Presentation on theme: "Flint Group A re-introduction"— Presentation transcript:
1Flint Group A re-introduction Rich EmmerlingTechnical ManagerFlint Group Flexographic ProductsHaving the speaking slot right after lunch can be a challange but this is a better slot as compared to the last two times I have skoken at the FPPA these slots were the last talk of the FPPA and the golf outing followed.By reintroduction I mean that we have had a a strong corrugated product for several years but have not gained a signficant market share in the US. In Europe we are the market leader with this product line. Our US market share can be attributed to a number of reasons but but plate material quality or print quality are not factors.Today I will go over our correugated product line. Followed by our thin plate technology and end with Flint Groups managing the platemaking waste stream program.But first a quick FG overvciew.
2? A History BASF Morrison Inks Inks Chemicals B&T CQIB Temple Inks News/Publication
3Flint Group Divisions Packaging & Narrow Web Pigments Print Media Flexo InksGravure InksOffset InksPackagingPigmentsPrint MediaPigmentsCoatingsPlatesSleevesPlate Making EquipmentOffset InksBlanketsPressroom ChemicalsNews InksCommercial Printing
4Quick Facts 140 Facilities, in over 40 countries worldwide ~ 7,500 PeopleRevenues of $3.5 billion in 2009100% derived from sales to the printing and packaging industry#1 or #2 in all markets servedFlint Group was formed from the merger of XSYS Print Solutions and Flint Ink in 2005XSYS was the combined companies of ANI and BASF Printing Products (2004)Flint Group acquired Day International/Rotec in 2007
5North American Plates Facility North American Technical & Training Center In Charlotte, NC with nyloflex® FV flowliner, drier, top lift exposure unit, image analysis systems, and ablative lasers.Team of experienced Technical Service people for plates set up and equipment installation & training.
7Differentiate to Thrive Offer something different to your customers Rich EmmerlingTechnical ManagerFlint Group Flexographic ProductsNow to move into the corrugated section
8Surviving in a challenging economy requires differentiating yourself in the market. Offering new products to your customers – ones that address their need for quality and value – set you apart from your competition.In the spirit of differentiation, Flint Group is introducing two new products for the corrugated market, and a new, thinner plate that will address both quality and sustainability concerns.
9Corrugated Industry Focus For too long it’s been a " me too" world for corrugated post print plate productsEveryone was after the formidable leader to duplicate the performance of the market leading productEach supplier has developed a product that is essentially similar to that market leaderBut now it’s time to do something differentFlint Group has refocused its product development on the corrugated post print market to introduce new products that take the print performance for corrugated to new levelsOur R&D department took some unique steps to learn more concerning the plate needs of the corrugated market, besides the usual required physical properties like solvent swell resistance, high chip resistance in the W/O unit, and robust finished plate storage properties. The development group actually decided to leave the labs and look into non traditional areas for ideas and they were good enough to share a couple of these with me.
12nyloflex® FACThe premium, high quality plate for corrugated post printAvailable in digital and conventionalWide market share globallyProven high quality printing plateConventional up to 52x80"32 Shore A
13nyloflex® FCC The " economic" alternative to FAC Durable, ideal for line and halftone work on a variety of boardsVery good ink transfer and solids coverage, even on coarse liners32 Shore A
14Requirements of Corrugated Post Print Print QualityDealing with the trend to lower liner qualityLower board quality demands a plate that will work with low impression to avoid compression of fluteThe market needs a plate that will provide excellent solids coverage, print clean, open reverses, and minimize dot gainCan these requirements be filled with one plate type?What would be the effect of using a harder plate?Would a softer plate be able to reduce impression while still providing smooth ink lay down and still print with low level of dot gain?
15Introducing New products for the corrugated post print market FSC – a soft durometer (25 Shore A) plate for excellent solids coverage with fine, detailed reverse and positive printing on A-, B-, C-Flute, rough surfaces, recycled, and low quality linersFHC – a higher durometer (38 Shore A) product for high end post print applications on C-, E-, Micro-Flute coated and uncoated liners
16nyloflex® FSC – High Quality Print Conventional and DigitalExcellent solids coverage, particularly on low cost linersVery good ink transferDeep, sharp reverses, for excellent print resultsSuperior performance in line workAlso suitable for halftone work
17nyloflex® FSC Digital – Cost Efficient & Reliable Standard solid plate processingSuperior durability and long lifetime, no chippingProcesses in standard equipmentEstablished, proven technologyEasy handling – fast processingReduced plate cleaningExcellent plate thickness tolerance
18nyloflex® FHC Conventional and Digital Excellent dot reproduction Fine line and reverse printingExcellent ink transferWide exposure latitudeLonger press lifeExcellent impression latitude
19Print TrialsTwo separate print trials were conducted with all productsTrials were done at Clemson University on the Bobst press and at Fox Valley Technical College on their Grant International Workhorse press
32The broadest product line for corrugated Conventional and DigitalConventional and DigitalConventionalConventional and DigitalHardness (Shore A)
33nyloflex® Product Range Product Application Board Quality HardnessShore AFHC/FHC DPre-, Post PrintVery High38FAC/FAC DPost PrintHigh32FCCStandardFSC/FSC DBasic, Low25
