Hybrid printing, choose customization, or choose cross-border?
Printing technology and production methods are constantly changing as market demands change. This, combined with the "can do" nature of print packaging service providers, continues to drive technology and equipment manufacturers in new ways. New modular component production solutions can be integrated and combined with almost all printing technologies, including digital, offset, flexo, screen and inkjet, either in-house or offered as a configurable product solution for manufacturers.
What problem or application do you want to solve?
With the advent of modular technology solutions and the digitization of almost all printing technologies (especially analog technologies), there is really nothing that cannot be done to create application-based print production solutions. Modular production technologies are almost everywhere, especially in packaging applications, because the needs are so diverse. However, they are also making their way into production for commercial printing applications. So where do you start?
Cross-border and hybrid solutions
As market needs evolve, many equipment manufacturers have been developing more flexible configurations to better meet these needs. A good example is the newly released HPIndigo V12 label press, which offers flexo-printable performance in an all-digital press. If we look at MGI's AlphaJET, we can see the modularity and flexibility that can be customized for many packaging and commercial applications.
Flexo printers have been providing product-specific customization services for decades, and now flexo manufacturers are further expanding their product range. Bobst, W & H, McAndy and many others have been leaders in the field for many years. Heidelberg has recently increased its focus on flexo printing with its Geras division, and offers unit-based manufacturing solutions for labels, folding cartons, liquid packaging, lottery tickets and more. Their solutions are designed to be modular, flexible and scalable, so they can adapt to changing needs. With Agfa's acquisition of Inca Digital Printers and Screen GP IJC, and Canon's acquisition of Edale, we may start to see more flexible targeted printing and packaging solutions.
Analog presses and post-press equipment have always offered "a solution that fits all designs, with the exception of some flexo applications, where production is mainly limited to discontinuous processing steps. It has served the printing industry well and continues to do so." Market demands have changed. As a result, offset press and even digital press manufacturers are realizing that their products require greater flexibility and are working more with partners for this.
Customized Solutions
What if you can't buy one off-the-shelf? Certain printing and packaging applications may require custom solutions, but mainstream equipment manufacturers can't provide them. The most important thing to understand is what your end-use requirements are, and don't get torn on how to get there in the first place. People are often obsessed with "how to do it", and for them, "how to do it" is more important than "why", and "why" can produce less than ideal results.
The next step is to determine what unique features are required. For example: imaging, decoration, post-press processing, material transportation or all of the above? This is key because if you start here, you can start identifying partners early, which can help you refine or even build your final solution.
Take Zumbiel Packaging in Hebron, Kentucky, a large cardboard packaging manufacturer that worked with partners Graphic Systems Solutions (GSS) and Tresu to integrate new and refurbished flexo stations with Kodak inkjet technology to achieve a combination of digital and flexo on-demand printing. The Zumbiel configuration requires approximately 6-8 months of engineering preparation to be installed in the market, costs 25% -30% less than other production inkjet press solutions on the market, and it is aimed at his specific application needs.
Another great example of a custom application is V Shape Alphaflex. The solution was developed to meet the specific needs of creating single-hand open single-part packages for almost any liquid or powder (from food to pharmaceuticals). It starts with a blank substrate roll made from recyclable homopolymers and other compostable biodegradable materials, then uses Memjet inkjet components for printing, processing, filling and sealing. It can print and fill manufacturing solutions that can produce up to 300 filled single bags per minute.
The introduction of inkjet has furthered hybrid and custom production solutions, enabling imaging engines to decouple from standard transmissions and, instead, become part of custom solutions. So we're just, starting to see creative opportunities that can be realized. This is a great place to get creative inspiration and see what kind of unique solutions can be designed and built, and maybe even find some parts that meet specific needs.
There are also engineering firms with extensive experience in designing unique printing and packaging solutions. Based in East Dorset, Vermont, Engineering Printing Solutions is a custom printing solutions engineering and manufacturing company whose motto: "No two presses are the same" encapsulates the term custom printing solutions.https://www.risedongsheng.com/
Located in Woodstock, Georgia, Kirk-Rudy has been designing and manufacturing custom solutions for printing and packaging material handling since 1967. Grafisk Maskinfabrik, commonly known as GM, is a global player in the label market, providing advanced solutions for the self-adhesive label processing, post-press and flexible packaging industries.
Industrial Inkjet Integration has developed unique printing systems for printing on nonwovens, textiles, cermets and even direct food. Nozzle manufacturers have extensive experience and can also play an important role in designing and developing final solutions. While they all sell nozzles, most now produce component solutions, including nozzles and electronics, designed for unique blending and custom solution development.https://www.risedongsheng.com/
These include Xaar's Versatex print engine; Memjet, with three different modular solutions; and Kodak, with Stream and Ultrastream printhead systems and unique Ektaflex technology for functional printing and electronics. HP has a Professional Printing Solutions division that can work with you to develop everything from imprinting to 3D product printing.
Nixka has been producing inkjet systems since the early 1990s and focuses on supporting press manufacturers, brand owners or industry leaders to implement unique solutions. Myohua Software Parts Group is a unique company that, individually or collectively, works with manufacturers and interested equipment developers to develop solutions using inkjet technology, both hardware and software. This is just a sample of what is available and people. Able to help.
Fujifilm Dimatix has always partnered with OEMs for product development. However, with the increased demand for hybrid and custom development, they created an integration services division. The division focuses on meeting the company's growing desire to develop solutions that can utilize Fujifim Dimatix component printheads Headquartered in Lebanon, NY, they acquired Unigraphica AG, a print integration company based in Ruger, Liechtenstein, to provide engineering and manufacturing after-sales support for the EMEA region.https://www.risedongsheng.com/
So these parts and resources can help you create tailor-made production solutions, either crossover like the HP V12, or hybrid, leveraging multiple technical components, or even custom if something special is needed.