Digital printing for flexible packaging: outstanding print image, product safety and recyclability  

Elgin, IL, 24 August 2023 – Sappi, the world’s leading manufacturer of flexible packaging papers with integrated barriers and heat-seal capability, has joined forces with digital printing pioneer Xeikon in a developmental partnership. Sappi’s long-standing expertise in innovative, paper-based packaging solutions and Xeikon’s far-reaching knowledge of cross-sector digital printing applications and innovative ink technology ideally complemented each other in this collaborative venture. Together, the partners took an important step towards direct printing on paper-based materials and perfecting the recyclability of the resulting flexible packaging. 

Digital press manufacturer Xeikon, a division of the Flint Group, has over 30 years of expertise in both UV and aqueous inkjet and dry toner technology. With its latest dry toner innovation, TITON and the Xeikon TX500, the company has set its sights on the paper-based flexible packaging market, which, as Xeikon’s collaboration partner Sappi has been reporting for some time,is experiencing strong growth due to demand for resource-saving, recyclable and plastic-free alternatives from end-users as well as brand owners and converters.

TITON meets paper: No additional varnishing or lamination required

Frank Jacobs, Market Intel & Senior Product Manager at Flint Group Digital, understands that the demands made on inks for direct printing on paper-based materials for applications in the flexible packaging sector, e.g. for food packaging, such as those offered by Sappi, are very high: “Over and above ensuring a good print result, the inks need to be extremely resistant throughout the packaging process and insensitive to temperature, e.g. for heat-sealing. And, especially for applications in the food sector, they also need to be odourless, tasteless, food-safe and migration-proof.”

Grounded in the principles of quality, flexibility and sustainability, Xeikon designs, develops and delivers web-fed digital colour presses for label and packaging applications. These printing machines work with different imaging technologies, open workflow software and application-specific consumables and substrates. Each product is designed with careful planning for the best application-based substrate and toner or ink combination to maximize the output. 

With TITON, Xeikon is meeting the industry’s need for environmentally friendly and product-safe packaging production: The new toner formulation combines the best features of toners and UV inks, merging the food-safe and odourless properties of dry toner with the special resistance to chemicals and mechanical abrasion of UV inkjet ink. It also withstands temperatures of up to 220-260°C – essential for ensuring packaging integrity and product protection. The most important feature of the new technology is that, thanks to its special formulation, TITON can be used to print directly onto paper-based packaging materials without the need for additional varnishing or lamination to protect the print.

Best results with Seal Silk and AvantGuard S

Of course, an innovative toner such as TITON works best when the substrate used is just as innovative and perfectly matched to the respective application. With this in mind, it only made sense to test the groundbreaking technology with Sappi products. The company has the most extensive portfolio of paper-based packaging solutions on the market. Since the beginning of the collaboration at the end of 2022, extensive tests have revealed two qualities in particular that work especially well with the toner: 

“We achieved the best printing results with our innovative functional papers Sappi Seal Silk with a 67 g/m2 basis weight and Sappi AvantGuard S Natural in 75 g/m2 grammage,” explains Sibylle Hajostek, Market Manager Packaging Solutions at Sappi. “Both papers have an exceptionally high-quality appeal and were developed specifically for the flexible packaging market. The results we achieved in combination with the TITON technology left absolutely nothing to be desired – neither visually nor functionally.” The one-side coated, heat-sealable Seal Silk is recommended for standard flexible packaging in the food and non-food sectors in particular, while the uncoated, heat-sealable AvantGuard S Natural high-barrier paper is equally suitable for various flexible packaging applications in the food and non-food markets.

Frank Jacobs is also delighted with the results: “The print image we created in combination with the Sappi papers was nothing less than phenomenal! Results like these on paper-based substrates can otherwise only be achieved with flexo printing.” The results of the tests with brand owners and converters were so impressive that Xeikon’s customer ACM Plastic in Italy is now permanently producing with Sappi barrier paper. Initial tests are also underway at ACM to put another Sappi quality, AvantGuard S Gloss, through its paces: “It would appear that an engineer at ACM couldn’t wait to test more substrates from Sappi,” Frank Jacobs reports with satisfaction about the customer’s eagerness. “Just like the other two grades, AvantGuard S Gloss has so far shown the best visual and functional results – without primer or varnish. To say the least, it’s very promising. And we’re just at the beginning of this journey!”

