With color management in flexographic printing, converters often face persistent challenges that can impact the quality of their products. Although these issues may appear unique to individual shops, they frequently arise from common problems. Companies can implement effective solutions by leveraging deeper knowledge, technical expertise, and attention to detail. This case study focuses on Label Tech Inc., a New Hampshire-based label manufacturer, and how they addressed their color management issues.
The Challenge of Color Management in Flexographic Printing
“We were having some color issues,” admits Jonathan Routhier, Prepress Manager at Label Tech. “Solving them meant learning more about color and getting a new proofer.” With over 30 years of experience, Label Tech specializes in pressure-sensitive labels for both local and international brands in the food and beverage, medical, and nutraceutical sectors. Given the variety of flexographic presses on their shop floor, finding a color management solution that would function across all machines was crucial.
Collaborating for Solutions
To tackle these color challenges, Label Tech initiated discussions with Anderson & Vreeland (A&V), a trusted supplier in the flexographic printing industry. “We talked with the Technologies Team even before we invested in any new machines,” recalls Mr. Routhier. “Anderson & Vreeland was very helpful and supportive in identifying problems and solutions.”
Jessica Harrell, Manager of the A&V Technologies Team, quickly grasped Label Tech’s color management issues and, along with Regional Manager Peter Spain, recommended the Epson P7000 Proofer. This modern proofer would help improve color accuracy in their production process.
Implementing New Technology
The A&V team provided invaluable support in implementing the new proofer, assisting with advanced fingerprinting, and integrating an inline spectrophotometer into daily operations. Mr. Routhier noted that a series of written A&V reports were particularly useful, helping his production team achieve optimal performance from the new Epson proofer.
Meeting Demanding Deadlines
As Label Tech continued to expand, the need for timely production became even more pressing. The existing plate processor was causing delays, hampering their ability to meet customer deadlines. “Like any label shop, we have some very demanding deadlines,” Mr. Routhier explained. “We were running into delays because we’d have an issue with the plate processor but could not get the response we needed. Deadlines don’t stop!”
To address this challenge, the A&V Technologies Team recommended the XSYS nyloflex Xpress Thermal Plate Processor. “The Xpress is a modern design that uses a system of plate materials and consumables meant to work together,” said Mr. Routhier. “We find the plates do a better job of transferring ink to the substrates, resulting in more saturated colors and less plate distortion.”
Durability and Handling Improvements
One significant advantage of the XSYS nyloflex Xpress Processor is the enhanced durability of the plates. Mr. Routhier pointed out, “The other plates had to be babied and stored with foam layers between them to avoid damage. The plates used in the XSYS system don’t require as much special handling.”
Careful Decision-Making Process
Switching to a new plate processor required careful consideration. Label Tech began the process with conference calls and virtual demonstrations of how the new proofer and processor would work in their facility. A trip to Labelexpo in Chicago provided an opportunity to see the machines up close and address any questions. “The A&V Technologies Team was right there with us to ensure we understood everything we needed to know,” Mr. Routhier recounted. After confirming that the produced plates met their needs, Label Tech made the decision to proceed.
Positive Outcomes
Since the introduction of the Epson P7000 Proofer and the XSYS nyloflex Xpress Processor over a year ago, Label Tech has observed substantial improvements in productivity and efficiency in their color management processes. “The nyloflex Xpress Processor goes to work faster and more easily than the machine it replaced,” Mr. Routhier stated. “Customers don’t necessarily notice the difference, but with the Epson P7000 Proofer and the Xpress Processor, we have solved our color issues and definitely see a difference in the quality of the labels we produce.”
Final Thoughts
This case study highlights the significance of color management in flexographic printing and how strategic partnerships and technological advancements can lead to significant improvements. By working with Anderson & Vreeland and investing in the right equipment, Label Tech has successfully addressed its color management challenges, enhanced overall productivity, and improved the quality of its labels, ensuring competitiveness in a demanding market.
