Author: Christine Duggan

Corrugated Converters at the Crossroads Blog Series Part 4 “The Digital Printing Revolution”

Our first post in the Corrugated Converters at the Crossroads blog series looked at changes in the corrugated printing market, the factors driving them and how big-box retailers and CPCs are increasing their requirements of packaging suppliers. The major areas of change range from graphics quality to flexibility to velocity, and pressroom versatility is the name of the game.

The final post in our series will explore how digital printing is becoming a key player in the corrugated evolution, with added insight from Paul Aliprando, VP of Digital Technologies at Sun Automation Group. Expanding with digital technology can help printers meet demands for short runs, fast turnarounds, stunning graphics and customization without sacrificing efficiency or, more importantly, profits.

Sun Automation CorrStream® Digital Printer

A new take on old news

Digital printing is already being used in corrugated plants to produce samples, prototypes and other one-off or small-batch jobs due to its relatively cheap cost to produce shortruns compared to flexo. But the use of digital technology is ramping up as a growing number of jobs creep into its sweet spot – high resolution graphics, smaller order sizes, short lead times, fast turnarounds, customization and personalization.

Aliprando says, “some users are applying digital to increase value to their customers which allows higher product margins. Other users apply digital as an alternative to current methods for lower total production costs. Either way, money is the motivator.”

Let’s take a look at the ways digital technology is having the biggest impact in the corrugated post-print sector:

High resolution graphics

High-definition visuals, desired by today’s brand owners to create product differentiation and appeal, require high-resolution printing. A flaw with Flexo is as the sheet moves through each color station in the press, it shifts slightly, making it impossible to overlap every ink color and produce the image exactly as it was designed. Bleeds and traps have to be incorporated into the design to hide the registration issues.

Aliprando states, “In general, Digital has a higher resolution than ‘standard’ Flexo for corrugated. Although there are excellent flexo machines capable for printing Process work direct to corrugated, the cost, maintenance and operation knowledge is specialized.“

With a digital printer, images are printed in one pass. There are no registration issues and minimal dot gain, making digital printing a better option for reducing waste and producing images with high graphic resolution – especially with gradients and very detailed print that requires fine lines or images.

Smaller order sizes

The digital process offers an economical way to produce low-volume and custom print jobs. With flexo presses, high setup costs are offset by their faster speeds and lower production costs over a high-volume, long run job.

But digital presses are much more agile and a smarter choice for small print lots. The image is transferred directly onto a substrate, with no print cylinders, die-cut tooling, plates, ink tanks, anilox rolls, doctor blades or complex set up processes.

Short lead times and fast turnarounds

The quick and easy set-up of a digital press also makes it conducive to short lead times and fast turnarounds. Remember flexo’s cumbersome and expensive setup process – creating plates, filling the ink tank, assembling the ink roll and print cylinder? Digital files can be easily created, changed or updated so customers can request new or custom packaging on short notice or make changes on the fly. The full CYMK spectrum is readily accessible and producing gradients and other detailed effects is easy. Less waste…

Brands need responsive suppliers that can meet their needs for speed and versatility.

The flexibility that digital printing brings to the corrugated pressroom can also turn the package printer into a value-added service provider. With short lead times and fast deliveries, CPGs and big-box retailers can keep inventory levels low to save on warehousing and prevent outdated stock. However, Aliprando urges printers to consider the additional converting process with digital printing, stating “an added requirement for the corrugated facility is converting the printed sheet into a box. The digital printer is just that, a printer.”

Customization and personalization

Although, “Digital has its own ‘specialization’… it is offset by the variability and versatility digital allows,” says Aliprando. With digital, versioning is simple to execute – brands can customize graphics for multiple adaptations of the same package based on the audience, season, geography, event, market or any other segmentation criteria. The full range of CMYK colors are readily accessible for quick changes. Variable data – personalization with customer names, product expiration dates or any varying data used to personalize packages – is a snap to produce on a digital press.

Things to Consider

The Rise of Digital is a hot topic in the industry, and like many others, you may be hesitant to incorporate digital printing in your pressroom. Aliprando advises to “stay hesitant and get knowledgeable. Take the time to increase your understanding and knowledge of the complete digital process. You need to be comfortable about the technology and, once comfortable, decide if it fits into your current market or a new market you may want to pursue.” Aliprando adds,

“Ask yourself if your current manufacturing operation – order receipt to shipping – can accommodate digital. Digital is not for the faint of heart.”

By adding digital printing capability to the corrugated pressroom, printers can optimize efficiency and profitability by using the “right man for the job” every time. And that is just the tip of the iceberg – Digital press manufacturers are continually improving the digital print process with new technologies.

In October 2018, Sun Automation will introduce the new CorrStream®, which will have a new Aqueous ink set, capable of printing on standard white top sheets and clay coat for more “pop” to the printing. The new system allows 600dpi printing without any pre or post coating of the sheets and boasts a modular design, equipped to accommodate future system upgrades. “Obsolescence is not in our design”, comments Aliprando.