Easy recycling in the paper waste stream

The two partners embarked on this journey together – with a single-minded focus on a resource-conserving approach to nature. The use of a primer or varnish, which sometimes required, can have a negative impact on the recyclability of the final packaging. And paper-based substrates in particular usually require a primer when printing with water-based inkjet or UV inkjet technology and liquid toner to ensure satisfactory results. Dry toner technology, on the other hand, usually requires an additional coating for mechanical stability in the further packaging process and often reaches its limits in terms of thermal stability.

Thanks to TITON technology, these additional processing steps are no longer necessary. Combined with Sappi’s recyclable barrier paper-based solutions, complete recycling of the entire packaging in the paper waste stream and subsequent recovery, e.g. for corrugated applications, are easily achieved. 

Product safety for brand owners, new business fields for printers and converters

As numerous tests demonstrate, the technology passed all criteria of the Nestlé Standard on Printing Inks for Food Packaging, the EUPIA Exclusion Policy for Printing Inks, the Swiss Ordinance as well as what is known about the German Ink Ordinance and other migration tests with flying colours. This makes the combination of TITON technology and Sappi’s paper-based solution ideal for a wide range of applications with direct or indirect food contact. For example, the two partners have helped brand owners switch to paper-based alternatives for food packaging, such as flexible packaging for baked goods, confectionery, sugar, flour, herbs and spices and tea. 

The technology even opens up new business areas for printers and converters: Applications that were previously only possible with conventional flexo presses can now be addressed more quickly and flexibly via digital printing. Xeikon recently introduced the TX500 – a new member of its CHEETAH series – the first digital press to use TITON technology. Furthermore, in combination with paper-based substrates, additional set-up time for coating, laminating and the usual required maintenance can be saved and waste can be prevented.

To find out more about Sappi’s paper-based solutions with integrated functionality, visit the following link: https://www.sappi-psp.com/de/products/functional-paper-packaging

Schaumburg, IL – August 24, 2023 – The printing world has experienced significant changes since the last Labelexpo Europe was conducted in 2019. INX International introduced its Coloring a Safe and Sustainable Future (CSSF) model the next year to improve sustainability performance and help brand owners address their circular economy objectives. Each and every new eco-friendly solution and digital inkjet technology is created with customers and consumers in mind.

Some of the new products INX has since developed will be showcased in booth 7D54 during the world’s largest label and packaging print show, September 11-14 at the Brussels Exhibition Centre in Belgium. Cleo Nomikos, Vice President of Sales for INX Europe, said INX offers a complete range of high performing inks and coatings for the tag, label, and flexible markets, including screen and digital ink solutions.

“INX can help because we have global-based technology platforms and local-based manufacturing that actively adapts to customer demands,” he explained. “We address the market and regulatory challenges for sustainable solutions, and understand the desire for lower applied costs. We also have great expertise in color management and are dedicated to making accurate and consistent brand color available in every part of the world, all with a circular economy in mind.”

INXFlex™ Contour and GenesisÔ washable inks, and EcoStage GB-XA Oxygen Barrier coatings are some of the sustainable solutions Nomikos mentioned that will be at the show and benefit brand owners in their efforts to recycle and meet regulatory standards.

INXFlex Contour flexographic inks for shrink sleeve applications cure both UV and LED. These inks offer high performance, excellent transfer, fast drying, and printability at high speeds, while maximizing shrink contouring and eliminating post-shrink adhesion loss and ink flaking. The Dual Cure (DC) version allows switching from UV or LED unit by unit, providing an option to cure two ways with one ink system for increased efficiencies and lower applied costs.

