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  • Plastic Doctor Blade Materials Are Way Better Than Steel

    Plastic Doctor Blade Materials Are Way Better Than Steel

    blankMarket pressures continue to challenge the printing industry to deliver products that differentiate and delight. Doctor blade manufacturers have stepped up, introducing plastic blade technology that offers a viable alternative to steel and delivers a competitive edge. Here are some of the reasons that plastic doctor blade materials are way better than steel.

    Safety

    Steel blades cause a lot of pressroom injuries. Press operators put themselves at risk of being cut anytime they’re handling steel blades, but never more than when they are removing them from the press. The blades’ edges become honed as they wear, leaving razor-sharp tips.

    By comparison, the properties of polymer materials prevent plastic blades from ever developing dangerous cutting edges. Even when worn, plastic blades are never sharp enough to injure press operators. Switching from steel to plastic blades will reduce lost-time accidents and save a printer a lot of money in workman’s compensation expenses, medical bills, labor replacement costs and press downtime.

    blankPerformance

    While safety is the hallmark of a plastic doctor blade, in the past, printers sometimes had to forego this benefit for the wiping capability of steel. Traditional plastic blades needed thickness to provide rigidity. They were unable to achieve a fine area of contact with the anilox roll in high-graphics applications, and steel blades were the only option.

    But now, next-generation polymer materials and innovative tip technology can be combined to provide  stiffness at thinner gauges. As a result, today’s plastic blades are able to maintain a fine contact area with the anilox roll and deliver metering performance on par with steel. The lower surface tension of polymers also facilitates an easier transfer of ink or coating to the plate. These properties enable plastic blades to resolve many press issues – such as UV spitting – that are commonly experienced with steel blades.

    Durability

    blankPlastic blades are durable and last longer than steel. The material is incredibly tough and stands up to abrasive chemistries like high titanium white inks and special effects coatings. The blade material is also self-lubricating with a low coefficient of friction to resist mechanical wear. Reducing the frequency of blade changes with plastic blades means presses can run longer without interruption.

    Cost-Effectiveness

    blankPlastic materials protect anilox rolls. Installing steel blades incorrectly or with too much pressure can cause fragments of metal to break away and destroy rows of anilox cells as the roll turns. Plus, the friction between a steel blade and anilox surface can erode cell walls. In either case, anilox damage leads to print defects, waste and significant costs to repair or replace the roll. Plastic blade materials, on the other hand, are non-abrasive. In the same way they will not cause injuries to operators, they will never damage rolls or cause premature anilox wear.

    Sustainability

    Last, but not least, using plastic doctor blades reduces a printer’s carbon footprint. Today’s next-generation polymer blade developers strive to create products that help their customers achieve their sustainability goals. Many new polymerizing methods use recaptured carbon monoxide (often from steel mills!), preventing the release of CO2 into the atmosphere. The process of producing plastic is much less energy-intensive than steel, emits less greenhouse gases, and has a smaller transportation component for raw materials and finished goods.

    Tresu XL blade holder E-Line TruPoint Orange

    Early doctor blade chamber systems were designed for use with steel blades. But, to address the increasing demand for plastic doctor blades, chamber manufacturers, like TRESU, have introduced new blade holder systems that fit a range of blade thicknesses. With an interchangeable clamp apparatus, press operators have the flexibility to run plastic or steel or easily switch back and forth depending on their job requirements.

    Printers looking for innovations to streamline their processes and keep pace with market demands are finding the solution in plastic doctor blades. Polymer blade materials provide durability and sustainability, and drive performance that exceeds steel – all while staying true to what made them great in the first place: safety. As the market continues to appreciate the benefits of plastic, industry suppliers will no doubt continue to develop products that help make them an option in every pressroom.

  • Installing TruPoint: 3 Key Elements for Success

    Installing TruPoint: 3 Key Elements for Success

    blankInstalling your TruPoint Orange doctor blade incorrectly will result in disaster. Well, not really. But it will create headaches for the press operator and waste valuable resources. It will also prevent you from getting the maximum value from your doctor blade investment.

    The TruPoint Orange doctor blade is a lifesaver in many pressrooms when it comes to eliminating UV ink spitting and start-up lines, reducing the frequency of blade changes and offering a safe alternative to steel blades. However, the blade requires a bit more finesse than steel when it’s being installed in order to work its magic.

    Principles of proper doctor blade installation

    It goes without saying that the surface the blade will rest on should be clean, so the blade can firmly rest against the blade stops. Also, tightening the blade clamp screws starting in the middle and working outward is a good way to get a uniform fit.

    But, if we had to name the three most important factors to keep in mind when installing a TruPoint Orange doctor blade, it would be handling, orientation and pressure. That’s not to say that other considerations such as angle and alignment aren’t important. It’s just that these particular variables, if not executed properly, will almost always foretell the failure of the blade.

    1. Protecting the blade edge

    A press operator should take care to protect the integrity of any doctor blade (and his or her own safety when using steel) during blade transit, storage and installation. But particular caution should be exercised to keep a MicroTip® edge from coming in contact with anything that may damage it.

    The MicroTip on an Orange blade is amazing in its ability to achieve and maintain a fine area of contact with the anilox roll blanksurface. After all, this is the driving force behind the blade’s ability to match the metering performance of a steel blade. Its material is also incredibly tough, able to stand up to the abrasiveness of even the harshest chemistries like high titanium white inks and special coating formulas. But some of the same characteristics that give the TruPoint Orange doctor blade its awesome wiping power and durability also make its MicroTip vulnerable to nicks when handled or stored improperly. Once the edge is compromised, the blade can cause printing defects such as continuous streaks, marks and lines on the substrate. Keep the blade safe and always run your finger along the leading edge of the blade to ensure no imperfections are present before locking it into place. (Remember, there is no danger of cutting yourself with a TruPoint Orange doctor blade!)

    2. Correct blade orientation

    To reap the full performance benefits of the TruPoint Orange blade, the blade must be installed with correct orientation. When blankthey are manufactured, TruPoint Orange blades are imprinted with text to guide you when you install them. It is important that the MicroTip edge is pointed away from the roll, with the text facing towards you and the arrows pointing to the anilox. It’s simple – if you can’t read the text, the blade is installed the wrong way. A blade that’s installed “backwards,” (with the MicroTip facing towards the roll), will not make even contact along the anilox roll and result in streaking on the printed piece. If your Orange blade is beveled, the bevel should face the inside of the chamber, or away blankfrom the roll, when properly installed. If using a doctor blade chamber, the containment blade should be the first to touch the anilox roll and the metering blade, second.