All in all, Digital Printing gives Corrugated Converters a cost-effective way to meet the market’s demands for flexibility and responsiveness. At the same time, the flexo presses are freed up to do what they do best – crank out large volumes of standardized products at fast speeds and low cost.

To sum up our Corrugated Converters at the Crossroads blog series, the logic is simple: what the consumers want, the manufacturers have to produce, and what the manufacturers want, the suppliers have to provide. The corrugated converting industry has responded to this market evolution with advancements in ink delivery, equipment, substrates, and digital processes to name a few. By adopting these market innovations, converters can embrace the market evolution as a great opportunity for not only survival, but future growth and prosperity.

For more information on Sun Automation and the new Corrstream Digital Printer, contact Paul Aliprando at [email protected].

We hope you enjoyed our Corrugated Converters at the Crossroads blog series. Click on the links below to view previous posts in the series:

Part 1: “The Consumer Is King” – Read about the forces behind the corrugated package printing renaissance

Part 2: “Necessity Is the Mother of Ink Delivery Innovation” – Read about ink delivery system innovations

Part 3: “This Is Not Your Father’s Pressroom” – Read about innovations in equipment and substrates
The Spectrum of Culture: From Employee to Customer
The Cultural Spectrum

As printers, or as suppliers to printers, we obsess in the pursuit of perfection– perhaps in no area with so much focus as on the spectrum of color. The perfect color match, the lowest Delta E, correct ink density and a flawless alignment of parts and plates from station to station. All to deliver the exact hues our customers demand. But there is a different spectrum that is perhaps even more difficult to master, and for which alignment is even more critical: the Cultural Spectrum.

People, and the culture they share, are the true core of our businesses. The owners and leaders of the organization who direct our businesses; the employees designing our packaging, running our presses; the vendors and partners supplying us with the tools we need to get the job done; our audience, the manufacturers buying our packaging—these people are all part of a complex cultural spectrum. Each group has its own standards and expectations, its own motivations, and its own collective personality.

Most people, when asked about their company’s culture, are unlikely to think in terms of this entire spectrum and may miss the opportunity to drive greater success. Seeking to create a culture that recognizes and fosters alignment across all of these interdependent work groups is a challenging path, but one with great rewards. We’d like to share with you the story of how our team identified the elements of its own spectrum, as well as the steps we took to pursue alignment across the spectrum.

Our Culture Journey

Rachel Acevedo and Phil Ryan of Flexo Concepts speak on The Spectrum of Culture at the 2018 FTA Forum.

In 2015, our company, Flexo Concepts, felt a need to work on and improve our culture. But what does that even mean? To us, we wanted to improve employee retention and satisfaction, but really had no idea how to get started. To help us, we engaged a cultural consultant and embarked on a journey so much bigger than just building employee morale. It started with one of those intensive 360° reviews typically done of individuals by persons from every part of their work sphere. For us though, it was a 360° review of our entire business. Customers of all sizes were interviewed to learn the market’s perception of our business. We also went about privately interviewing every single one of our employees—the owners, the guys running our equipment, our accounting team, engineers, customer support—everyone!

The result of this process was not just the most complete view of our business we have ever had. We understood our customers better. We learned firsthand about their perception of our brand, our strengths and our weaknesses and then used a simple Venn diagram to map our capabilities and also those of our competition against the wants and needs of our customers. The areas where our business uniquely supported the customer expectations were defined as our “Points of Distinction” [PODs]. We worked with this information to create a new focus and strategy for the business. For example, one of our PODs is centered around innovation. To grow this strength, we constructed an R&D lab specifically to support application testing and the development of new polymers.

While the PODs gave us a tactical roadmap, we had more work to do to understand and develop our culture. The cultural consultants had helped us to collect and compile information, but for the next 6 months we worked on our own to further grow the concepts. This process was done by way of a biweekly meeting held with the entire management staff. All departments worked together, taking a ground-up approach to write our Vision, Mission and Promise statements. It’s an exercise many organizations go through, but one we took a fanatical approach toward. We had a rule in these meetings that no one was ever to leave in silent disagreement. To say one thing during the meeting, but to act out of synch in the day-to-day would completely undermine the process and would not foster alignment.

People, Trust, Accountability and Performance

Another product of these meetings was a clear definition of our values, organized around four pillars—People, Trust, Accountability and Performance. These values closed the loop of a sort of “corporate operating system,” which we were ready to roll out not just to our organization, but to the rest of the spectrum as well. The efforts to understand and align ourselves to our audience were a good start, but we felt a more holistic approach would be more effective. To achieve this, we did more than work with our own staff; we reached out to our key vendors as well and educated them on our corporate values. We met with them to find common ground in our values and to get them to understand not just our needs, but the needs of our customers. We felt our own transformation would do little good without the support of our partners. Some suppliers got weeded out in the process, but our supply chain is as strong now as it has ever been.