Genesis washable inks offer a host of sustainable benefits. They are de-inkable from cPET films and floatable with roll-fed OPP labels where ink is typically required to stay attached in the recycling process. With minimal bleed in the caustic wash solution and a reduced impact on recycled PET discoloration, new clear bottles can be produced from the circular reuse of recovered material.

EcoStage GB-XA oxygen barrier coatings are formulated to address food safety and preservation issues, as well as improvements in sustainability and recycling. The cost effective, high performance coatings allow for mono-material packaging to replace multi-layer packaging for certain food applications, making the package easier to recycle. An alternative to expensive barrier films, it also extends shelf life and reduces food waste.

Other INX products available at the show include digital inkjet solutions, sealers and primers, various lacquers including high gloss, silicon, tactile, ultra matte, UV and water-based, and RUCOINX UV screen inks. Experts will be available in booth 7D54 to answer questions about the entire product line, and can provide technical service information about G7 certification assistance, quality improvement processes and more.

To learn more, visit the INX website or schedule a booth meeting.

About INX International Ink Co.

INX International Ink Co. is the third largest producer of inks in North America, with full-service subsidiaries in Europe and South America and is part of Sakata INX worldwide operations. We offer a complete line of ink and coating solutions technology for commercial, packaging and digital applications. As a leading global manufacturer of inkjet inks, we provide a full palette of digital ink systems, advanced technologies and integrated services. Stay updated on the latest developments and follow INX on LinkedIn, Facebook, and X, or visit the website.

(UPM Raflatac, Helsinki, 24 August 2023 at 13:00 EEST) – UPM Raflatac, a global supplier of innovative and more sustainable self-adhesive paper and film products, has received a new certificate of validity from leading international assurance service provider, DEKRA, for its Label Life service. This new certificate confers validity to the LCA calculation engine and the whole process of generating LCAs at scale. As a result, customers wanting to communicate their potential impact in the labeling value chain can now do so with increased assurance.

With the EU in the process of developing a ‘digital product passport’ (DPP) that will be issued for all products on the market, UPM Raflatac decided to be a step ahead of the legislative requirements. The company has designed its product passport prototype (PPP), an environmental declaration, based on existing standards and norms.

Generated by the newly validated Label Life service, the product passport prototype enables UPM Raflatac’s customers and brands to communicate their labeling’s potential environmental impact. It includes a wide range of metrics that are broken down into life cycle stages: cradle-to-gate, transport-to-customer, printing, and end of life.

“With global regulations increasingly targeting environmental reporting, credibility and transparency are vital to any company with sustainability on their agenda. We wanted to be industry frontrunners and ahead of the regulations with our new product passport prototype,” explains Flora D’Souza, Sustainability Manager for Label Life at UPM Raflatac. “We wanted to make sure that the product passport prototypes include all relevant environmental information, and that the declaration stands up to scrutiny. That’s why we brought DEKRA on board to ensure that we are delivering the highest quality.”

“The validation found the process for generating Life Cycle Impact Assessment (LCIA) results appropriate for the intended goals and approved the quality checks put in place to ensure consistent and reliable results consistent with the relevant International Standards ISO 14040 and ISO 14044,” affirms Peter Paul Ruschin, Head of Sustainability Services at DEKRA Assurance Services GmbH. The validation report further concludes that the methods and inventory modelling applied in the tool are scientifically and technically valid, following methodological approaches of industry norms and standards PEF/EN 15804 and ISO 14067.

Label material choice can have a significant impact on packaging sustainability. UPM Raflatac is the first label materials company committed to going Beyond Fossils and is continuously developing new products that enable customers to reduce the environmental impact of their packaging. Over its 10 years of service, Label Life has continually evolved offering customers and brands both cradle-to-gate and tailored cradle-to-grave calculations. The new validation by DEKRA confirms the credibility of UPM Raflatac’s LCA calculations and supports customers to make better informed choices, bringing them closer to their own sustainability goals.

Wausau, WI — Wausau Coated Products Inc., an independent family-owned and operated, leading manufacturer of adhesive-based label products, is excited to announce the launch of a New Wash-Away Adhesive Solution WA-769. It is an emulsion acrylic permanent adhesive with good initial tack and adhesion to most surfaces. 