    3. Minimal blade pressure

    Assuming a doctor blade chamber is properly aligned, much less blade pressure is needed to get a clean wipe of the roll with a plastic doctor blade than with a steel one. For best results, find the minimum amount of blade pressure required to contact the anilox surface when installing TruPoint Orange. Unlike with steel, TruPoint Orange should generate few or no streaks on the anilox when starting up. Minimizing blade pressure against the anilox roll will not only ensure print quality but also extend blade life (and end seal life if applicable).

    A good way to gauge the correct amount of doctor blade pressure is to look at the rollblank once it’s inked. Before the clamp is tightened, the anilox roll will appear glossy – a sign that too much ink is remaining on the surface. Blade pressure should be increased gradually until a satin finish appears on the surface of the roll. A dull sheen is a good indication that the correct amount of pressure has been achieved and the doctor blade is effectively shearing the excess ink from the roll. If pressure is increased beyond this point, the doctor blade edge will bend, and contact area with the roll will grow. The anilox surface will begin to look glossy again or show light streaks or lines because it is being flooded with too much ink. At this point, lessening blade pressure, rather than increasing it, will alleviate the issue.

    When a TruPoint Orange blade is installed properly, its metering power is brilliant in terms of executing consistent print quality over the life of the blade. Take care to ensure the three key elements of success – proper blade handling, correct blade orientation and the right amount of blade pressure – and your TruPoint Orange doctor blade will likely become your press operator’s new best friend.

  • Doctor Blade Chambers Play a Key Role in Print Quality and Pressroom Efficiency

    Doctor Blade Chambers Play a Key Role in Print Quality and Pressroom Efficiency

    enclosed doctor blade chamberAfter years of being relegated to jobs with low graphics requirements, flexography now rivals other printing methods for quality and efficiency thanks to advances in the ink delivery process. Specifically, doctor blade chamber systems allow for better control over ink film thickness, color consistency, ink consumption, cleaning costs and press run time.

    A chamber doctor blade system uses two doctor blades along with an enclosed ink chamber to dispense the ink to the anilox roll. The reverse angle blade acts as the metering blade and wipes excess ink from the anilox roll, and the trailing blade acts as a capture or containment blade and holds the ink within the chamber. Foam, rubber or felt gaskets seal both ends of the chamber and keep ink from leaking out.

    The enclosed chamber design provides protection from evaporation of solvents or amines from the ink, depending on whether the ink is solvent or water-based, so a printer can maintain ink viscosity. Also, the ink is sheltered from dust, and slinging and skimming on the surrounding area are minimized. Better control over ink usage means lower ink consumption by as much as 15% per year. The system holds less ink than open pans, so there is less leftover ink at the end of a press run, and this ink can be removed and stored for future use.

    Doctor blade chambers also allow for a more efficient and eco-friendly cleaning process than open ink systems. A smaller amount of cleaning solution and water are needed, so cleaning solution and water usage are reduced along with disposal costs. Color changes are quick, speeding up changeover and setup time on a run.

    Absolute Engineering carbon fiber chamber with Green bladeRecently, chamber producers have incorporated innovative engineering concepts and next-generation materials to improve the equipment’s performance and usability. New carbon-fiber constructions are lightweight, strong, durable and temperature-stable, and they reduce press vibrations even on wide format presses. Their surfaces are coated with resin to provide anti-static, corrosion-resistant properties. Advanced clamping systems, like TRESU’s E-Line and P-Line Systems, replace screws with eccentric and pneumatic apparatuses, respectively, to make blade changes faster and easier for operators.

    Early chamber systems were designed for use with steel blades. But, to address the increasing demand in the industry for plastic doctor blades, TRESU worked closely with doctor blade manufacturer Flexo Concepts® to develop the exclusive new Series XL Blade Holder. The interchangeable

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    Tresu: xl blade holder E-Line Orange

    quick-change clamp apparatus can accept slightly thicker TruPoint® plastic doctor blades, giving printers access to a much wider variety of blade options. Those who prefer plastic blades over steel – whether to improve safety, extend blade life or solve press problems like UV ink spitting – have the flexibility to use plastic or switch back and forth between materials based on job requirements.

    When selecting a doctor blade chamber, there are several factors to consider in order to maximize the return on investment. The doctor blade chamber and its loading system should prevent blade misalignment and ensure even contact across the face of the anilox roll. It is also important to make sure that the system allows operators to adjust pressure between the doctor blade and anilox roll. Minimum pressure, particularly when using TruPoint blades, is important to optimize print quality, prolong blade life and preserve anilox integrity.

    Today’s flexo printers are able to produce attractive packaging in a cost-effective way thanks in part to the benefits provided by doctor blade chambers. These enclosed systems contribute to high print quality and bring considerable efficiency and cost savings to the pressroom. Along with cutting-edge press, ink, substrate and doctor blade innovations, advances in chamber technology have further improved the ink delivery process, making flexography a viable option for today’s most demanding print applications.

  • How Flexo Concepts® Was Digitally Transformed

    How Flexo Concepts® Was Digitally Transformed

    digital transformationFlexo Concepts has completely transformed the way it does business.

    Digitally, that is.

    It began the way all of our projects do, with a vision – to create a digital cohesiveness throughout our company to optimize our customers’ experience with us – and a plan to make that vision a reality. Together, they led us down a 4-year path of pervasive digital transformation that reached into every corner of our company and united all of our business functions.

    “A company’s digital transformation may not be very noticeable from the outside,” said Greg Howell, Flexo Concepts’ president and de facto project leader. “If done correctly, customers won’t notice initially.  But over time they will see increasing examples of improved experiences as they engage with suppliers who are transforming.”

    Greg Howell and Phil RyanA successful digital transformation requires hard work that needs to be done inside the organization, necessitating a sustained, company-wide focus on a long-term goal and plenty of patience along the way.  A key player in the company’s transition was Flexo Concepts’ Supply and Customer Experience Manager, Phil Ryan. Together, Greg and Phil piloted a process to attack this initiative over a period of 4 years, leading to countless examples of technology being used in game-changing ways.

