West Midlands based converter Daymark Labels claims it has enjoyed major growth in both output and profitability in the 12 months since it installed two Mark Andy narrow web presses.  The family-run business in Hartlebury invested in an Mark Andy Evolution Series E5 flexo press and a Digital Pro 3toner-based press back in the Spring of 2022 and has not looked back according to Jon Bird (Snr), who owns the company with son Jon.

Founded in 1974 and built on a reputation for top quality work in some of the more testing niche markets, the decision to invest in Mark Andy technology was relatively straightforward, according to Jon (Snr): “We’d been looking to upgrade our flexo capacity and knew that we needed to add digital capability and wanted to source both from the same manufacturer.  Mark Andy has the broadest portfolio of all narrow web manufactures, so the choice was easy, and I’m pleased to say it’s worked out well.”

The Evolution E5 features the latest Mark Andy servo platform for flexo.  It has 330mm (13”) web width, eight flexo print units, and was the first to be installed in the UK fitted with GEW’s LeoLED/UV curing technology.  Specification also includes a web cleaner, overhead rail with turn bar unit, delam/relam, double die stations and a sheeter/conveyor.  “I’m so glad we opted for LED/UV,” said Jon (Jnr) “it’s so efficient and with energy costs rising, it has made a real difference.”  Daymark is looking to add inline lamination capability that will facilitate more efficient production of labels for hazardous products which it is looking to do in one-pass.  “The Evolution Series E5 allows us to win jobs we just couldn’t handle before – it’s such a confidence booster for our operators and our customers because they know we can deliver reliable quality.”

Turning to the Digital Pro 3, both Jons agree that they couldn’t be without it!  “It has a learning curve for those new to digital, but it’s an easy press to operate and has allowed us to improve our customer service by having digital in-house and being able to colour-match it with the flexo press.  This gives us the freedom to choose how we produce each job, and the facility to switch from one to the other without any loss of quality,” explained Jon (Jnr).  Especially noteworthy is the Digital Pro 3’s capability with textured stocks, and for the fast-growing range of artisan businesses, this is proving a winner.  “A typical job might be 1000 labels of five types, which the digital machine can handle equally well on porous or textured substrates – it’s a great all-rounder,” he added.  Having become something of a short run specialist, Daymark has spent time growing its web-to-print business, and the Digital Pro 3 is ideal for this.

Phil Baldwin, Mark Andy UK’s Sales Manager explained why the Digital Pro 3 is so capable.  “It’s the second-generation of our hybrid that combines a toner-based digital engine for 1200dpi CMYK with flexo printing before and after the digital module, as well as laminating, cold foiling, rotary or semi-rotary die-cutting, slitting and rewinding, or sheeting and stacking, all in one pass.  It is capable of printing on a variety of stocks, from tags to pressure-sensitive and Tyvek materials, typically self-adhesive stocks, wine label substrates, and PP, without any need for primer.”

Digital Pro has a production speed of 23.4m/min (77ft/min) and requires no cleanroom environment nor involves any ‘click charge’.  It features a simple to use RIP that allows any existing pdf to be printed at the touch of a button, and its small footprint and onboard compressor for its air-cooled LED-UV curing system, make for a ‘plug-in and go’ installation.  In fact, its compact size, and the high performance of the Evolution Series E5 flexo press have resolved a major problem for Daymark, whose production floor had been bursting at the seams and threatening a need to move to larger premises.  The two new Mark Andy machines have given the company breathing space to evaluate its next investment.

Since installing the new presses, Daymark has enjoyed a 15% hike in sales with no additional staffing costs or change in shift pattern.  “We have always been conscious of maintaining a healthy work/life balance for all of our staff while building a profitable and growing business  – it’s a model that has served us well in the past and we see no reason to change,” said Jon (Snr).  He was also quick to compliment Mark Andy on its after sales service and technical support.  “We see them as an important partner in strengthening our capability and extending our offering to customers,” he concluded.