WCP is offering WA-769 wash-away adhesive on two of our most popular roll label facestocks; 70# Bright White Felt with 30% PCW & Wet Strength (WS) and 60# Estate Label® #8 Vellum with (WS). These products are an excellent choice for facilities where bottles are returned, rinsed, and cleaned for reuse. In addition to the wash-away adhesive properties, when these label stocks are immersed in an ice bucket, they will remain affixed keeping the label intact due to their wet strength properties. 

“Wash-Away adhesives are becoming more popular as an eco-friendly way to reuse glass packaging,” states, Adam Frey, Director, North American Sales, Wausau Coated Products. “We paired this unique adhesive with a 90% PCR content 1.2 Mil r-PET liner and sustainable facestocks when developing these two new products. Our customers continue to come to us to for wash-away solutions and we are happy to support their efforts with this new adhesive.” 

About Wausau Coated Products: 

Wausau Coated Products, Inc. is an independent family owned and operated manufacturing company with distribution facilities located throughout the USA and Mexico as well as distribution channels throughout Central and South America, the Caribbean, New Zealand, and Australia. As a leading manufacturer of adhesive-based products, Wausau Coated is a one-stop resource worldwide for premium quality stocked products and custom engineered constructions to meet customer specific applications and end user needs. For more information on Wausau Coated Products, visit our website: http://www.wausaucoated.com. 

Rochester, NY – August 2023: The dedication, skill, and expertise to keep a business thriving for a century is no small feat. Albert Basse Associates Inc. (ABA) is proud of this legacy, and with plans to grow their business, turned to Durst technology to continue their success.  

Just south of Boston, in Stoughton, Massachusetts, is one of the country’s longest continually operating, family-owned, printers in the nation. ABA has prided themselves on “Getting the Job Done” for the past 95 years. To continue their growth, and the changing needs of their customers, Albert “Chip” Basse III, President of ABA and his team knew exactly what they needed, stating “our goal was to improve our digital quality, increase overall capacity, increase our size capabilities, and improve output speeds.” They went with the best printer on the market to accomplish this: a Durst P5 350 HS.   

“The press has been a real game changer and has opened up markets and volume that we could not have achieved otherwise,” said Basse. “Due to size and speed constraints in the past, we had to pass up many opportunities with existing & new accounts. With the P5, we are now able to offer our clients improved quality and larger size output, and also improved lead times and turnaround. Ease of use, quick setups, incredible quality and performance.”  

The high-performance P5 350 HS has proven to be the most efficient hybrid printer on the market, designed specifically to increase efficiency and production capacity. This all-in-one hybrid solution for roll and board media has a printing width of up to 11.48 feet (3.5 meters) and reaches a productivity up to 7,000 sq.ft/h.   

A P5 350 HS was the best recommendation after sitting down and listening to ABA’s business needs. Larry D’Amico, Director of Sales: LFP & Fabric, commented, “It’s important to look at a business today, and see what it will be in the next years and decades to come. We are pleased Albert Basse Associates Inc. have chosen Durst as a partner for their future. Durst technology will continue their long legacy of quality and customer satisfaction, while enabling them to grow into different markets.”   

“Durst has been a great partner and resource in this digital age. As our needs grow, we expect to rely on Durst to help us grow with new equipment and software solutions,” said Basse. The new press is just the beginning. ABA presently uses Durst Workflow software for their prepress automation and is implementing Durst Lift Software to be their shop ERP.  

About Albert Basse Associates Inc.:  

ABA is one of the longest continually operating, family-owned, large format digital and screen printers in the nation. ABA produces a wide range of products covering every category of standard and custom graphic display, signage and industrial applications including: point of sale, decals, banners, signs and posters, door and window clings, floor graphics, and much, much more! The company is proud to have achieved 95 years of success through several generations and is looking forward to reaching their 100 year milestone! With the help of Ed Basse; VP of Sales & Marketing, Al Basse IV; Director of Product Development, and all of their Associates, their mission is to build long term business relationships, to provide unequaled customer service, and to produce the highest quality, cost effective, graphic solutions possible for their customers. 