    From the start, Greg realized the importance of drawing ideas and buy-in from all areas of the company – not just IT or Sales where the initiative started, but also Accounting, Engineering, Operations, Marketing, Manufacturing and Customer Experience. This was important not only to generate the best ideas, but also to ensure that knowledge and capability were distributed throughout the company and not centered around a few people.  He was sure that everyone in the organization – from top to bottom and across – needed to work together for this to succeed. And so, our “Digital Transformation Team,” with representatives from each department, was born.

    Since the beginning, the team would gather every other week to communicate progress, celebrate “wins”, vet ideas, and plan next steps.  Tasks were decided upon, and members would return to their departments after each meeting with tactical to-do lists. Gradually, the assignments were moved from “to-do” status to “completed” and crossed off the list.

    digital transformationOver time, wonderful things began to happen in different parts of the organization. Tighter control over billing and collections, better cost tracking, easier multiple currency billing and simplified sales tax management were achieved in the accounting department, for example. Our engineers started using “cases,” or CRM system tickets, to manage the process of blade analysis. Manufacturing personnel came to enjoy the ease of using an on-platform shipping tool that allowed direct creation of shipments from a sales order within a single application. SOP’s and master batch records created clear, accessible guidelines for daily operation in a digital format. New inventory management automation and a centralized procurement system ensured access to accurate, up-to-the-minute levels of available product, improved cost allocation and better raw material tracking. The customer experience team began using surveys to gauge the company’s performance at not only meeting customers’ current needs, but also to get a sense of new services people would like to see from us.

    Internal and external quality issue tracking through digital cases enable us to recognize issues early, investigate them, and resolve problems as quickly as possible. Internal costs savings were realized, too, when the operations department declared “paperless status” in September 2019, eliminating over 87,000 pieces of paper and about $10,000 in related expenses annually! An order is now received, processed, manufactured, packed, shipped and invoiced using only a single piece of paper – the packing slip.

    Steve KaoThe sales and marketing teams were also rewarded with automated processes to pinpoint customers’ pain points and offer customized solutions. The integration and optimization of software systems provide quick and easy account “snapshot” analysis and tracking via personalized dashboards, providing our salespeople with all the information they need at their (keyboard-operating) fingertips. Our marketing staff has gained tools to determine the information prospective customers are looking for and deliver it to them not only when they want it, but how. A central repository offers the entire international team access to all online marketing collateral, and a Kanban process enables them to request sales support materials digitally.

    Today, we are proud to report that 100% of our business processes are in the cloud (except for a few processor-intensive applications and some local file storage). Our entire office staff company-wide has access to all job functionality via the web, facilitating remote operation on laptops, iPads, mobile phones and other devices. As a result, we now have maximum flexibility to maintain uninterrupted service to our customers despite unforeseen events that may impact our ability to operate from a central location.

    Greg sees our company’s digital transformation as a logical extension of our continuous improvement mindset and believes that you can’t really do one without the other. “Our culture has always placed an emphasis on finding ways to work smarter and leverage technology to do it. Much like continuous improvement, meaningful digital transformation is an accumulation of very small improvements done over time that come together to create large, efficient and more capable systems.”

    It began with the belief that if we could create a digital record of all our customer interactions, we could attain operational bliss and deliver amazing experiences for our customers.  And we did. For now. Because, almost by definition, digital transformation is a never-ending process with infinite room for improvement. As our ways of conducting business keep evolving, our technology capabilities grow, and our customer focus remains steadfast, there’s no doubt we will continue to “transform.”

  • Defeat Back Doctoring with Polyester Containment Blades

    Defeat Back Doctoring with Polyester Containment Blades

    In flexographic printing, perfect print quality and efficiency are the ultimate goals for press operators. One pesky obstacle that often disrupts this quest is the notorious “back doctoring” or “trail doctoring.”

    Understanding Back Doctoringback doctoring explained

    No press operator wants to deal with the hassle of frequent press stoppages for cleaning sessions. Back doctoring or trail doctoring, is not only a nuisance but also a costly problem, leading to lost press time, wasted ink, and substrate.

    Doctor Blade vs Containment Blade

    The doctor blade and containment blade play different roles in transferring ink from the anilox roll to the substrate. Choose each blade carefully to ensure the doctor blade chamber works optimally.

    Doctor blades ensure precise ink transfer to the printing plate and substrate. It meters ink from the anilox roll before the transfer takes place. The doctor blade needs to be stiff and rigid to prevent ink from passing underneath it, leading to excess ink on the anilox roll.

    Conversely, the containment blade collects any excess ink post-transfer. The rotation of the anilox roll lifts the tip of the containment blade, allowing ink to flow underneath. The ink flows back into the chamber, reclaiming it for future use. Unlike the doctor blade, the containment blade should be thin and flexible to create a one-way “valve.”

    Back Doctoring Explained

    Back doctoring occurs when the containment blade meters or doctors the ink, preventing its return to the chamber. The primary culprit of back doctoring is a steel containment blade. Due to its stiffness, steel doctor blades prohibit ink from re-entering the ink chamber on the back side of the anilox roll. Back doctoring can also occur when operating at high speeds or with smaller anilox diameters. The centrifugal force of the roll as it turns is greater causing the containment blade to become ineffective.

    Defeat Back Doctoring

    The key to eliminating back doctoring is using the right containment blade.

    The containment blade should be thin and flexible so the rotation of the anilox roll can lift it. This allows the containment blade to effectively remove excess ink and create a one-way path for it to return to its chamber. Unlike a doctor blade, a containment blade does not require a bevel to function correctly. Choosing a straight or radius blade edge will optimize performance and cost.

    Polyester containment blades offer a winning combination of flexibility, stability, and solvent resistance. Not only are they more cost-effective than steel doctor blades, but they also enhance safety during the printing process. With no sharp fragments to worry about, polyester blades reduce anilox roll scoring and excessive wear.

    Back doctoring is a common pressroom problem that, fortunately, has an easy fix: converting to a polyester containment blade. Choosing a plastic blade keeps unused ink in the chamber reducing downtime and increasing print efficiency – even at high press speeds.

    Read our blog post, “5 Reasons to Switch to Polyester Containment Blades” to learn more about the benefits of using high-performance polyester containment blades.