Mark Andy Marketing Team

(UPM Raflatac, Helsinki, 28 June 2023 at 13:00 EEST) – UPM Raflatac, a global supplier of innovative and sustainable self-adhesive paper and film products, will showcase its solutions for labeling a smarter future beyond fossils at Labelexpo Europe 2023, taking place in Brussels, Belgium on 11 – 14 September. These solutions include UPM Raflatac’s products and services that are designed to enable their customers to Reduce, Recycle, Renew and Reuse.

Visitors to UPM Raflatac’s stand (5D41) will have the opportunity to speak to the company’s experts and find out more about its products and services. Examples of the products being presented include Ocean Action labels made from ocean bound plastic waste, the new PureCycle wash-off paper label materials, the RAFNXT+ paper label products and linerless labels.

Also, following the business’ recent acquisition of AMC AG and the Intercoat brand in 2022, visitors to this year’s Labelexpo Europe will be able to explore the Intercoat by UPM Raflatac product range, including the renewed T7 product portfolio.

Alongside its array of labeling solutions, visitors to the stand will be able to explore UPM Raflatac’s range of services, such as the RafCycle label liner waste recycling service and the Label Life lifecycle assessment (LCA) service. Attendees can also take part in the MyRaflatac customer portal demonstrations. MyRaflatac is a tool designed to empower UPM Raflatac’s customers to make business decisions about labeling materials at any time of day, any day of the week.

To find out more, make sure you stop by stand 5D41 to meet UPM Raflatac’s experts and learn more about how you can harness the power of the label for your products. The stand program will be published closer to the exhibition.

Perhaps it’s no surprise that a company originally founded in 1904 should be one of Ohio’s best all-round suppliers of offset, flexo and digital print products for niche markets, though in truth, it says as much about the dynamic leadership of its President Ron Busch and the late Luigi LaValle III who acquired the business in 1987 and created BLT Corporation doing business as Queen City Printing.  Sadly, Luigi died a few years back, but the business continues to thrive today.

Located in Norwood, in the suburbs of Cincinnati, Queen City Printing has built an enviable reputation for being good at everything, which as Ron Busch explains, is what any small company needs to be to survive these days.  The company’s tightly packed 10,000 sq/ft production facility houses a range of print and finishing technology that allows it to offer a large portfolio of products, but it’s in the pressure-sensitive narrow web market that the company has seen major growth, and most of its technology is Mark Andy branded.

“We started with a 7” five-color Comco Cadet back in 1990 and haven’t looked back – in fact the Cadet is still running and producing good quality roll-to-roll jobs for the pharmaceutical sector,” he said.  In the mid ‘90s, the Company saw a growth in demand for sheeted wet glue labels and installed two digital presses, but it was the move by the chemical industry, which provides much of the Company’s business, towards roll labels, that prompted Busch to investigate what options were available.

“It was Labelexpo in 2016 that we started talking with Mark Andy and ended up installing one of their Digital One flexo/toner hybrids in early 2018.  It was unique in offering both types of print and converting/finishing inline for single-pass operation – it was tailor-made for our work,” he explained.  Simple to operate and with a small footprint and no ‘click charge’, Digital One pioneered technology for the short run digital labels that were enjoying a growth in demand from, amongst others, artisanal products and local breweries.

In 2019, with the elderly Cadet at full stretch and demand for flexo work showing no signs of slowing, the Company installed a Mark Andy Performance Series P4 press.  Its wider 13” web, sixth color and higher running speed significantly extended flexo capacity and has opened new market opportunities for Queen City.

Two years on, it became clear that the Digital One was not providing sufficient capacity to meet the demand for short run digital labels, and the decision was made to replace it with a second series machine, known as the Mark Andy Digital Pro.  Essentially a grown-up version of its predecessor, Digital Pro offers a higher running speed, the option of a flexo unit before as well as after the toner engine and a choice of full or semi-rotary die cutting units.  Its 13” web width and 77 ft/min performance at 1200dpi resolution makes it a formidable tool.  It has a simple and easy to use RIP for handling existing PDFs, requires no clean-room environment and comes complete with an air-cooled LED/UV unit.