(Ghent, Belgium) HYBRID Software (www.hybridsoftware.com), leading innovator of packaging design and visualization software, is proud to announce the release of iC3D Version 9, which showcases powerful automation capabilities, new features and user-experience improvements. 

IC3D Suite V9 introduces a major enhancement to its PDF Editor, leveraging cutting-edge technology from HYBRID’S own PDF Libraries to deliver an elevated user experience and pixel-perfect rendering. As users engage with PDF files within iC3D, they can anticipate upgraded performance with faster rendering speed, improved software stability, and advanced functionality. 

Recognizing the evolving needs of the company’s valued CLOUDFLOW users, Version 9 offers seamless integration with HYBRID Software’s CLOUDFLOW Plugin Suite. This transformative addition has been designed to provide a comprehensive solution that enhances the way users interact with their workflows.

The CLOUDFLOW Plugin Suite serves as a dynamic bridge between customers’ creative endeavors and the efficiency requirements of digital workflow management. The suite permits users to readily open, save, and insert files, regardless of their format or source, directly into their workflow. The suite seamlessly merges into the iC3D environment, becoming an intrinsic part of the user experience. This integration ensures a cohesive and intuitive interaction, ultimately increasing productivity and streamlining processes. 

iC3D Version 9 delivers enhancements to the overall performance of its suite, including file saving security. Users can now save their dynamic background within iC3D files and safeguard their creative work. To address a growing global customer base, iC3D announces an updated and expanded range of software languages; which includes improvements to existing translations and a fully localized Portuguese version.  

Live demonstrations of iC3D and its integration within HYBRID Software will be showcased at Labelexpo Europe 2023 in Brussels. Hybrid Software Group’s booth #8B45 will welcome all visitors from September 11th to 14th 2023.  

International prepress company Hamillroad Software are preparing to make a trip of legendary proportions next month to attend Labelexpo2023 in Brussels. Their 16 strong exhibitor team includes four highly respected Bellissima Trade Shops from across Europe who will be on hand to offer their insight, knowledge, and expertise to brand owners, printers and flexible packaging converters.

Hamillroad has fully embraced Labelexpo’s ‘modern legends’ theme for this year’s expo by creating a fun and memorable marketing campaign around their own AI generated modern characters, perfectly orchestrated for Bellissima’s strapline ‘Seeing is Believing’. At the centre of this campaign is an AI generated ‘Chameleon’ featuring a vivid colour spectrum tying into Bellissima’s stunning Ultra High-Definition print capabilities.

Since its launch at Labelexpo in 2017, Hamillroad’s Bellissima DMS has transitioned from an innovative technology to a globally adopted flexo solution winning multiple ‘Best on Show’ production awards.

Andy Cave, CEO said: “Although our technology has now matured into a solid production offering, it’s exciting to see how we continue to push the limits of what’s possible in flexo, with our latest developments providing an ever increasing point of difference for printers and converters like Catapult Print in Florida and StarPak in Texas”.

Jane Petrucci, Head of Marketing said: “Labelexpo2023 is very much a place to share knowledge and insight and we’re inviting printers, converters and brand owners to visit us and learn about new developments in Bellissima’s halftone screening and surface pattern technology. We’ll also have a range of stunning print samples available, plus a big announcement too… so keep your eyes peeled for some very exciting news!”

To find out more about how Bellissima DMS can help your business drive efficiencies, visit: https://hamillroad.com/bellissima-labelexpo or email: info@hamillroad.com.

From Austria via Germany and the Netherlands to France – meet Siegwerk at the next conferences dedicated to the European paper and board industry and learn more about its coating expertise for the development of sustainable and future-oriented paper and board packaging solutions.

