hanging, and advanced color management systems. Larger print providers have taken automation even further with ink delivery systems, automated inventory management for paper and ink, and supply chain workflows,” says Bob Waddington, product line leader for curing and drying, BW Converting.
Many print providers already focus on automating press setups. “For example, features like auto-register, auto-pressure, and connected color workflows allow press-side color measurements to communicate directly with the ink room for safe and precise corrections,” offers John Cusack, product line leader, BW Converting.
Another critical area is the automation of print verification. “Using proofing software to compare the first images off the press to the reference PDF file ensures that errors are caught early, avoiding costly recalls or reruns due to incorrect setup,” says Cusack.
Automation at the finishing stage is critical to overall workflow and cost management, and to avoid late-stage errors. “Correcting errors at the finishing stage are the costliest errors to correct potentially resulting in costly reruns, planned overruns, estimating errors, scheduling challenges, delayed delivery, missed service level agreements, and lost business,” says Jacquie Perno, business development manager, ACCO Brands.
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Mar2025, DPS Magazine