“The ability to lay down a flexo white before overprinting CMYK toner on filmic materials has been a real benefit.  We use the second flexo unit for security numbering on the reverse for pharma labels and have both types of die station so that we can choose whichever is best for each job,” he explained.  “The decision to upgrade was a complete ‘no- brainer’ as far as we are concerned, and while we run mostly self-adhesive stocks on it, it does a brilliant job on the vinyl we use for the industrial market.”  With the increasing use of BOPP and especially silver BOPP, the Company has had issues with static electricity build-up, which has been resolved by locating humidifiers strategically around the production area.  

One change brought about by the Covid pandemic was the switch by many from paper to PET liners, which run better on all the label presses.  “The pandemic added about 20% to our sales because we had both substrate and press time available when others did not – it’s fallen back a little, but the market has changed because of different consumer shopping habits, and we are feeling the benefit.”

With press capacity now well capable of meeting demand, Queen City knew it had to relieve the bottleneck post press, especially with inspection/rewinding, and once again turned to a Mark Andy Group product, in this case Rotoflex and an HSI 330 model.  The HSI is an operator-friendly machine with a horizontal table.  It’s a well-proven design that offers time and waste savings to increase efficiency.

“It’s given us four times the capacity we had before and the advantage of 100% inspection before and after the rewinding, which is essential for our pharma work.  It’s easy to use and offers us the ability to vary tension in the rewound rolls – some customers prefer a tightly wound roll, for example in the industrial sectors, while our pharma customers prefer a more loosely wound roll.”

This is the benefit of the HSI’s eDrive 2.0 system, which by making better use of power results in improved roll characteristics.  It offers high roll quality at any speed and with any number of speed changes and is quick to accelerate and decelerate under full control.  Although a recent installation, Ron Busch claims it has already made a major contribution to efficiency post-press and completely removed production hold-ups.

Technology aside, Queen City Printing prides itself on customer service.  When you are small and serving niche markets you need to work closely with your customers, many of whom are also small and inexperienced – it’s vital to build trust and the best way is through repeat business.  We’re happy to tackle jobs that others won’t even quote for – but we have a skilled and experienced staff and machines we can rely on, so the rest is personal relationship and getting the job done on time and on budget.”

The Company is also proud of the detail it records in the production of every job.  Traceability has long been a byword in the pharma market, but the principles are equally valid across the board, and Busch says that by closely observing a strict manufacturing procedure there is less pressure on staff and fewer opportunities for error.  “I’m not saying we always get everything right, but if there is an issue, we can quickly identify and rectify it – the Rotoflex is a perfect fit for that.”  Looking to the future, he sees inkjet as the next logical move but his strategy of careful and extensive research before investment suggests that it won’t be coming any time soon.  He sees growth coming organically from existing customers, many of whom started small and are growing fast.  Typical run lengths today are 2500 to 100,000 labels but he says he’s happy to do more or less – by planning and grouping, the company can make maximum use of the Digital Pro press and the workforce can keep to its single-shift five-day week operation.  “Work/life balance is very important here – and the company’s successful growth rate proves we’ve got it about right!” he concluded.

• Mondi is investing over €16 million at its Krapkowice plant in Poland to increase production of its MailerBAG range.

• Investment comes in response to demand for sustainable packaging from growing eCommerce industry.

• MailerBAG lines in Poland ideally placed to serve customers across the whole of Europe.

• Mondi’s eCommerce portfolio is widely recognised as a supplier of economic, efficient and easy packaging solutions using base materials that are sustainable by design.

27 June 2023 – Mondi, a global leader in sustainable packaging and paper, is investing over €16 million in its Krapkowice plant in Poland in response to demand for sustainable packaging from the eCommerce industry.