With leadership, employees, and our upstream support network now closely aligned, we had to circle back to the final group: the audience. A strong, progressive and uplifting culture is a great asset for an organization, and we wanted to communicate it to our customers—especially because they had been so key in shaping the changes we made. To do this, we boosted our social media presence, opened our business for employee-led tours and started sharing our story: the day-in-day-out ways our culture shapes our business and our interactions with each customer; the journey of continuous improvement that we want our customers to enjoy and benefit from as much as we have.

After a year and a half of work, we found ourselves with the improved culture we had sought, and it extended beyond the sphere of ourselves and our employees. We feel

our culture and values are bigger than ourselves because our Vision and Mission are bigger than ourselves and they require more than what just the people in our building can provide. We recognize that our aspirations require a big-picture perspective, one aligned across the whole spectrum. It is not an impossible task, and though it is one that never ends, it also is one which never stops paying back. We would encourage any team looking to repeat this work for themselves to ask:
- Who is in your Cultural Spectrum?
- Does your Culture value what your Spectrum values?
- Is your Culture aligned through the Spectrum?
If you attempt to honestly and thoughtfully answer these questions, your own cultural reinvention will have already begun!
Flexo Concepts® Sets Sail to Celebrate 30 Years as Doctor Blade Leader

Plymouth, MA, July 6, 2018. Capping off three decades of success as a leading global doctor blade maker, Flexo Concepts celebrated its 30^th anniversary on historic Plymouth Harbor. The company treated its local business partners to a tour of its manufacturing facility followed by a sunset cruise aboard the Pilgrim Belle with employees and their families.

Thirty years ago, Flexo Concepts was established to help design a doctor blade for box makers, a move that secured its longstanding place as a dominant player in the worldwide UHMW corrugated blade market. Since then, the company has grown to serve the tag & label, flexible packaging and many other printing markets worldwide as a top industry innovator. Its TruPoint Orange®, TruPoint Green® and TruPoint DuraPoint® doctor blades are among its most renowned doctor blade products that have transformed the flexo printing market.

The company was acquired in 2001 by Kevin McLaughlin who later added longtime friend and industry colleague Greg Howell as his business partner. When asked about his proudest professional accomplishment, McLaughlin responded, “Our brand identity. Wherever I go in the industry, people tell me how impressed they are with us, and I think it goes beyond our bright orange shirts!” He is delighted that the company is known as a pioneer in the non-metallic doctor blade market and a partner dedicated to helping its customers be successful.

“I would say I am most proud of the team we have at Flexo Concepts and the work they do,” said Howell. He credits a culture that values individual contribution, collaboration, and a work environment that is meaningful and fun. “Across all departments, our employees are smart, hardworking, and enjoy taking on new challenges. So, we’ve got a lot to celebrate at our 30-year mark.”

In addition to continuously working to create new and improved products, Flexo Concepts is currently exploring new applications for its blade technology outside of the printing industry.

To learn more about Flexo Concepts’ history and 30^th anniversary celebration, visit www.flexoconcepts.com. A complete press kit can be downloaded at www.flexoconcepts.com/media.

About Flexo Concepts

Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint® doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com. For regular updates, follow Flexo Concepts on Facebook and Twitter.
Corrugated Converters at the Crossroads Blog Series Part 3 “This Is Not Your Father’s Pressroom”

The third post in our Corrugated Converters at the Crossroads blog series will look at how some pressroom equipment and substrates have evolved to help printers keep up with the times.

Antiquated Equipment

Many of the corrugated post print presses running today were installed as long as a half century ago. How can box makers, running this equipment, possibly keep up with the graphics quality and turnaround times expected these days?

The answer is, they can’t. At least not without incorporating the latest machine technology in their pressroom. Advancements in the powertrain, sheet transfer systems, substrates, coating chemistries and drying methods have made a huge impact on the speed and efficiency of the printing process and the quality of the output.

Direct Drive Servo Motors

Conventional presses use mechanical gear systems to drive the anilox roll and plate cylinder in the ink delivery process. But as press speeds and the demand for higher quality print grows, these systems can’t hold sufficient registration and adjust for in-run variation. Wearing of the mechanical gears produce backlash in the system and cause deviations in the print registration. For this reason, corrugated OEMs have followed the lead of other flexo press manufacturers by substituting direct drive servo motors for gearing systems. These new direct drive configurations synchronize the transfer rolls with a much higher level of precision, removing the variability in the process, allowing for more repeatable registration and better control over in-run adjustments.

Vacuum Transfer

Similarly, new vacuum transfer technology removes the registration variation from the sheet transfer process. The original systems use a knurled pull roll to grip and pull the sheet through the print area of the press and, over time, create the same registration challenges. As the substrate’s abrasiveness wears the knurling on the roll, the sheet slips and the printed image becomes blurred and fuzzy. New vacuum transfer technology eliminates the mechanical pull rolls, instead using suction to smoothly move the substrate through the press. The system holds the sheet firmly in place and allows for a consistent and superior level of print registration accuracy, even at high speeds. (The elimination of these wear parts also makes set-up times faster, prevents jams and takes up much less space in the machine to make room for IR dryers which we will get to later!)