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    Request a Free Sample of TruPoint Polyester
  • Flexo Concepts Joins Local “Scallop Roll”

    Flexo Concepts Joins Local “Scallop Roll”

    Flexo Concepts Scallop Shell Plymouth, MAFlexo Concepts recently joined 29 other area businesses participating in the latest Plymouth Area Chamber of Commerce street-side art project – “The Scallop Roll.” Part of a celebration to commemorate our country’s upcoming 400-year anniversary, the project features a collection of large, fiberglass scallop-shaped forms about 4 feet tall and 3 feet wide. Company sponsors worked with local artists to come up with design concepts and paint the structures – front and back. The shells have Flexo Concepts Scallop Shell Plymouth, MAbeen installed at various locations around the downtown and waterfront areas for residents and visitors to admire, and maps are available to help people make a fun activity out of finding them as they explore the town.

    According to the Plymouth Area Chamber of Commerce, “The scallop was selected for this year’s campaign because of its symbolism for pilgrimage. Artwork of the shell can even be found on local headstones dating back as early as 1681.”

    For its design, Flexo Concepts chose a nautical theme radiating a message of acceptance and equality. The front of the shell depicts a seaside display with a rainbow-colored lighthouse at its center. The back features a quote by John Lennon, “It matters not who you love, where you love, why you love or how you love; it matters only that you love.”

    Anyone visiting the area is encouraged to visit the Plymouth, Massachusetts downtown waterfront to see the shells.

  • TRESU and Flexo Concepts boost flexibility and efficiency in the pressroom

    TRESU and Flexo Concepts boost flexibility and efficiency in the pressroom

    Tresu and Flexo Concepts partnered at Labelexpo Europe 2019Industry partners TRESU and Flexo Concepts set their sights on boosting flexibility and efficiency in the pressroom. The result: a doctor blade clamping system that allows printers to quickly change between steel and plastic blades to optimize their ink and coating delivery system for effectiveness, efficiency and safety. Two amazing products – the E-Line Chamber Doctor Blade System by TRESU and Flexo Concepts’ TruPoint Orange® doctor blade – have been brought together to revolutionize the ink delivery system for today’s printers.

    The E-Line Chamber Doctor Blade System

    TRESU’s E-Line Chamber Doctor Blade System has been simplifying and speeding doctor blade changes for steel blade users since 2013. In its spirit of “innovating tomorrow’s printing,” TRESU designed a simple clamping apparatus that replaces screws with an eccentric rod that can be actuated from the end of the chamber. Printers using the E-Line system no longer have to loosen and tighten multiple screws across the clamp, and blade changes can be completed in a swift two minutes or less.

    Growing Demand for Plastic Doctor Blades

    Market developments have inspired the introduction of a variety of new ink and coating formulas – UV chemistries, specialty coatings and digital priming solutions to name a few – to enhance the look of packaging and gain press efficiencies. Steel blades are effective when applying water and solvent-based inks, but many printers have problems when using steel to apply these new formulas. Press operators are increasingly finding that plastic blades are superior in these applications.

    Tresu E-Line blade clamp with TruPoint Orange doctor bladeThe NEW TRESU Series XL Blade Holder

    The E-Line Chamber Doctor Blade System was originally created for steel doctor blades, and its design limited its use to steel or very thin polyester blades. To address the increasing demand for plastic doctor blades, TRESU worked closely with Flexo Concepts to develop its exclusive Series XL Blade Holder. The interchangeable quick-change clamp apparatus, used with the E-Line System, can accept blades between .02″ or 0.5mm and .04″ or 1mm thick. E-Line users will now have access to a much wider variety of doctor blade options, and printers who prefer plastic blades – whether for safety, blade life or solving problems – can also enjoy its benefits.

    Limitations of Steel Doctor Blades

    When metering UV chemistries, a steel blade’s surface energy and flexibility can prevent a smooth transfer of ink or coating to the plate. The higher-viscosity formulas tend to build up behind the blade and spit onto the web, especially at high press speeds. Inks containing large particulates and specialty coatings such as grit, glitter, dull and satin, and the coarse anilox surfaces used to apply them are also extremely abrasive to steel doctor blades. Blades have to be changed frequently which impacts press running time and blade costs. Fast blade consumption also occurs when steel blades are used to apply digital priming solutions which are highly corrosive to metal. In all of these applications, slivers of a steel blade can break off and cause issues with print quality and anilox scoring.

    TruPoint Orange Doctor Blade

    Since its introduction in 2013, the TruPoint Orange doctor blade has been widely adopted as a replacement for steel in narrow web pressrooms due to its equivalent metering performance and safety benefits. But its ability to eliminate UV ink spitting and last longer in abrasive and corrosive environments is what has made it more popular than ever in digital and sheetfed offset pressrooms as well.

    TruPoint Orange is a safe doctor blade optionA product of Flexo Concepts’ doctor blade innovation lab, TruPoint Orange is constructed from a next-generation polymer material and finished with a precisely engineered MicroTip® edge. The combination of material and tip provides enough stiffness – at thinner gauges than traditional plastic blades – to maintain a strong blade contact area that not only delivers exceptional metering but also prevents ink and coating from slinging. TruPoint Orange blades are highly abrasion-resistant and chemically compatible with all specialty ink and coating formulas, producing better lay-down and outlasting steel. As an added bonus, TruPoint Orange is safer than steel for blade handlers and anilox rolls – no injuries or metal slivers that cause scoring.

    A Perfect Match

    As TRESU’s original E-Line Chamber Doctor Blade System improved efficiency in the pressroom, the latest enhancement adds flexibility. The company’s Series XL Blade Holder makes it quick and easy for a press operator to change out a blade and choose a steel or plastic blade based on the demands of the job. And by making the use of a TruPoint Orange blade possible, the new design gives printers access to a blade that can handle difficult chemistries and deliver what today’s customers are looking for – eye-catching, brand-differentiating, vibrant packages that sell products.

    Current Models

    TRESU’s new XL Blade Holder is available for the D1E, D2E and D3E versions of its E-Line Chamber Doctor Blade System. These models make up the majority of systems used in narrow web, digital priming and coating, offset coatings and some wide web applications. No modifications to the chamber are required to retrofit the new clamp system into existing flexo printing units.

    Watch how easy it is to change a blade with the E-Line clamping system!