Siegburg, Germany, August, 22, 2023. – Siegwerk, one of the leading global providers of printing inks and coatings for packaging applications and labels, will participate in four conferences and expert symposia in September and October 2023: Specialty Papers Europe, the PTS Coating Symposium, the Functional Fiber-Based Material & Packaging conference as well as the FEFCO Technical Seminar. They all focus on the latest innovations and developments in the European paper and corrugated packaging industry, bringing together packaging producers and partners from the entire supply chain. By providing insights into its development expertise of functional coatings and sustainable ink solutions for paper and board, Siegwerk will once again underline its relevance as a partner for the development of sustainable packaging solutions in the sense of a Circular Economy.

“Especially in light of the sustainability trend, functional coatings offer a lot of potential for the future of fiber-based packaging,” explains Oliver Waddington, Head of Business Development, Water-based Coatings at Siegwerk. “By providing specific functional properties that are crucial for the performance and durability of packaging, they play a key role in enabling fiber-based solutions in the sense of a Circular Economy.” Siegwerk has already been focusing on the development of functional coating technologies for several years now. With its UniNATURE Water-Oil Barrier Coating, the company for example launched the first barrier solution with fully natural content, enabling the use and recycling of paper plates through the existing paper recovery cycle.

“To successfully promote sustainable packaging development, exchange and collaboration along the packaging value chain is crucial,” adds Waddington. “That’s why we attend selected industry events to discuss the latest developments and challenges with other experts, share knowledge and ideas, and find new partners to jointly drive the change towards a circular packaging industry.” Today, Siegwerk can already look back on several successful development projects with customers and industry partners along the entire supply chain that have resulted in advanced packaging solutions with improved performance and recyclability, further paving the way for an increased circularity of packaging.

Speciality Papers Europe 2023

Specialty Papers Europe will take place from September 5 to 6, 2023, in Vienna, Austria. As the leading conference in the EU, it provides the latest updates on advancements and trends influencing specialty paper and packaging today. Siegwerk will be on-site presenting the company’s barrier and functional coating developments for paper and board packaging. Besides, Oliver Waddington will give a presentation about collaborative solutions to enable fiber-based packaging, highlighting the role of coatings and inks in packaging as well as the challenge of product safety and responsibility.

PTS Coating Symposium 2023

The PTS Coating Symposium is the international meeting point for experts from industry, research and development to learn about and discuss the latest innovations in coating and surface upgrading of paper and board materials. It will take place from September 13 to 14, 2023, in Bamberg, Germany. Here, visitors can meet Siegwerk’s experts at the exhibition area to get more insights into the company’s functional coatings and sustainable inks for improved recyclability and barrier properties of paper and board substrates.

Functional Fiber-Based Material & Packaging

The Functional Fiber-Based Material & Packaging conference will take place from October 10 to 12, 2023, in Rotterdam, the Netherlands. The 3-days event will not only give insights into the latest industry updates on fiber-based packaging in food and non food applications, but will also offer a perfect platform for meeting experts from across the entire supply chain. As one of the speakers on-site, Siegwerk’s Oliver Waddington will give a talk about collaborative solutions to enable fiber-based packaging that meet the growing functional requirements for paper packaging in the sense of a Circular Economy.

FEFCO Technical Seminar 2023

Under the motto “Shaping our future through innovation“, this year’s FEFCO Technical Seminar will take place from October 25 to 27, 2023, in Lyon, France. It is a scientific conference and trade show in one and brings together all kinds of experts from the European Corrugated Industry. Siegwerk’s experts will not only present the company’s coating and inks for the development of future-oriented and sustainable corrugated packaging solutions, but Oliver Waddington will also give a spotlight session on October 27, 2023, diving into the differences between traditional and printed barrier coatings.

To learn more about Siegwerk’s coating offering, please visit https://www.siegwerk.com/en/inks-coatings/coatings.html or directly download Siegwerk’s Coating Guide for Paper and Board Solutions.