Coated Substrates

But the advancements in ink delivery and sheet control are meaningless if the substrate can’t sustain the improved graphics and high press speeds. Printing on corrugated board is challenging. Its absorption and surface tension qualities affect print density, drying, trapping and dot gain. Today’s brand owners are demanding not only eye-catching, differentiated products, but also precise graphical representation of their brands and messaging. So, the market has introduced semi-coated and fully-coated papers on finer fluted board that can support these requirements.

IR Dryers

Along with the market’s introduction of new substrates comes the challenge of drying. The new coated papers are difficult to dry at high speed, so dryers must be added to optimize press output. IR dryers heat the ink using infrared energy to accelerate evaporation of the liquid bases, leaving only the pigmented ink solids on the substrate. The technology significantly reduces drying time and allows for drying at full speed with coated papers and high-quality inks. As we mentioned earlier, the adoption of vacuum sheet transfer systems has freed up space in the press to install IR dryers between stations. The overall improvement in color brilliance, gloss levels and processing speeds more than justify the investment in this technology.

UV Curing

The final step is to protect the high-quality graphics on a semi- or fully-coated sheet with UV curing capability. When a corrugated box is being used only for shipment and protection, there is little need to apply a UV coating.

But as corrugated packaging is becoming more of a marketing tool, the coating delivers the same benefits as it does in other flexo markets – maximizing gloss, protecting the print, and improving water, scuff and rub-resistance at full speed. The same goes for UV-curable specialty coatings used to apply finishes such as soft touch, glitter and sand to create innovative, unique-looking packages.

Like ink delivery system OEMs, corrugated equipment manufacturers and paper suppliers have responded with innovations to help converters thrive in the current market evolution. From direct drive motor systems to coated substrates, these new products help optimize pressroom efficiency and profits.

In the next post in our Corrugated Converters at the Crossroads blog series, we will continue to look at how digital technology is expanding into the flexo pressroom and playing a key role in the converting industry. Watch for Part 4 – “The Digital Printing Revolution”

Click on the links below to view previous posts in the series:

Part 1: “The Consumer Is King“ – Read about the forces behind the corrugated package printing renaissance

Part 2: “Necessity Is the Mother of Ink Delivery Innovation“ – Read about ink delivery system innovations
Flexo Concepts® To Be Featured Supplier at Gallus Innovation Days 2018

Plymouth, MA, June 20, 2018. Flexo Concepts will be a featured supplier at Gallus Innovation Days 2018, where the OEM and partners will present new-to-market innovations and talk about how digital technology is transforming the label market.

The event will take place on June 26-28 at the company’s headquarters in St. Gallen, Switzerland, a larger venue than in previous years. Gallus will introduce its newest digital label printing system, Smartfire, to an audience of 1,000 or more visitors. The press is designed as an easy-to-handle, affordable printing solution for flexo printers who are producing constantly-changing short runs and want to enter the digital market. The company will also run live demonstrations of its new Labelmaster Advanced conventional label press which boasts a modular design that combines exceptional flexibility with a high level of automation.

As one of 30 invited co-suppliers, Flexo Concepts will promote its TruPoint Orange® doctor blade with MicroTip® as a good blade option for label printers. The blade serves as an alternative to steel blades for producing high-quality graphics as well as a solution to common pressroom issues such as UV spitting and short blade life. Due to the blade’s abrasion- and corrosion-resistant material and MicroTip design, TruPoint Orange delivers a smooth and even lay-down of all types of inks and coatings including UV formulas and white inks.

To learn more about the benefits of TruPoint Orange, visitors are encouraged to attend the presentation, “TruPoint Orange – Tomorrow’s Doctor Blade for Today’s Printers,” by Flexo Concepts’ CEO, Kevin McLaughlin. He and international sales representative Bernat Ferrete will be on hand at stand #19 to answer questions and distribute Orange blade samples.

Visit www.gallus-group.com to find out more about the event or to register. For more information about TruPoint Orange or to request a blade sample, go to www.flexoconcepts.com/orange-doctor-blade.

About Flexo Concepts

Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint® doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com. For regular updates, follow Flexo Concepts on Facebook and Twitter.
Second Export Award in 2018 Recognizes Flexo Concepts® at the National Level

Plymouth, MA, June 5, 2018. “Flexo Concepts’ achievements have undoubtedly contributed to national export expansion efforts that support the U.S. economy and create American jobs,” said Secretary of Commerce Wilbur Ross when presenting the President’s “E” award to the company last month.

For the second time this year, Flexo Concepts has been recognized for its strong export initiatives, accepting the latest award at a ceremony in Washington D.C.

