Sam Merenda and his partners at Graphics2Press had a crucial decision to make. Operating a trade shop that produced plates for converters of corrugated boxes and poly bags, they had relied on liquid photopolymer plates and analog sheet photopolymer plates since the company’s inception in 2004. Despite keeping an eye on the evolving digital sheet polymer market, they initially believed their business didn’t justify the need for digital plate making.
Graphics2Press Explores Future-Proof Plate Making Technology
“Analog always worked very well for us, and we didn’t have a pressing need to switch to digital,” says Mr. Merenda. “However, we realized that there’s no future-proof technology in analog sheet polymer. All imaging technology is shifting to digital, so we needed to explore our options.” This realization led Mr. Merenda to attend Drupa in Dusseldorf, Germany, in 2016 to learn more.
At Drupa, he engaged with leading digital photopolymer technology providers and met with Xeikon to explore their ThermoflexX digital platemaker. Back in the U.S., he continued discussions with representatives from both companies, including Anderson & Vreeland, the independent North American distributor for ThermoflexX plate makers. Graphics2Press had a longstanding relationship with A&V for various supplies and equipment, which boosted Mr. Merenda’s confidence. However, he found that the 80-inch ThermoflexX platemaker was more expensive than the other digital polymer systems he was considering. He needed to understand why.
A&V explained the numerous advantages of the digital plate maker, such as speed, efficiency, and its industry-leading 5,080 dpi resolution. Mr. Merenda recognized that while the 5,080 dpi resolution was currently crucial for some companies using flexible packaging, it would soon become a standard expectation for brand owners specifying folding cartons and corrugated containers. Balancing the needs of customers satisfied with the 2400 dpi capabilities of analog polymer and those seeking higher image quality, Mr. Merenda realized that adopting a digital plate maker was essential for future-proofing his business.
Embracing Digital Plate Making with ThermoflexX
“A&V answered all our questions and addressed our concerns,” Mr. Merenda explains. “We’ve had an excellent relationship with them since we opened our doors. Knowing we’d be working with Anderson & Vreeland when making an investment like the ThermoflexX made the decision much easier.”
Once the new digital plate maker was operational, its advantages quickly became apparent. The most immediate benefit was the improved plate quality. “The ThermoflexX can image plates at a very high resolution but also works for the lower resolution jobs we do every day. This gives us unparalleled flexibility and lets us raise the bar on what we offer customers,” Mr. Merenda continues. “It’s not about one being better; it’s about having the choice of which to use for a given customer requirement.”
Operational Benefits of Digital Plate Making
For Mr. Merenda and his team, the operational benefits of the ThermoflexX transformed their workflow and personnel requirements.
“Handling an 80-inch digital photopolymer plate is definitely a learned skill,” says Mr. Merenda. “We thought we might need two people to ensure the plate’s digital layer didn’t crack, but the ThermoflexX’s automatic plate loading and auto-feed features quickly dispelled that concern. Plates load quickly and accurately, requiring less human handling and making the training process much faster and easier. The time savings have been fabulous.”
Additionally, digital plates enable more precise and repeatable imaging compared to analog plates. This consistency is particularly advantageous for jobs that go to converters across the nation. For example, if a converter needs to replace a damaged cyan plate, digital plate making can reproduce the single plate accurately, ensuring no loss of image quality or registration. This consistency is crucial for brand owners, giving digital plate making a valuable competitive advantage.
Increased Productivity
In a fast-paced industry, the greater productivity of digital plate making significantly enhances capacity. “We can save up to 20 minutes per plate, which translates to about a 25 percent increase in throughput,” says Mr. Merenda.
These time savings allow Graphics2Press to turn around more jobs within a given shift, reducing turnaround times for customers and increasing the number of completed and shipped jobs each week. Combining this throughput with faster, easier loading and consistent, repeatable imaging, the 80-inch ThermoflexX digital plate maker is proving invaluable.
A Bright Future
“The digital system does require learning some new skills,” admits Mr. Merenda, “but the advantages are proving their value to our business.”
The transition to digital plate making has positioned Graphics2Press to meet current and future customer demands, ensuring high-quality, consistent results while improving operational efficiency and productivity. This strategic move highlights the importance of embracing technological advancements to stay competitive and deliver exceptional service.