    Learn how the P-Line clamping system gives corrugated printers access to truPoint blades.

  • TruPoint Orange®: A Versatile Multi-Tasker in the Pressroom

    TruPoint Orange®: A Versatile Multi-Tasker in the Pressroom

    blank As the label and packaging markets evolve, printers need products that can keep up. TruPoint Orange offers a versatile doctor blade solution that delivers high-quality graphics, keeps presses running longer, reduces waste and solves common pressroom problems in a single doctor blade product.

    Orange meters like a steel doctor blade

    TruPoint Orange delivers the metering performance of a steel doctor blade in highly demanding graphics applications. The next-generation polymer material together with an advanced MicroTip® edge allows the blade to achieve a fine contact area with the anilox roll and deliver effective wiping on line screens up to 785 L/cm. Due to the tip design, the small contact area is maintained throughout the life of the blade, and metering is consistent for the duration of the print job.

    Orange eliminates UV spitting

    ink spitting steel doctor blades vs plastic doctor bladesWhen used to apply UV inks and coatings, TruPoint Orange is strong enough to withstand the force of these higher-viscosity formulas without flexing – even at high press speeds. Its controlled metering keeps the ink from sliding underneath the blade and spraying or “spitting’ onto the web and surrounding area. The material also has a lower surface tension than steel, decreasing the attraction of the ink to the blade and allowing a smoother transfer to the plate.

    Orange is a good option for white decks and specialty coatings

    Applying inks and coatings that contain titanium dioxide, metallic, glitter, sand or other large particles requires a tough, durable doctor blade that can stand up to their harsh properties and the coarse anilox surfaces required to transport them. The TruPoint Orange blade not only effectively meters these formulas, but the blade material resists their abrasive and corrosive properties, so it also offers superior longevity in these environments.

    Orange is safe and lasts longer

    The next generation polymer material that TruPoint Orange is constructed from retains the blade life and safety benefits that distinguish plastic doctor blades from steel. The material is self-lubricating, with a low coefficient of friction to resist mechanical wear, so blade life is extended in every application and presses can run longer. Even the worn blades will not damage anilox rolls or cut operators when handling them.

    MicroTip doctor blade edge lamella doctor bladeOrange thickness and MicroTip can be customized

    TruPoint Orange blades are available in thicknesses ranging from .7mm to 1.25mm to offer varying degrees of stiffness, rigidity and deflection. Add to this a variety of MicroTip profiles and these blades can be customized for a “perfect fit.”

    With options that can be tailored to fit every application, TruPoint Orange with MicroTip edge technology at once presents a versatile, safe and “problem-solving” doctor blade option for the narrow web pressroom. Choosing Orange to reduce blade changes, waste, mess and injuries can not only simplify the job of the press operator but also significantly enhance the printer’s bottom line.

  • Flexo Concepts®: Distinguished Exporter of TruPoint® Doctor Blades

    Flexo Concepts®: Distinguished Exporter of TruPoint® Doctor Blades

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    If a time period in a company’s history can be characterized by a single phrase, 2018 could be called the “year of the export” for Flexo Concepts.

    On the verge of wrapping up its 3rd decade of selling overseas, doing business globally is nothing new for our doctor blade manufacturing company. But 2018 has been a year to celebrate. Flexo Concepts received two high profile export awards, won its fifth export grant, and is about to onboard its third international business development manager.

    First, Flexo Concepts was named, “2018 Exporter of the Year” for Massachusetts by the U.S. Small Business Administration in April. The very next month, Flexo Concepts was recognized at the national level, receiving blankthe President’s E Award – considered the highest recognition any U.S. entity can receive for making what Secretary of Commerce Wilbur Ross calls “a significant contribution to the expansion of  exports.”

    In November, Flexo Concepts received notification that it was awarded funding for the fifth time through the Massachusetts State Trade Expansion Program (STEP) to facilitate long-term export growth. When allocating the grant, the Massachusetts Export Center chooses companies based on their demonstrated commitment to boost exports, create jobs and impact the economy.

    blankAnd now, the company is adding to its team of overseas sales representatives fully dedicated to international business development and service.

    Flexo Concepts understands the importance of having salespeople in the field who understand the regional markets, speak the native languages and are intimately familiar with local cultures and business practices. Soon Arnoud de Jong will join Bernat Ferrete (based in Spain) and Steve Kao (based in Taiwan) in promoting the TruPoint line of doctor blades globally. Arnoud will be based in his home country, the Netherlands, and brings a wide range of strategic capabilities to his new role – a good sense for the European flexo industry, strong marketing background and proficient language skills in his native Dutch, English and German.

    The activities of the international business development managers are fortified by support from back home – Flexo Concepts’ headquarters in Plymouth, Massachusetts. The company actively participates in foreign trade associations and regularly exhibits at key trade events around the world. To localize its selling, the company’s marketing department provides translated versions of its sales tools and promotional materials – brochures, installation guides,  email campaigns, blogs, white papers, infographics, ads, training documents, etc. – and recently launched Spanish and Chinese versions of its blankwebsite (with French and German to follow in 2019).

    Behind the scenes, developing and executing a successful international business model is a whole-company team effort. From navigating the intricacies of international accounting, to mastering the complexities of shipping and logistics and maintaining compliance with foreign regulations, every department is involved.

    But, while “internationalizing” the business has been (and will continue to be) one of our biggest challenges, it will surely also remain one of our biggest rewards. Exports have grown from 17% of revenues in 1991 to over 40% today. We maintain OEM relationships and distribution on every (habitable) continent, and our current customer base spans 50+ countries worldwide. The recognition we have received in 2018 celebrates our efforts over the past 30 years to advance the global flexo printing industry.

    And we’re pretty darn proud of it.

  • Manufacturing Manager Adam Yock Talks about Plant Safety at Flexo Concepts

    Manufacturing Manager Adam Yock Talks about Plant Safety at Flexo Concepts

    Adam Yock Flexo Concepts Plant SafetyOne of Flexo Concepts’ most important cultural values relates to its people and keeping them safe is one of its highest priorities. For this reason, the company has established a “Safety Team” and protocols throughout the building to create and maintain a safe environment for its employees.

    Today we will talk with Manufacturing Manager Adam Yock to learn more about what Flexo Concepts does to keep workers safe.

