Deltabach, the top-flying commercial print house based here, has reported a substantial upturn in operation following its adoption in the latest generation LED-UV curing system from Air Motion Systems. The AMS XP9/17W unit was retrofitted to the coffee printer earlier just last year but, as Deltabach Director Marc de Jong explains, it wasn’t till the final quarter that the possibility of the brand new system to change his business became fully evident.
“Our primary basis for making an investment in the AMS LED-UV technology ended up being to increase the efficiency and productivity in our B1 press,” he shares. “It took us a while to have the balance of consumables right and adapt our practices and processes, but the numbers show this first objective has been realized. In the year before the upgrade we printed 24 million sheets; that rose to 30 million, pro rata, during our transition period and today, if we maintain our current amounts of output, we shall hit 36 million sheets this current year. This can be without any modifications in shift patterns, increases in manpower or electricity use together with added savings on things like spray powder, which we no longer use.”
The rise in productivity is largely caused by three key benefits associated with the AMS LED-UV curing technology.
First in the year 2011, carrying out a three-year period during which its turnover had quadrupled to €6 million, Deltabach made the decision to change its B2 press using the B1 Heidelberg CX 102. However, an added costs incurred in changing formats at pre-press and bringing in a larger guillotine flow line meant their budget would not stretch to some long delivery for that press. The compromise became problematic in practice: “It resulted in we were only in a position to run at 12- or 13,000 sph (sheets per hour) when coating and this was obviously not satisfactory from a commercial standpoint,” says Marc de Jong. “With the AMS system we don’t should coat, so we can run every job at approximately 16,500 sph – that’s a 20% differential.”
Second, sheets printed with AMS LED-UV curing are dry from the delivery and tend to be ready for immediate printing around the reverse side and downstream processing:
“This doesn’t just mean we are able to promise better turnaround times to our customers,” explains Mr de Jong, “it includes a major impact on our pressroom practice. Previously, on turn-and-tumble work, especially where uncoated or smooth papers were involved, the operator would output eight plates for the reason that job would have to wait – maybe overnight, and even longer – before the piles might be turned and place back with the press. Obviously, then another 10-20 minutes could be lost in obtaining the settings returning to the proper levels… now we turn and go ahead. If you attempt to quantify that – it’s amazing. Additionally, it gives another dimension to our planning as the timings have grown to be predictable.”
And the third factor is just one that may be often cited, but perhaps without its full ramifications being appreciated:
“By eliminating spray powder we not simply make life easier on the press as well as in the bindery, and enhance the product for your customer, we have been boosting the production time seen on the press,” shares de Jong. “We utilized to take three hours at the end of every week to de-powder the press, as well as the same was true of most of the finishing machines, given that is not really required it gets more available production up-time. All of this factors into our financial well being. We save dexmpky56 to an hour on a daily basis for the reason that LED-UV inks overnight inside the ducts, and many more time at the coating unit, where we used to have to alter plates and clean up between different jobs.”
The impact of your changes on workflow is clearly visible within the phone case printer where a large floor space is marked out into eight ‘lanes.’ This is formerly the marshaling yard where pallets of print were held and shuffled because they waited to dry before turning and reverse printing, or moving to publish-press. It now works as a buffer zone for print which is immediately ready for the next process, leaving a lot of free space for, possibly, the following press investment.
With around 70% of its business being with agencies, brokers and also other printers, production efficiency is essential for Deltabach to protect its margins whilst keeping its prices competitive. The added features of the AMS LED-UV technology will also be helping win new company. As de Jong continues, “Many in the major brand owners and designers specify a requirement for coating as standard procedure. We now have been able to show them that the is not necessary when utilizing our system… we actually placed our product among those from the other suppliers plus they couldn’t find the difference. This was the green light for AMS LED-UV.”
In another instance, the advantages happen to be much more dramatic. A serious national lottery company ended up being by using a spread of print houses to deliver its countless tickets for mailing to potential entrants. The A4 sheets are printed on G-Print with the personalized ticket info on one side and also the lottery company’s solid red corporate ID on the other. Because of this, the waviness in the papers from the coating, and slippage from your spray powders were causing mayhem at the mailing house:
“When we switched for the AMS system we supplied our quota as always, but without telling the buyer of your alternation in production,” explains de Jong. “It had not been prior to they called us in because their mailing house was demanding for all the tickets to become supplied this way. Their machines had never run so well. They could also realize that the standard of the solid was better, too, and the reality that we have been now capable of supply at such short notice meant we won the complete contract.”
Now Deltabach is exploring other aspects of the benefits how the AMS LED-UV brings. For just one from the property agency clients it is actually already printing ‘SOLD’ stickers which was previously sent for screen printing as they are on non-absorbent stocks, and tests are under means for innovative POS, packaging and promotional items on unusual substrates which may have added-value to develop better margins. Mr de Jong sees this being a separate enterprise, that is to be targeted at direct customers within the region:
“We will appear at any display, promotional or printed requirements the customer may have so we will supply. So far as our commercial printing service is concerned, Air Motion Systems’ LED-UV makes a significant difference, like waving a magic wand over our business. The designers love the product quality as well as the texture in our print, we compete on price so we are receiving a reputation as the go-to supplier for quick turnaround work – even within 24 hours – that’s pretty challenging to beat.”
For Air Motion Systems, European Managing Director Carsten Barlebo reports, “Deltabach’s experience is an ideal instance of the way the AMS LED-UV solution can improve performance in the press and just how this, therefore, can energize the entire production process. As well as being entirely mercury-free, another essential good thing about the AMS solution is our patented Dynamic Collimation system, allowing Total Flexible Lamp Positioning throughout the press and can make it a good choice for retro-fitting and re-commissioning as required. This means that any print company being forced to improve its efficiency and increase capacity has an investment path that fails to necessitate outlay on a new press.”
Deltabach was founded in 1970 by de Jong’s father being a spin-out of your stationery in plant he managed for the newspaper publisher in Leiden, between Amsterdam and The Hague. Although still specializing in commercial stationery print, it always championed new technology and was among the first adopters of CtP and MIS systems inside the Netherlands. When expansion forced relocation to a eco-friendly business park in Nieuw-Vennep, nearer to Amsterdam, in 2007, a sales partner was appointed to build up new jobbing commercial and trade work. The largely self-contained operation included studio, pre-press, textile printer and also in-house bindery. The mushrooming of turnover from €1.5 million in 2008 to €6 million in 2011 resulted in the unusual decision to replace the B2 press with a brand new B1 Heidelberg CX 102.
Marc de Jong comments, “We hadn’t created to move out of the Leiden area, but there have been no suitable possibilities there. Mainly because it been found, the transfer to a whole new high-tech, eco-friendly building has been ideal for us; it’s a fantastic environment to welcome our high-end corporate clients, agencies, designers and print brokers into … they never neglect to be impressed. We were also fortunate that people chose to never specify a long delivery with IR drying when we made the proceed to B1. It was the constrictions imposed by that press configuration that led me to research alternative solutions as our business developed. I come up with a point of using the latest innovations by checking the trade media in the states, Printweek.com and the like, so when I find out about AMS LED-UV I found myself astounded by the claims for eliminating powder, increasing speeds along with the sheets being ready for immediate back-up printing or finishing; I wasn’t considering the ability to print on awkward stocks or plastics. Each of the reports looked good so we made enquiries and Wifac, the agent for Air Motion Systems from the BeNeLux countries, arranged some site visits for us. If we saw it functioning we were convinced that AMS LED-UV was the best choice for us.”