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New press gains prove more than cosmetic

A new sheet-fed press at All Packaging boosts the converter's efficiency, speed, uptime and print quality. Neoteric Cosmetics is the first to benefit, obtaining vibrant folding cartons for its retail cosmetics.

All Packaging?s operations manager Bob Nobles, vice president John Chaisson, and president Ken Pepper (left to right in the phot
All Packaging?s operations manager Bob Nobles, vice president John Chaisson, and president Ken Pepper (left to right in the phot

Greater efficiency through increased speed, less downtime and simpler troubleshooting are helping converter All Packaging Co. justify its recent $2 million investment in a new offset printing press.

Located near Denver, APC in May began running its new press from Mitsubishi Lithographic Presses (Lincolnshire, IL). The six-color, sheet-fed equipment immediately replaced an outdated press that was sold. And the new unit has made expendable another six-color press that's still being used, though it too is up for sale at press time. The phase-out of that press stems both from its own limitations and the efficiency of the new Mitsubishi 3F-6.

Compared to the press that's being phased out, APC's new model has:

* Increased uptime by 30%;

* Boosted output to 11ꯠ sheets/hr, from 7ꯠ/hr;

* Reduced make-ready time to 45 min from 75 to 90 min; and

* Improved print registration accuracy, color quality and consistency.

Before it added the Mitsubishi, APC operated the two six-color presses. One "was outdated, slow and was no longer economical to run," says operations manager Bob Nobles. It was sold. The press that's currently up for sale, Nobles believes, might have been too advanced for its own good.

Purchased in 1994 as a "state-of-the-art" machine, he says the unit uses digital fiber optics and a sophisticated system of 26 computers to execute press functions.

"Rather than hard wiring, the press uses fiber optics, with light carrying information through glass tubes," explains Nobles. "When we start up the press in the morning, we have to wait about a half hour just to get the light traveling through the system consistently."

Besides that warm-up period, interruptions in the light signals "continually shut down the press," he laments. "We had major problems where one computer wouldn't be able to communicate with another and that would shut the press down."

Troubleshooting the fiber optic press was also vexing, Nobles explains. "If a problem was detected, a monitor would show a series of error messages that we'd have to decipher. Many of these were in German, so it took us a long time to determine where the problem was and how to fix it."

Seeking efficiency, reliability

Looking to eliminate those problems, APC evaluated presses from four manufacturers, observing equipment at shows in Germany and the U.S. The converter supplied boardstock to press suppliers and had them print the board as tests. "The [printing done by the] Mitsubishi impressed us the most," says Nobles.

"We wanted reliability and efficiency," states Ken Pepper, APC's president. Those factors sold APC on the Mitsubishi. "Both the Mitsubishi and the fiber optic presses are forty-inch, six-color presses," explains Pepper.

"But while this new press uses computers," Nobles says, "it is hard-wired, and has override systems, which represent a significant improvement. That way, if there's a glitch, the system will inform us and we can manually make changes."

For example, he explains, if a safety switch is stuck, an operator can pull up a screen for safety-related information and the specific location of that safety switch will be flashing on the screen. The operator can go to that point and make the necessary adjustment.

"We track uptime carefully, and we estimate that with the new press, we're up and running about thirty percent more than with the fiber optic press," says Nobles. "So if we compared identical jobs on both presses for a week, the Mitsubishi would probably run five or six more jobs."

That, Nobles says, "translates into greater operating cost efficiencies. That's important because in a manufacturing plant like ours we're trying to save five minutes on a job here, ten there. If we can improve the efficiency and speed of each process by a few minutes for each job, then over the course of a year we've made significant changes."

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