    Adam, can you tell us about the Safety Team and their responsibilities?

    The Safety Team consists of five members from the production staff who meet on a regular basis to review the overall safety of the premises and address any areas of concern. As the manufacturing manager, I perform random safety audits to identify risks and make suggestion tickets available for employees to communicate any safety concerns they may have. The tickets are posted on a master board in the shop, tracked through our CRM system and attended to by the Safety Team. Safety tickets receive immediate attention and take priority over ideas for needed repairs or continuous improvement posted on the board.

    What are some of the safety measures you have in place in the manufacturing area?

    flexo concepts manufacturing

    On the manufacturing floor, there is a wide variety of safety equipment available to protect workers from injuries. All our machines are guarded at the cutters to keep operators from being hurt and prevent loose pieces of blade scrap from flying into the air. Ear plugs or muffs are worn by employees running the blade cutting equipment to protect from the loud machine noise. There are anti-slip mats throughout the shop and anti-fatigue mats in all blade fabrication areas. Bench heights are kept at a comfortable height that allows the operators to work without being hunched over, and windows have been installed in doors entering/exiting the shop to prevent someone from being hit by a door being opened from the opposite side.

    The company purchased flow racks for the storage of raw material to reduce the need for workers to bend when picking material, and an automated conveyor system makes it easy to move heavy boxes from the production lines to the shipping area. Flexo Concepts also installed a Dura-Vac central trim collection system to gather and dispose of manufacturing waste, eliminating the need to physically remove blade scrap from the workstations.

    We also use 5S practices which not only drive efficiency but also a continuously tidy and safer shop environment. The company has structured, documented procedures and shop floor workforce training programs in place to ensure that blade fabrication, order fulfillment and scrap removal are done properly and safely. All manufacturing employees are formally trained and certified in the proper use of forklift equipment.

    How do you communicate safety procedures with your employees?

    Safety procedures are communicated through monthly team meetings, quarterly company meetings, building-wide notices and training events. Evacuation procedures and instructions specific to each department are posted throughout the facility. Also, the Safety Team sends out safety tip sheets to all employees before each major holiday to help protect them and their families from accidents at home.

    Do guidelines change and evolve over time, and if so, how?

    flexo concepts doctor blade manufacturing supplier

    Flexo Concepts takes pride in being proactive when it comes to safety. Our company stays in compliance with Osha guidelines and has outsourced the management of some of our safety initiatives to vendors. Through contracts with providers such as CINTAS and Yankee Sprinkler, our equipment specifications and instructions are continuously monitored and kept up to date. For example, Cintas has installed a first aid station in our shop, including AED technology with on-site monthly service to maintain the device. Yankee Sprinkler is under an annual contract with Flexo Concepts to maintain our fire protection system. Both companies provide regular training for our staff on the proper use of this equipment.

    How successful has your company been with plant safety?

    Flexo Concepts continues to be very successful with its safety protocol as indicated by our low injury rates and minimal lost-time accidents. Since establishing a Safety Team dedicated to this important aspect of our business, the number of accidents that occur in our building has been reduced to almost zero. We are proud of our great track record and feel confident that the safety systems and procedures we have in place will keep it that way!

    To learn about how using plastic doctor blades can improve safety and reduce costs in your pressroom:

    [Read our white paper, “The [Hidden] Costs of Using Steel Doctor Blades”]

  • Safety First: Discover Why Plastic Doctor Blades Are Preferred over Steel

    Safety First: Discover Why Plastic Doctor Blades Are Preferred over Steel

    blankEveryone agrees that plastic doctor blades are safer than steel. But why exactly is this true? The answer lies in the fundamental differences between the two materials: steel blades are harder and sharper than plastic blades. While this is commonly understood, the reason becomes clear when we examine the molecular structures of these materials.

    What Does It Mean to Be Sharp?

    Steel and plastic materials (and all matter) are comprised of small particles. As a doctor blade wears, the material is removed in clusters of particulate which can be no smaller than the basic particle size of the material. So, the finest tip on a blade can only be as wide as one particle. And since plastic particles are larger than steel particles, a plastic blade worn to its finest point will be wider than steel. This combined with the fact that plastic is inherently softer than steel, results in a plastic blade edge that is less “sharp” than steel and safer to handle.

    Ink Metering with Plastic Bladesblank

    Given this information, one might wonder if plastic blades can wipe as effectively as a steel blade. The answer is some can, and some can’t. UHMW plastic for example is perfect for applying ink or coating in applications where graphic difficulty is limited.  But it is too soft for applications involving high screen anilox rolls or precise metering requirements where a fine contact area is required.

    Thanks to next-generation polymers like Delrin, Polyether Ether Ketone (PEEK), or glass/Kevlar reinforced materials, there are compositions that are rigid enough to support a fine contact area similar to that of steel. The bonus is these blades are plastic, so they are inherently softer and do not develop a dangerous cutting edge risking injury to press operators.

    Making the Switch

    Next-generation polymer doctor blades offer the performance of steel blades while providing the safety of plastic blades. The combination of advanced materials and innovative profile (MicroTip, bevel, etc.) design enables these safe doctor blades to perform in demanding applications previously dominated by steel. Substituting a next-generation polymer doctor blade for steel is a great way to produce a high-quality product while maintaining a safe work environment.

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  • In Safe Hands with Polymer Doctor Blades Blog Series Part 2 “Steel Doctor Blade Risk Management”

    In Safe Hands with Polymer Doctor Blades Blog Series Part 2 “Steel Doctor Blade Risk Management”

    blankWorkplace hazards are present in almost every industry, and the printing industry is no exception. A press operator faces many dangers at work every day. One of the greatest is the risk of serious lacerations to his hands if he’s using steel doctor blades. He is exposed to being cut anytime he’s handling them – installing or removing them from the press, cleaning them, disposing them and when changing end seals. The blades are especially dangerous when being replaced – their edges become honed through contact with the anilox roll as they wear, leaving razor-sharp tips that can cause serious cuts.

    Fortunately, printers have a variety of options to reduce or eliminate the risk of injuries from steel doctor blades without sacrificing print quality.