The ”E” Award is the highest recognition any U.S. entity can receive for making what Secretary Ross called “a significant contribution to the expansion of exports.” He presented the award to Flexo Concepts’ owners Kevin McLaughlin and Greg Howell at a service in the Herbert C. Hoover building.

“Since 2001, we have worked hard to expand our presence globally. This prestigious award is an endorsement of our success, and we are extremely proud to be honored in this way,” remarked McLaughlin after receiving the award. Howell, added, “This award reflects the dedication of our entire staff to overcoming the challenges that come with selling overseas. We are thrilled to be able to share it with them.”

In total, Secretary Ross honored 43 U.S. companies and organizations from across the country with the President’s “E” Award for their role in strengthening the U.S. economy by sharing American ingenuity outside of our borders. U.S. companies are nominated for “E” Awards through the U.S. Commercial Service, part of the Department’s International Trade Administration.

The President’s “E” Award represents the second time this year that the company has been distinguished for its focus on growing exports. In April, Flexo Concepts was named Massachusetts SBA “2018 Exporter of the Year” for its commitment to increasing its exports and supporting marketing and distribution programs.

For more information about the “E” Awards and the benefits of exporting, visit www.export.gov. To learn more about Flexo Concepts, go to www.flexoconcepts.com.

About Flexo Concepts

Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint® doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com. For regular updates, follow Flexo Concepts on Facebook and Twitter.
Corrugated Converters at the Crossroads Blog Series Part 2 “Necessity is the Mother of Ink Delivery Innovation”

The first blog post in our Corrugated Converters at the Crossroads series looked at how new consumer buying behaviors are changing what is expected of corrugated packaging printers. Converters are being asked to step up their game, and how they do it will define their future.

But how can they get the most innovation bang for their buck? Ink delivery system innovations are a good place to start. Adding ease, automation and better control over the application of ink will improve press efficiency and enhance graphics quality.

Doctor blade chamber systems

Once made of aluminum, chambers are now constructed from strong polymer and composite materials which resist pitting and corroding and maintain their strength without warping or twisting. Newer models have simplified loading and mounting designs that allow for easier installation and consistent blade contact angles with minimal pressure. Also, the new equipment is engineered to accommodate multiple blade thicknesses without modifications or shim stock, so printers are not limited to only the doctor blade materials that the chamber will hold.

Doctor blade materials

UHMW is the longstanding traditional blade material used in corrugated applications. But as the demand for higher quality graphics creeps into the market (and anilox line screens rise), the blade material can’t effectively control the volume of ink delivered to the plate. As the blade edge wears, its contact area quickly becomes too large to effectively meter the roll – ink film thickness grows, ink mileage declines and blade wear accelerates, all driving the price of the box up.

Some newer chamber designs can hold thinner materials, such as polyacetal, steel and TruPoint Orange® with MicroTip®, without a shim or modification. But many of the early chambers were designed to hold only a specific UHMW blade thickness such as .060” (1.6mm) or .080” (2mm). In these cases, a next-generation polymer blade, TruPoint Green®, is a good solution. It can be made in .060” and .080” thicknesses, has 3 times better spring memory than UHMW and is about 20% stiffer – all while having an equal or longer blade life.

Anilox rolls

Until recently, about 85% of corrugated anilox engravings have been under 300 lpi (120 L/cm) and 60° angle. Like other flexo printers have done, corrugated printers are beginning to take advantage of complex anilox surface configurations, cell shapes and higher line screens. New technologies such as elongated cells, tri-helical cells and wave style engravings give printers more control over their ink delivery, so they can create eye-catching POP displays and other attractive packaging.

Plate materials and plate carriers

New performance-grade cushion mounting material is made from higher durometer foam that resists compression set and reduces plate make-ready time. Superior impact and deflection during the print run allows for stable print reproduction and a reduction in fluting or “washboard” phenomenon. Great advancements are being made with patterned photopolymer plates (often referred to as “plate on a plate” technology) to help the printer manage ink delivery volume and distribution from the plate.

Ink temperature control systems

Water-based inks run best between 66°-74° F. This is typically well-below the ambient temperature of the plant, so ink will often go to press above its optimal temperature. There is more energy (and heat) added to the ink as it is pumped through the hoses and chambers and transported by the anilox roll.

As ink temperature rises, pH levels drop and viscosity increases – impacting ink tack levels and flow characteristics – and affects print quality and making for tricky anilox and plate clean-up.

By installing an ink temperature control system, printers can maintain steady command over all the ink properties without using additives. They also enjoy better imaging, easier wash-ups and quicker job changes.

There is no question that basic market pressures are challenging today’s corrugated printers. But industry suppliers have responded with skill in refining their technology to help their customers meet these demands. As an integral part of the printing process – from blades, to chambers, to anilox rolls, to plate, to cushion, to temperature, to viscosity, to pH – the ink delivery system is a good place to start.

