Data-mail integrates flexographic printing technology in their direct mail production facility.

Data-Mail Enhances Operations with Flexographic Printing Technology and A&V Expertise

Data-Mail, one of North America’s largest full-service direct mail lettershop companies, leverages a mix of conventional and digital printing technologies to produce over 1.5 billion pieces of direct mail annually.

Transitioning to Flexographic Printing Technology

With two facilities located in suburban Hartford, Connecticut, Data-Mail has historically relied on roll-fed offset presses and pre-printed, converted envelopes from suppliers. However, as their run lengths varied from a few thousand to millions of impressions, the company sought a more efficient and cost-effective solution.

As a first step in adopting flexographic printing technology, Data-Mail utilized two FL Smythe RA flexographic envelope-converting presses and subsequently added two more. They began acquiring imaged printing plates from a supplier, which streamlined their envelope production. Ultimately, the optimal solution was to bring plate production in-house, leading Tom Forrest, Pre-Press Manager at Data-Mail, to Anderson & Vreeland.

Cost Savings with In-House Plate Production

“The vast majority of our jobs are just two colors: black ink for the indicia and one or two spot colors for company logos and branding,” explains Forrest. “When we added the third and fourth flexo presses, we knew we’d see significant savings in plate costs and efficiency by doing the work in-house.”

Transitioning to flexographic printing technology required Data-Mail’s prepress department to adapt to the unique requirements of this method, as they were previously comfortable with offset and digital printing. Anderson & Vreeland’s prepress and flexographic printing experts provided crucial support, supplying printing plates, sticky back tapes, and technical expertise for all of Data-Mail’s flexo printing and prepress operations.

Implementing Advanced Equipment

The plates are imaged using a Piccolino Flexo Laser, complemented by Anderson & Vreeland’s Orbital X water-wash system and Whirl-A-Way Polymer Removal System. These systems ensure that all components remain clean and ready for continuous workflow, along with A&V’s software portfolio, which manages the overall production process. Having Anderson & Vreeland’s expertise in flexographic printing technology was a strategic advantage for Data-Mail, enabling them to reduce costs, gain complete control over their envelope production, and access valuable technical knowledge and support.

Reliance on A&V for Flexographic Printing Technology and Ongoing Support

Forrest emphasizes the importance of Anderson & Vreeland’s support in their transition to flexographic production. “They are very responsive and reliable, always quick to answer any questions by phone or in person. Our A&V sales rep regularly checks in to ensure we’re maintaining equipment and running smoothly. Because we’re all new to flexo, the help A&V has provided has been invaluable.”

Through their partnership with Anderson & Vreeland, Data-Mail has successfully integrated flexographic printing technology into their operations, enhancing efficiency and cost-effectiveness in their envelope production processes.

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