    Wear personal protective equipment

    blankWhen worn correctly, cut-resistant gloves can prevent injuries to operators when using steel blades. However, the U.S. Bureau of Labor Statistics 2012 figures show that about 70% of lost-time hand injuries occur on workers who aren’t wearing gloves. The remaining 30% are wearing gloves at the time of the accident, but the gloves are inadequate, damaged or the wrong type for the job. It goes to show, the steel doctor blade risk of serious lacerations to a press operator’s hands doesn’t just go away with wearing protective gloves.

    Establish occupational health and safety programs

    Companies with safety and health management programs reduce their injury and illness costs by an estimated 20-40% according to the Occupational Safety and Health Administration (OSHA). In fact, an ASSE white paper by OSHA’s Office of Regulatory Analysis suggests that companies that implement effective safety and health programs can expect a return of $4 to $6 for every $1 invested. These programs lead to improved productivity and employee well-being in addition to reducing injury-related direct and indirect costs. Training employees and documenting handling procedures can also be beneficial in reducing the doctor blade risk of lacerations. In the pressroom, operators should be taught how to minimize their exposure to the risks from steel doctor blades by following standard protocols – for example by keeping blades in their protective packaging until they are ready to be installed and not changing blades on a machine while it’s running.

    Switch to plastic doctor blades

    The above options will certainly lower the risk of getting cut by steel blades but switching to plastic doctor blades will completely eliminate this doctor blade risk. Plastic materials are inherently softer and less sharp than steel. Even when plastic blades are worn, their edges are not sharp enough to cut a press operator.

    Unlike in the past, a printer producing high-quality graphics now has the option of choosing a plastic blade for its safety benefits. Next generation polymer blades with MicroTip® technology can compete with the metering performance of steel in even the most demanding graphics applications while retaining the safety benefits of traditional plastic.

    Next generation polymers with MicroTip®

    blankToday’s advanced polymer material is stiffer than traditional plastic and can support a precisely engineered MicroTip edge. This tip design allows the blade to achieve and maintain a fine contact area with the anilox roll comparable to a steel blade. Next generation polymer blades are able to effectively meter line screens up to 2000 LPI or 785 L/cm and produce graphics of the highest quality. The MicroTip has a long and steady wear period which reduces the frequency of blade changes and delivers consistent ink film thickness for the duration of the print job.

    Today’s printers have more options than ever to improve workplace safety. Protective gear and safety programs will no doubt reduce the risk of injuries from steel doctor blades. But if you want to completely eliminate these injuries, then completely eliminate steel blades from your pressroom. Switch to next generation polymer blades and get the best of both worlds – high performance metering and safety.

    Look for part three of our In Safe Hands with Polymer Doctor Blades Blog Series – “Not the Sharpest Blade in the Pressroom.”

    Part 1: Numbers That Add Insults to Doctor Blade Injuries – Read about the frequency of hand injuries in the workplace and their impact on a company’s bottom line

    Request a Free TruPoint Doctor Blade Sample
  • Eliminate the Dangers of Steel Doctor Blades with TruPoint® Blades

    Eliminate the Dangers of Steel Doctor Blades with TruPoint® Blades

    Eliminate the Dangers of Steel Doctor Blades with TruPoint® Blades

    Every industry has its challenges, and for the flexo printing industry they include the dangers of steel doctor blades – anilox scoring and pressroom injuries. Fortunately, due to advancements in polymer materials and tip designs, press operators no longer have to trade the safety benefits of plastic doctor blades for the effectiveness of steel. Today’s next generation TruPoint doctor blades deliver the best of both materials – longer anilox roll life, enhanced pressroom safety and superior metering performance.

    Anilox Roll Scoring Is One of the Dangers of Steel Doctor Blades

    The anilox roll has been referred to as the heart of the flexo printing press. It is responsible for transferring the precise amount of ink required to create an image exactly according to a customer’s specifications. If the roll’s surface becomes damaged, the defects will show in the printed image.

    The most common types of anilox damage are scoring and wear caused by steel doctor blades. All doctor blades must be installed correctly to work properly. But the dangers of steel doctor blades include anilox roll scoringinstalling a steel doctor blade at the wrong angle, backward or with too much pressure can cause small fragments of the metal blade to break away. The jagged pieces become lodged against the roll and cause a deep scratch or “score line” that destroys bands of anilox cells as the roll rotates.

    Steel blades also accelerate wear across the surface of the anilox roller. Friction between the blade and roll erodes the anilox cell walls over time. As a result, the cell volume is reduced and the anilox can no longer carry the precise volume of ink that it was designed to transfer.

    When an anilox roll becomes scored or worn, the damage is permanent and the roll has to be resurfaced or replaced. There is loss of material and productivity as well – discarded substrate, ink waste and press downtime – all at a significant cost to the printer.

    Pressroom Injuries Are Another One of the Dangers of Steel Doctor Blades

    Another downside of steel is that the material is responsible for a large number of pressroom injuries. A press operator is exposed to being cut anytime he’s the dangers of steel doctor blades include pressroom injurieshandling steel blades – installing or removing them from the press, disposing them, and when changing end seals. The blades are especially dangerous when being replaced. Their edges become honed through contact with the anilox roll as they wear, leaving razor-sharp tips that can cause serious lacerations.

    Workplace injuries are not only traumatic, but also have a significant effect on a company’s bottom line. Printers spend substantial amounts of money every year on workman’s compensation insurance and medical bills which come directly out of hard-earned profits. In addition, there are a variety of indirect costs that are harder to quantify but still impact earnings – lost productivity, work interruption, machine downtime, equipment repairs, training of replacement employees and accident investigation.

    TruPoint Next Generation Blades Eliminate the Dangers of Steel Doctor Blades

    Flexo Concepts’ TruPoint polymer doctor blades provide smarter and safer alternatives in a wide range of flexo printing applications. All TruPoint blades are constructed from plastic materials that won’t damage the anilox roll or injure press operators. The materials don’t separate, splinter or crack and are inherently softer and less sharp than steel. Even when plastic blades are worn, their edges are not sharp enough to destroy a roll or cut a press operator. [Download our Safety white paper: “The Hidden Costs of Using Steel Doctor Blades.”]

    TruPoint next generation doctor blades are engineered for printers who want to combine the best benefits of both plastic and steel in one blade. Unlike with eliminate the dangers of steel doctor blades with TruPoint Orangetraditional plastic materials, the TruPoint Orange® blade is constructed from an advanced polymer material that’s rigid enough to support a special MicroTip® edge. MicroTip is designed to achieve and maintain a fine contact area with the roll over the life of the blade. Orange is capable of metering line screens up to 785 L/cm as well as a steel blade and is a popular choice in flexible packaging, coating and label printing applications, where the blade also prevents UV ink spitting and start-up lines.