In the next post in our Corrugated Converters at the Crossroads blog series, we will continue to look at how the industry is responding to these big changes and evolving with new technology. Watch for Part 3 – ” This Is Not Your Father’s Pressroom“

Click on the link below to view the first post in the series:

Part 1: “The Consumer Is King” – Read about the forces behind the corrugated package printing renaissance
9Septembar Opts for TruPoint Orange® Doctor Blades on Tissue Equipment

Plymouth, MA, May 21, 2018. Flexo Concepts® is excited to add 9Septembar to its list of equipment manufacturers whose machine performance is optimized with the TruPoint Orange doctor blade.

The blade is being used on the print station of the tissue converting company’s napkin production line. After trialing TruPoint Orange doctor blades in this application, 9Septembar Chief Engineer Constructor Branko Brković found they “improved performance of the printing section, increased safety during handling operations and were faster and easier to change than other doctor blades.”

Like numerous OEMs, the company will be shipping new napkin machines with the TruPoint Orange blade. Brković went on to say, “We are satisfied with the durability of the blades and we see Flexo Concepts as a reliable partner in the future.”

Located in Serbia, 9Septembar also manufactures handkerchief-making equipment, slitters and rewinders and sells to over 40 countries worldwide. The company delivers turn-key solutions that can be customized with a lamination station, a variety of embossing and perforation sections, and wrapping units in addition to print decks with up to 6 colors.

To learn more about TruPoint Orange or request a blade sample, visit Flexo Concepts at www.flexoconcepts.com. To access a complete press kit, go to www.flexoconcepts.com/media.

About Flexo Concepts

Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint® doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com. For regular updates, follow Flexo Concepts on Facebook and Twitter.
TruPoint Keon™ Doctor Blade to Make Its Debut at China International Battery Show

Plymouth, MA, May 14, 2018. Flexo Concepts® is excited to announce that it will introduce its newest doctor blade, TruPoint Keon, at the China International Battery Fair (CIBF) in Shenzhen on May 22-24, 2018.

The blade will make its debut in the market as a high-precision metering blade that can be used to apply the separator film in the manufacture of lithium ion batteries. The specialized Keon blade material is stiff, durable and highly-resistant to heat and abrasive chemicals, making it an excellent choice in this application. An exact lay-down of coating is required to improve the mechanical properties and thermal stability of the separator film, facilitating the charge and discharge of the battery while preventing short-circuiting.

Considered the largest battery fair in the world, CIBF will provide an opportunity for the doctor blade supplier to network with local industry partners. Flexo Concepts’ Asian Key Account Manager, Steve Kao, will be available to explain the advantages of using TruPoint Keon and handing out mini-blade samples at the company’s stand #1GB020.

To learn more about TruPoint Keon, go to www.flexoconcepts.com. A press kit can be accessed at www.flexoconcepts.com/media.

About Flexo Concepts

Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint® doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com. For regular updates, follow Flexo Concepts on Facebook and Twitter.
Flexo Concepts® Named Massachusetts SBA “2018 Exporter of the Year”

Plymouth, MA, April 30, 2018. Flexo Concepts has been named “2018 Exporter of the Year” for Massachusetts by the U.S. Small Business Administration. The company was selected for innovation in sales, marketing and distribution in the printing and related industries and outstanding growth in export revenue.

SBA Massachusetts Director Robert Nelson reflected on the growth Flexo Concepts has achieved since 2001 when the company began actively focusing on growing its global business: “With exports to 36 countries currently generating 40% of total sales, Flexo Concepts has grown its current export revenue to levels that surpass the company’s total revenue in 2001.”

“We cannot think of an achievement that better represents the efforts of our entire team. Our employees are very proud to receive this recognition,” said Flexo Concepts’ CEO Kevin McLaughlin. He also credited industry partners and organizations like the SBA, MassExport, MassMEP and others who have helped along the way.

The company has been awarded Massachusetts STEP Grants in each of the last 5 years to bolster export activities. Funding was used to support its presence at international trade events that paved the way for new business development relationships.

“There are a lot of challenges selling globally,” added McLaughlin’s business partner and Flexo Concepts President Greg Howell. “It takes a coordinated effort and commitment from everyone in the organization to achieve the success we have had.”

“Flexo Concepts is an exceptional small business and exporter and we are thrilled to see them recognized by the SBA,” said Assistant Secretary of Business Development & International Trade Nam Pham. “We look forward to watching their continued growth.”

For more information about Flexo Concepts, visit www.flexoconcepts.com. To access a complete press kit, go to www.flexoconcepts.com/media.

About Flexo Concepts

Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint® doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com. For regular updates, follow Flexo Concepts on Facebook and Twitter.
Corrugated Converters at the Crossroads Blog Series Part 1 “The Consumer is King”

Corrugated package printing is evolving. Lead times are shortening, order sizes are decreasing and pressure to reduce turnaround times is growing. At the same time, brand owners and big-box retailers are demanding high quality graphics, customization and flexibility – all with an eye toward sustainability and, of course, keeping costs down.

