Hybrid, Crossover and Bespoke

Print technology and production methods have been changing along with the changing market requirements. All of this coupled with the "can do nature" of print and packaging service providers, continues to push 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. They can be "home grown" or offered as a manufacturer’s configurable product solutions.

What problem are you trying to solve or what is the application?

With the availability of modular technology solutions and the digitalization of almost all printing technologies, especially analog, there really isn’t much that can’t be done to create an application based print production solution. Modular production technologies are becoming almost ubiquitous, especially in packaging applications, since the requirements can be so diverse. However, they are also finding their way into the production of commercial print applications. So where do you start?

Crossover and Hybrid Solutions

First of all, try not to reinvent the wheel. As the market requirements evolve, many equipment manufacturers have been developing more flexible configurations to better address those requirements.

A good example of that is the newly released HP Indigo V12 label press, which provides flexo performance in an all-digital press. If we look at the MGI AlphaJET, also known as their “printing factory," we can see modularity and flexibility that can be tailored to many packaging and commercial applications.

Flexo presses have been providing product-specific customizations for decades, and now flexo manufacturers are expanding their offerings even further. Bobst, W&H, Mark Andy and many others have been leaders in this field for years. Heidelberg has recently put more focus on flexo along with their Gallus division and is offering inline manufacturing solutions for labels, folding cartons, packaging for liquids, lottery tickets, etc. Their solutions are designed to be modular, flexible and scalable so they can adapt to your changing needs. With the recent acquisition of Inca Digital Printers and SCREEN GP IJC by Agfa and the acquisition of Edale by Canon, we may begin to see even more flexible targeted print and packaging solutions.

Analog press and finishing equipment have always provided the "one solution fits all" design, where production is primarily confined to disconnected processing steps, except for some flexo applications. It has served the printing industry well and continues to, however as the market demands change, there is a need to think about print production differently. As a result, offset and even digital press manufacturers are realizing that they need more flexibility in their offerings, and are working more with partners toward that end.

Bespoke Solutions

What if you can’t buy it off the shelf? Certain print and packaging applications may require bespoke solutions than aren’t offered by mainstream equipment manufacturers.

However, before you get out the welding equipment and electronics, while it may sound obvious, the most important thing you need to understand is what your end use requirements are, and don’t initially get hung up on how to get there. Too often people get hung up on the how, and it becomes more important to them than the why, which can produce less than optimal results.

Next is to determine what unique features are required. For example, is it: imaging, embellishment, finishing/converting, material transport or all of the above? This is key, because if you start there you can begin to identify partners early on that can help you refine and perhaps even construct your ultimate solution.

Take Zumbiel Packaging, a large paper board packaging production house in Hebron, Ky., where they live by the can do attitude of manufacturing. They worked with partners Graphic Systems Solutions (GSS) and Tresu to integrate new and refurbished flexo stations with Kodak inkjet technology to enable the combination of digital and flexo on-demand printing. Zumbiel’s configuration required about six to eight months of engineering preparation for installation, at a market price 25% to 30% below other production inkjet press solutions in the market, and it was targeted to his specific application needs.

Another great example of a bespoke application is the V-Shape Alphaflex. This solution was developed to address the specific need of creating one-hand-opening single-serve packets of almost any liquid or powder from foods to drugs. It starts with rolls of blank substrate manufactured from recyclable homopolymers and other biodegradable materials that are suitable for composting. From there it is printed using Memjet inkjet components, converted, filled and sealed. It can print and fill manufacturing solution to create up to 300 filled single sachets per minute.

There is help out there.

The introduction of inkjet took hybrid and bespoke production solutions further by enabling the imaging engine to decouple from the standard transport, and in its place, become part of a custom solution. As a result, we are just beginning to see the kind of creative opportunities that can be achieved. If you haven’t already, visit the one of the PackExpo events held in various cities around the globe. It is a great place to get the creative juices flowing and see what kind of unique solutions can be designed and built. You may even find some of the pieces you need to address your specific needs.

There are also a few engineering companies that have experience with designing unique print and packaging solutions.

Engineered Printing Solutions located in East Dorset, Vt., is a bespoke print solution engineering and manufacturing company. With the motto: "No Two Print Machines are Alike," they epitomize the term bespoke print solutions.

Kirk-Rudy, located in Woodstock, Ga., has been engineering and manufacturing bespoke solutions for print and packaging material handling since 1967.

Grafisk Maskinfabrik, commonly known as GM, is a global player on the labelling market, providing advanced solutions for the self-adhesive label converting, finishing and flexible packaging industry.

Integrity Industrial Inkjet Integration has developed unique printing systems that print on non-woven fabrics, textiles, metals, ceramics and even direct-to-food.

Inkjet printhead manufacturers have lots of varied experiences and can also play an important role in designing and developing your final solution. While all of them sell printheads, most of them now produce component solutions, that include printheads and electronics, that are designed for unique hybrid and bespoke solution development.

These include the XAAR Versatex Print Engine; Memjet, with three different modular solutions; Kodak, with their Stream and Ultrastream printhead systems and their unique Ektaflex technology, which is targeted at functional printing and electronics.

HP has a Specialty Printing Solutions division that can work with you to develop everything from imprinting to 3D product printing.

Nixka has been pioneering production inkjet systems since the early 1990s, and focuses on supporting press manufacturers, brand owners or industry leaders in implementing unique solutions.

The Hybrid Software Group is a unique collection of companies that both individually and collectively work with manufacturers and interested equipment developers on solutions using inkjet technology, with both hardware and software. This is just a sampling of what and who is available out there to help.

Fujifilm Dimatix has always worked with their OEMs on product development. However, as the need for hybrid and bespoke development has increased, they created an Integration Services division. This division focuses on the increasing desire of companies to develop solutions that can utilize the Fujifilm Dimatix component print bar solutions. Headquartered in Lebanon, Ny., they recently acquired Unigraphica AG, a printing integration company located in Ruggell, Liechtenstein, to provide engineering manufacturing after sales support in EMEA.

So the pieces, and the resources are out there to help you create a tailored production solution. It could be crossover like the HP V12, or Hybrid, utilizing multiple technology components, or even bespoke, if you need something special.

More to Come …

I would like to address your interests and concerns in future articles as it relates to the manufacturing of Print, Packaging and Labels, and how, if at all, it drives future workflows including ‘Industry 4.0’. If you have any interesting examples of hybrid and bespoke manufacturing, I am very anxious to hear about them as well. Please feel free to contact me at [email protected] with any questions, suggestions or examples of interesting applications.