    As graphics requirements grow in the corrugated printing sector, many printers are finding that standard UHMW cannot meter their mid-level line screen anilox rolls effectively. There is a “gap” between where UHMW is effective and steel is required on anilox line screens roughly between 120 and 200 L/cm. For printers who don’t want the safety and scoring risks of a steel blade, the TruPoint Green beveled doctor blade provides them with a good alternative. The material demonstrates better stiffness and twice the spring memory of standard UHMW, allowing it to maintain an effective contact area with eliminate the dangers of steel doctor blades with TruPoint Greenthe roll for the life of the blade. Green is an easy drop-in replacement for UHMW to enable printers to produce better print quality without resorting to a steel blade.

    Printers, like people in other industries, struggle to find ways to reduce operational costs and improve safety. New polymer doctor blade innovations now give printers safer alternatives to steel blades that deliver the same level of quality. Choosing TruPoint next generation polymer doctor blades over steel is a simple way to prolong the life of anilox rolls, reduce lost-time accidents and deliver exceptional metering performance.

    Request a Free TruPoint Doctor Blade Sample
  • In Safe Hands with Polymer Doctor Blades Blog Series Part 1 “Numbers That Add Insults to Doctor Blade Injuries”

    In Safe Hands with Polymer Doctor Blades Blog Series Part 1 “Numbers That Add Insults to Doctor Blade Injuries”

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    OSHA reports, “Businesses spend $170 billion a year on costs associated with occupational injuries and illnesses.” Also, “Employers pay almost $1 billion per week for direct workers’ compensation costs alone.” These statements by themselves are alarming. But even more concerning is the fact that these costs are “expenditures that come straight out of company profits.”

    It’s not hard to imagine how traumatic it can be to experience (or even witness) an accident at work. But what not many people think about is the frequency that these injuries occur and the impact they can have on a company’s bottom line.

    It’s true that government regulations have helped keep workers safer. But on-the-job accidents continue to be a big problem for many businesses – and the printing industry is no exception. In the pressroom, some of the most common accidents are cuts and lacerations that occur when operators are handling steel doctor blades. Their edges are incredibly sharp, and machinists need to be extremely careful when installing and removing them from the press to avoid seriously injuring their hands.

    Hand injuries in numbers

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    According to the U.S. Center for Disease Control and Prevention, hand injuries account for 1,080,000 emergency department visits by workers every year in the U.S. (Industrial Safety & Hygiene News, May 1, 2015). In fact, hand injuries ranked second in number after back strains, sprains and other work injuries to the torso in 2015, as reported by the U.S. Bureau of Labor Statistics (U.S. BLS), and close to 20% of all workplace injuries involved cuts and lacerations to the hand and fingers.

    Some other statistics assign dollars to these injuries. The U.S. BLS informs us that hand and wrist accidents, the most expensive of all emergency department injuries, cost $740 million every year; the average hand injury claim now exceeds $6,000, with each lost-time workers’ compensation claim totaling just under $7,500.

    Hidden costs of hand injuries

    Equally significant are the indirect costs associated with work-related injuries. A study published in the Journal of Bone and Joint Surgery indicates that productivity costs due to absenteeism contributed more to the total costs of hand and wrist injuries (56%) than did directly related health-care costs. The U.S. BLS recorded 124,540 on-the-job hand injuries in 2015 that resulted in recordable missed work time of 5 days each. These and other secondary costs – machine downtime, equipment repairs, training of replacement employees, accident investigation, implementation of preventive measures, not to mention bad publicity – contribute to the already steep costs of workplace injuries.

    Like many companies, printers pay a high price for on-the-job injuries. Some of these costs directly affect profits while others have an impact on operations and employee well-being that’s harder to quantify. One thing is certain though – as OSHA cautions, “In today’s business environment, these costs can be the difference between operating in the black and running in the red.”

    Look for part two of our In Safe Hands with Polymer Doctor Blades Blog Series – “Steel Doctor Blade Risk Management” to learn about ways to reduce or eliminate these risks.

  • 3 Ways to Conquer UV Ink Spitting in your Pressroom

    3 Ways to Conquer UV Ink Spitting in your Pressroom

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    Ever seen your perfect print job turn into a messy, chaotic artwork? If you’re a label printer, you’ve probably faced the nightmare of UV ink spitting. But don’t worry, we’ve got the solutions you need to reclaim your sanity! 

    1. Start with Some TLC

    Ensure your equipment is in top shape. Clean the anilox roll, inspect the doctor blade holder or chamber, and lower the doctor blade pressure for a perfect wipe. Minor tweaks can work wonders. 

     2. Opt for New Anilox Roll Engravings

    Traditional engravings can hinder UV ink flow. Because UV inks have a viscosity of 5-7 times greater than that of water-based or solvent-based formulations, different anilox configurations may be required. New elongated hexagonal cell engravings, or even newer channeled engravings, can improve ink transfer and reduce or eliminate ink spitting.  

     3. Try a Different Doctor Blade

    Doctor blades are an easy variable to change when up against UV ink spitting. It’s a low-cost part with a big impact. TruPoint polymer doctor blades are a fantastic choice for handling UV inks. Why? Our unique MicroTip edge ensures consistent ink metering but more importantly, TruPoint polymer materials have a lower surface energy than steel.  

    This lower surface energy reduces the attraction of the UV ink to the doctor blade and allows for a cleaner ink transfer. Steel’s high surface energy attracts UV ink, causing it to accumulate on the backside of the blade and then release. This is UV ink spitting! Ink Spitting explained

     Taming UV ink spitting can be easier than you think. Regular maintenance and the right doctor blade can make all the difference. Don’t let ink-spitting drive you crazy; we’re here to help! 

     

    Request a Free TruPoint Doctor Blade Sample
  • The Spectrum of Culture: From Employee to Customer

    The Spectrum of Culture: From Employee to Customer

    blankThe 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 packagingthese 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

    Spectrum of Culture FTA Forum 2018 Phil Ryan Rachel Acevedo
    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 blankholistic 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

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    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!