The savviest corrugated converters will use the tools at their disposal to meet these changes head-on. Our 4-post blog series, Corrugated Converters at the Crossroads, will not only examine the forces behind this evolution but also describe some of the “tools” that can help corrugated converters acclimate to these market changes.

Who is today’s consumer?

Demographics and lifestyles are changing – the population is aging, household sizes are decreasing and fewer families are eating together at the dinner table. Consumers are busy, finicky and impatient – they want convenience, quick satisfaction and competitive prices – and want to purchase in ways that fit into their fast-paced schedules.

People access information at their fingertips (or palms) so products are researched, reviewed, recommended, rebuked and requisitioned – all outside the scope (and power) of the brand owner. Manufacturers must make their products stand out on-line and on retail shelves to catch the consumer’s eye and “win” sales.

Let’s explore how these changes are affecting the job of corrugated converters.

High quality graphics

For years, corrugated converters were asked only to produce durable containers and packages with few embellishments and uninspired graphics. Now, in addition to protecting the products, secondary packaging is being used as a strategic marketing tool. Products must stand out from the pack and “speak” to the customer, and the way they are “dressed” is paramount. Box makers are expected to create enticing shelf-ready packaging and shipping containers that double-down as POP displays. The package design plays the important role of effectively and consistently conveying the manufacturer’s messages, differentiating the products from those of competitors and enticing the shopper to buy. The use of expanded gamut, finer plate screens, half-tones and higher anilox line counts is creeping into the corrugated pressroom, and predictable ink density and color control are essential for brand image and consistency.

Short Runs

As retail strategies take direct aim at the individual consumer, what used to be large jobs are being broken into smaller lots based on each “version” of the product. Globalization of brands requires that product packages be produced in multiple languages and “localized.” Variable data, where companies add a unique image or message to each package, has been found to improve the effectiveness of marketing and allows individual product skus to be “tracked and traced” through the supply chain. Customization and personalization are effective marketing tools that, by their nature, dictate shorter runs.

Faster Turnarounds

Everything in the marketplace is speeding up –today’s consumers are bombarded with messages, their attention spans are short, they get bored easily and they want products ASAP. Brand owners have to keep packaging fresh, interesting and relevant. They want to optimize their time-to-market and be able to test prototypes and make updates as fast as possible. The corrugated converter’s agility is key to his survival.

E-Commerce

Today’s consumers want to shop online from the comfort of their couch, desk, coffee shop (you name it!) in addition to conventional retail outlets. And shoppers expect not only convenient ordering but also quick and low-cost deliveries. Shipping boxes must still protect the contents but do so in the most efficient and economical way. People are also demanding environmental responsibility and “green” packaging from manufacturers and retailers which brings us to…

Sustainability

Even though corrugated waste is considered the most-recycled packaging material on the planet, eco-conscious consumers are demanding more from their manufacturers and retailers. The industry is undergoing pressure to not only reduce paper weights and streamline product packaging but also revamp its energy and water conservation programs and optimize logistics and transportation to reduce its carbon footprint.

There is no question that new consumer on-the-go lifestyles and buying practices are fueling the changes taking place in today’s corrugated package printing industry. To market to these “new” buyers, brand manufacturers and big-box stores need their suppliers to deliver high quality graphics, customization and fast response times in packaging that can serve on-line as well as brick-and-mortar demand in sustainable ways. That is a tall order.

In the next few posts in our Corrugated Converters at the Crossroads blog series, we will look at how the industry is responding to these market changes with new technologies. Watch for Part 2 – “Necessity is the Mother of Ink Delivery Innovation.”
TruPoint® Premium Doctor Blades and Corporate Culture at INFOFLEX 2018

Plymouth, MA, April 24, 2018. At INFOFLEX 2018, Flexo Concepts® will promote the advantages of its TruPoint® premium doctor blades as high-performance blade options that are safer and last longer than steel.

Shipping as the standard blade with many new press installations, TruPoint Orange® meters high anilox line screens effectively and prevents common problems in narrow web pressrooms such as UV ink spitting. For corrugated printers, better spring memory and stiffness make TruPoint Green® a good substitute for UHMW in applications that require mid-level graphics quality.

Visitors to the show can attend the forum presentation, “The Spectrum of Culture: From Employee to Customer,” on May 6^th to learn about the benefits of a company culture that’s aligned between the people inside and outside a company. Flexo Concepts’ representatives Phil Ryan and Rachel Acevedo will share their experiences and offer advice on how to connect the wants, needs and values of the marketplace with those of the employees to create a positive and productive corporate environment.

To learn more or request a blade sample, visit Flexo Concepts at booth #207 at the show or go to www.flexoconcepts.com. To access a complete press kit, go to www.flexoconcepts.com/media.

