Case Studies

Case Study - I

Customer: A mid-web Flexographic label printer

Challenge

A national mid-web Flexographic label printing company was experiencing challenges in producing nice minimum dot highlights and clean consistent color across the web. This is not uncommon in the Flexographic printing process. In this competitive market place, this customer wanted to expand into additional markets and targeted business that traditionally printed Offset. This exacerbated their current challenges.

Solution

The first step was to run a test plate on the press in order to find out how they currently were printing. With that data, SGI was able to create a curve and suggest using the new plate technology provided by Kodak via their Flexcel NX Flexographic Printing Plate.

Results

This minimum dot reproduction capability of this customer has significantly increased (currently printing a 1% highlight dot). The color consistency across the plate has exceeded their expectations. In addition, there have been some significant benefits realized due to the dot structure and Square Spot technology provided with these plates. Color make ready has been reduced by nearly half. In one case, a wine label project that took 2500 feet of “make ready” substrate with the prior printing plate technology to reach “not-so-pleasing color”, took only 200 feet with the Kodak Flexcel NX Flexographic Printing Plate. Also the run lengths have exponentially increased due to the flat-top dot and the plate running cooler. In another instance, 1.1 millions impressions (nearly 700 linear feet of substrate) have been produced on one set of plates. This set of plates has been filed and is waiting the next re-run of this product.


In a conversation with the in-house Pre-Press Manager, he said “There have been significant benefits across the board with this plate. My pre-press employees love to work on files that will be printed using these plates. There is so little to do in order to compensate for the nuances associated with Flexographic Printing as a result of the full tonal range and consistency of these plates.”

Case Study - II

Customer: Large offset packaging house

Challenge

A national prestigious packaging printer who did not have a Chicago presence was experiencing serious communications lapses as a result of being 800 miles away and in a different time zone from their customer. Proof delays, delays in color edits and approvals as well as last minute alts were some of the more tangible problems. Additionally, their in-house graphics team was having trouble keeping up with the higher volume of work that their client’s required.

Solution

Our team analyzed the various issues. We worked with the consumer product company and took control of the premedia work flow. In an effort to minimize time delays, we also put color managed proofers on both the printer and Consumer Product Company’s floor which were color managed by Splash.

Results

The results were miraculous. Splash worked thru the log jam which eventually turned into a steady timely stream of new work flowing thru production channels. The proofer on the printer’s floor helped them plan layouts, adjust them as needed and give us feedback early in the process. The proofer on the customer floor helped us to bring the brand manager color in a timely manner. No additional overhead was necessary. With a minimum investment we were able to bridle a fairly complex stream of work. This allowed the printer to focus on production and bring the client a timely product to the market. There was a 65% increase in turnaround time from what was being experienced prior to Splash’s involvement.

Case Study - III

Customer: Medium size cosmetic company

Challenge

A mid size cosmetic company was struggling with complex graphics that required various print solutions. Flexo, Offset, Digital etc. The nature of the brand required attractive eye-catching shelf presence. This required knowledge of various production processes that the in-house marketing and design team did not have. We were asked to help in procurement and file prep for the various processes that were being used.

Solution

As a plate service provider in offset and flexo, as well as strong premedia capabilities our staff was very familiar with the different file prep necessary for flexo vs. offset vs. digital. In addition to this premedia work we have also taken on a role of procurement for this customer.

Results

The customer is very pleased with our proactive style of getting involved and managing the above processes. Recently we were asked to take on inventory management for this client.