34nylosolv ® Low odor Rarely requires balancing Low plate swell for shorter drying timesLow plate swell prevents chipping in washout unitLargest market share of washout solvents in Europe
35ConclusionsThe softer plate produces excellent solids coverage at lower impressions levels, with clean, open reverses, and comparable dot gain to harder platesThe harder plate prints as well as current 32 Shore A products but has the durability of a harder plateThe harder plate provided a higher impression latitude without showing distortion of the finer detail
37What are Ultra Thin Plates? Flexographic plates with a thickness of .030" (0.76 mm)Have a relief depth/polymer layer of .023" (0.58 mm)Have a base PET film thickness of .007" (0.18 mm)Have no " floor" polymer, plates are washed down to the PET layerTypically a hard plate, 62 Shore A, (ASTM)Polymer LayerPET Base Layer37
38Why Ultra Thin Plates Now? Flexo platemakers and printers are looking for technology/quality advancementsSpeed to press, up to color time, registration, print quality are at measured by higher standardsPlatemakers and even packaging buyers want to use eco-efficient technologies to reduce waste and carbon footprintMost wide web presses are fitted with sleeves, allowing for the necessary change in tooling38
40Weight Raw material has about ½ the weight 40% more plates per box = less packagingLess handling boxes, crates, skidsEasier to carry sheets of material40
41Weight Finished plates have 1/3rd the weight Easier handling Lower shipping costsExample: 7 color job, 42x60" plates, shipped UPS Next Day from Chicago to Dallas:0.067" plates cost $191.850.030" plates cost $138.70Savings per shipment of $53.155 Shipments per 50 weeks would be a savings of $13,288Source: UPS.com June41
47Print Quality 2009: Equal or Better with .030" SID 1.1SID 1.4
48Print Quality: Conclusions As was concluded in the 1996 FQC Study, the 0.030" plates still print with less dot gain than 0.067“ plates.Medium to firm cushions tapes and sleeves are recommended for use with 0.030" plates.48
49Eco EfficiencyEco Efficiency was calculated from 0.045" and 0.067" plates with a degree of solvent recycling at 87.5%Data was not specially optimised for better processing conditions (exposure) for 0.030" platesGWP incl. plate, packaging and transport contribution is estimated to be 32% lower for 0.030" plates compared to 0.067" platesEnergy consumption incl. plate, packaging and transport contribution is estimated to be 40% lower for 0.030" plates compared to 0.067" platesFG commissioned a third party to complete an EEA comparing solvent washed plates with thermal plates. The results of this study were presented last year. The main conclusions were the carbon foot print of the solvent washed plate was either smaller of equivalent to the thermal process depending on the blotting towel used in the thermal processor. Also, the solvent process provides approximately 13% savings.CO 2 emission are used to measure GWP
50Eco EfficiencyGWP of 0.030" plates (.76mm) versus " plates (1.70mm) extrapolated estimate0.067".030"50
51Eco EfficiencyEnergy of 0.030" plates (.76mm) versus " plates (1.70mm) extrapolated estimate0.067".030"51
52Summary of Benefits with 0.030" Plates Plates process about 60% FASTER than 0.067" platesLighter weight can save thousands $$$ per year in shippingFlatter plates with less cupping = durability, fast up-to-colorLess packaging due to more plates per boxPerfect relief consistency, easier to process and print withEstimated 32% reduction in Global Warming PotentialEstimated 40% reduction energy consumptionPrints with less dot gain than 0.067" plates52
53Managing the Plate Making Waste Stream A new program in development at Flint Group
54nyloflex® Sustainable Solutions Thinner Plates to reduce time, energy and material consumption by up to 40%. Let Flint show you how and provide the materials and tooling, along with a detailed transition planCompressible sleeves to reduce the waste and cost of disposable cushion tapes. Improves run consistency while allowing for higher run speedsPlate room and pressroom audits, plus technique training to reduce production wasteHigh efficiency process equipment. Use less chemistry, energy and timeRecovery of plate packaging. Services available to recycle empty containersRecovery of used plates and distillation material. Services to remove plate materials and convert them into energy will be available soonRotec compressible sleeves reusable compressibility, available in three cushion levels the foam layer is extremely durable and provide equivalent print quality when compared to tradition cushion tapes.
55An offer to our Customers In our opinion the least that should be done with products after they have done their job in the Flexographic Process is to get part of the energy back that has been put into them during manufacturingFlint Group offers customized Solutions for a responsible way to handle Flexographic waste other than just land-fill" Waste to Energy" is one of the solutions that Flint will be offering to customers in a "removal and disposal" serviceFlint Group FP benefits from experiences with similar services that have been successfully offered to our ink customers over the years
56nyloflex® Sustainable Solutions More information will be available soon!
57Wrap Up Doing something different for your customer A new, softer plate for direct print corrugated that offers improved solid coverage, sharp and open reverses, and comparable dot gain to 32 durometer platesA harder plate that demonstrates sharp detail, low dot gainThin plates to improve print quality, reduce waste, minimize environmental impactA proactive program to reduce the environmental footprint of plate making operationsAnd now a closing photograph taken during a brain storming session during the development of the new corrugated products of our R&D director.Differentiate to thrive = offer something different to your customer.FSC = smooth solidsAndFHC = low dot gain