About Flexo Concepts

Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com. For regular updates, follow Flexo Concepts on Facebook and Twitter.
Flexo Concepts® To Be Featured Doctor Blade Supplier at Focus Open House 2018

Plymouth, MA, March 7, 2018. As a featured blade supplier, Flexo Concepts will present the benefits of its TruPoint Orange® doctor blade at Focus Label Machinery’s Open House on March 20-21, 2018.

The event will take place at the label press builder’s manufacturing, production and showroom facilities in Nottingham, U.K. Focus will demonstrate its premium e-Flex Servo with UV LED, accompanied by technical information session and analysis of the overall advantages of using LED technology. Among other partners, an ink supplier will be on site to recommend customized solutions for printers’ specific applications.

Flexo Concepts’ Bernat Ferrete will be on hand to tout the performance and safety benefits of the TruPoint Orange doctor blade. The blade’s material properties and MicroTip® allow for a more fluid transfer of ink to the plate and have been proven to eliminate UV ink spitting. Its abrasion resistance also makes it a popular choice for applying special coatings and tactile finishes. When asked for reasons why he chooses to demonstrate his equipment with TruPoint Orange, Colin Ellison, Print Technician at Focus, cited ink spitting and long blade life as the primary reasons.

To learn more about the event, go to www.focuslabel.com. For more information about the TruPoint Orange doctor blade, visit www.flexoconcepts.com. A complete press kit can be accessed at www.flexoconcepts.com/media.

About Flexo Concepts

Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com. For regular updates, follow Flexo Concepts on Facebook and Twitter.
Flexo Concepts® to Feature MicroTip® Technology Enhancements at FINAT Technical Seminar 2018

Plymouth, MA, February 26, 2018. Flexo Concepts will promote new refinements to its innovative MicroTip doctor blade edge at FINAT’s Technical Seminar 2018 in Barcelona. Enhancements to the tip further improve metering precision and reduce waste that occurs during press start-up.

A modification to the revolutionary MicroTip design doubles the tip’s stiffness at the contact point to further refine metering performance on high line screen anilox rolls. An improvement to the manufacturing process also produces a smoother contact edge, eliminating the start-up lines which are experienced sometimes by printers when using polymer doctor blades.

Since its release to the market in 2013, the TruPoint Orange® polymer doctor blade with a MicroTip has been endorsed by numerous press manufacturers. Last year at Labelexpo Europe, Orange was run on equipment by AB Graphic, Cartes, Domino, Edale, Focus, Werosys and others, many of which ship the blade standard with new equipment installations.

To learn more, visit Flexo Concepts at table #6 at the event or go to www.flexoconcepts.com. To access a complete press kit, go to www.flexoconcepts.com/media.

About Flexo Concepts

Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint® doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com. For regular updates, follow Flexo Concepts on Facebook and Twitter.
The Environmental Impact of Doctor Blades

Generally, printers choose plastic or steel doctor blades according to their graphic requirements (or maybe blade life or safety). But, all else being equal, choosing the eco-friendlier material can help you reduce your facility’s carbon footprint.

This infographic compares the environmental impact of the two most common doctor blade materials: steel and plastic. For printers looking for innovative ways to reduce their carbon footprint, this infographic may help you better understand the impact your choice in doctor blade could have on the planet. Take a look and complete the form to download the PDF.
Flexo Concepts® Offers New, Easier Ways to Get in Touch in 2018

Plymouth, MA, January 29, 2018. Flexo Concepts has ushered in 2018 with new and easier ways for customers to get in touch. The company is encouraging people to use Live Chat, Facebook Messenger and an online meeting booking tool for personalized service with little-to-no wait and fast response times.

The Live Chat system allows website visitors to converse in real time with a sales or technical representative to find out about products, get troubleshooting support or ask general questions. Customers can also use Facebook Messenger to contact the company, a method that’s expected to be popular with the international market due to time zone differences and high dialing rates.

Live Chat and Facebook Messenger are available on most devices. Some of the benefits of Facebook Messenger are the ease with which customers can send pictures or video and that the conversation is saved and can be added to over time. These features make it a great tool for product usage issues and for press operators using the product on 2^nd and 3^rd shifts.

Finally, if a customer has limited access to a phone or internet during the workday, he can use Flexo Concepts’ new meeting booking tool to select a convenient time for a representative to contact him. A call can be general or technical in nature and can be scheduled up to a year in advance.

“We want to be available for customers on the platform or method of their choice,” said Phil Ryan, Flexo Concepts’ Supply Chain and Service Manager. “We still answer the phone with a live person when customers call and we’re active on email. In our private lives, people are using chat and direct messaging more and more to communicate and we think this trend is increasing in the business world.”

These new ways to connect demonstrate Flexo Concepts’ commitment to making doing business with the company easy. Other customer-focused services include short lead times on orders, inventory management programs and consultative selling practices.

For more information about Flexo Concepts, visit www.flexoconcepts.com. To access a complete press kit, go to www.flexoconcepts.com/media.

About Flexo Concepts
Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint® doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com. For regular updates, follow Flexo Concepts on Facebook and Twitter.