About Siegwerk
Siegwerk is one of the leading global manufacturers of printing inks and coatings for packaging applications and labels. Based on 200 years of expertise, we provide customized solutions for all types of packaging needs – from functional and eye-catching to safe and sustainable. As a sixth-generation family business, we have long been aware of our responsibility for future generations. Under the motto “rethINK packaging”, we are therefore actively driving the transformation to a circular economy by developing eco-friendly solutions that enable packaging circularity. Here, 30+ country organizations and ~5,000 employees worldwide ensure consistent high-quality products and customized support around the world. Learn more at www.siegwerk.com

Kennesaw, Ga. August 16, 2023 – Focused on making investments that will usher its business into the future, Davis Direct, a commercial printer based in Montgomery, AL, recently installed a new Stahlfolder KH 82 from HEIDELBERG. The KH 82, which was purchased to increase the efficiency of the company’s signature folding, complements its high speed Speedmaster CD 102 and is a faster, more automated, and easier to operate alternative to the two older buckle folders it replaces. 

“I Wish We Bought This Folder A Year Ago”

“Commercial work is the heart of our business,” said Mitchell Vaughan, Vice President of Sales and Development at Davis Direct. “While we have a robust digital fleet, our customers are still demanding the longer runs, uncompromising quality, and specialty finishes that only offset printing offers.” Having purchased a new CD 102 with UV curing in 2019 to produce magazines, brochures, catalogs, and direct mail pieces for its primarily higher education, manufacturing, and government customers, Davis Direct continues to look for investments in technology that will help meet its customers’ needs not only now but also into the future. While the company’s new press helped play a role in its recent growth, there were moments during last year’s labor shortage when Vaughan and his team struggled with how they were going to finish all of their printed sheets. Davis Direct, who was previously equipped with three aging B 30 buckle folders, folds upwards of 2,000,000 sheets per month during its peak season. According to Vaughan, “It’s a lot of lifting and fanning and catching and being able to pile everything on a pallet. We were simply wearing people out with the manual folders.” Needing a more automated solution for its 12-, 16-, and 32-page signatures, Davis Direct recently installed a Stahlfolder KH 82 – replacing two of its older folders. 

Folding 12,000 sheets per hour and equipped with enhanced automation features like easy-to-use touchscreen control, automated roller settings, and a standardized makeready process, the KH 82 has drastically improved the throughput at Davis Direct. “I wish I had bought this folder a year ago,” said Vaughan. “It’s a perfect marriage – the speed and productivity of the CD 102 combined with the speed and productivity of the KH 82.” The improved productivity and automation mean that one person can now accomplish what used to take two operators; they also allow the operator more time to concentrate on the quality of the fold rather than the just the physical aspects of running the machine. With less bottlenecks and more staff available in finishing, Vaughan says the KH 82 will help the company, “target more work that suits us, and more work will be suitable for us. We can take on larger runs than ever before, and I don’t have to be afraid of what it means for the bindery department.”

While the company’s folder is now consistently running at top speeds, there was a large learning curve changing from a traditional buckle folder to a combination folder like the KH 82. During the initial start-up, Davis Direct received excellent training and support from both the HEIDELBERG service and product management teams. “One of the biggest reasons we bought from HEIDELBERG and continue to buy from HEIDELBERG,” said Vaughan, “is the support we know we will get whenever we purchase a machine.” As he looks for ways to keep his company moving forward, Vaughan says HEIDELBERG will continue to play an intricate role in the company’s future. “We’ve never sat down after a purchase from HEIDELBERG and said, ‘this was maybe not the right decision.’ We’ve had those conversations after we’ve purchased equipment from other people. HEIDELBERG means quality, and I’ve never experienced anything that would contradict that.” 

About Davis Direct

Davis Direct is a unique hub for marketing production and delivery – strategically managing the production, storage, tracking and distribution of materials for professional marketers. Building on more than 80 years of experience, Davis Direct has designed its own holistic and seamless approach for the marketing industry. Technological advancements keep the company, which is widely known for its stellar customer service, in sync with its clients. As Davis Direct progresses within the industry, it will never forget the two fundamental principles that it was founded upon: quality and integrity. These guiding principles define how the team at Davis Direct interacts every day with one another and with its clients. With its vision aligned, the true strength of Davis Direct is demonstrated in client goals delivered: on target and on time.