Durable, lightweight as well as puncture and tear-resistant, Mondi’s MailerBAGs are cost-effective for customers to transport as they save space and weight. Available in a range of sizes, the bags are easy to open and close making them ideal for delivery and returns. Excellent printability also ensures brands can communicate their key messages to consumers easily.

The Krapkowice plant is dedicated to the production of Mondi’s MailerBAGs, and based in Poland, is ideally located to serve the whole of Europe. This investment will more than double Mondi’s MailerBAG production capacity for 2023 in Poland and will include a new production line.

Mondi has a broad eCommerce offering, across its corrugated and flexible packaging businesses, which includes its MailerBAG solution. The MailerBAGs are made from Mondi’s kraft paper, which is made from responsibly sourced fibres, and produced and converted in-house – a benefit of the Group’s integrated value chain. In addition, the bags are designed to be recycled in conventional paper recycling streams across Europe, making them the ideal alternative to plastic mailers.

Thierry De-Vleminck, MailerBAG Director, Mondi Paper Bags, says: “Consumers are becoming more concerned about packaging materials, with research showing around 70% willing to pay more for best-fit packaging[1]. The growing eCommerce market needs a strong supply of quality packaging that has a real focus on sustainability, which is what we deliver, a bespoke solution for every customer, every time.”

Bogdan Rozio, Regional Manager Central and Eastern Europe and Managing Director Poland, Mondi Paper Bags, adds: “We’re delighted to be investing further in the eCommerce industry and in our Krapkowice plant. It contributes to our MAP2030 commitment to make all our packaging solutions reusable, recyclable or compostable by 2025, and allows us to respond to the market demand in this key region.”

(UPM Raflatac, Helsinki, 26 June 2023 at 13:00 EEST) – UPM Raflatac is pleased to announce the launch of its new collection of wine, spirits and beverage label materials – Rêverie 3 – that embraces circularity by using recycled fibers in aesthetically attractive labels. The new collection demonstrates, via unique collaborations with five leading Spanish designers, that sustainability and impactful design can work together to deliver stunning results. The Rêverie 3 collection offers packaging designers a toolkit of visually appealing labels that are all made with materials from well-managed, FSC® certified (FSC C012530) forests, recycled materials and other controlled sources.

With more and more brands now seeing the inclusion of FSC and PCR packaging as a necessity, UPM Raflatac wanted to showcase the potential of today’s sustainable label materials. With this in mind, five of the company’s responsibly sourced label materials were given to five Spanish design agencies, with the brief to create a new collection.

“The label designs in the Rêverie 3 collection were created for high end wine, spirits, sparkling cider, craft beer and tomato juice drinks, with excellent execution of the artworks with different printing techniques managed by Gráficas Varias,” Joss Ramel, Packaging Solutions Manager for Spain and Portugal at UPM Raflatac states.

The five UPM Raflatac label materials that were chosen are:

• BIARRITZ WSA PCR-FSC (20% recycled fibers) – Created for use with high-quality wine and spirits labeling applications, the natural pigmentation of the material accentuates the premium appearance of the label. Estudio Series Nemoused this material to create the sparkling cider bottle label design.

• DROPS WSA PCR-FSC (100% recycled fibers) – Designed for high-quality wine and spirits labeling applications, this label material features an accentuated uneven, textured surface combining a translucent effect and enhanced tactility, thanks to it having undergone a unique paper-making process. Estudio Mabaused this material to create the spirits bottle label design.

• FENIX WSA PCR-FSC (40% recycled fibers) – Developed for high-quality wine and spirits labeling applications, this paper shows minimal impurities, giving a delicate hint of the recycled content. Estudio Puigdemont Roca used this material to create the tomato juice bottle label design.

• HIPSTER WSA PCR-FSC (100% recycled fibers) – Created for high-quality wine and spirits labeling applications, it has a warm and elegant white shade that is combined with a delicate, uneven, felt marked surface that enables the creation of labels with unique personality. Estudio Calcco used this material to create the wine bottle label design.

• VINTAGE WSA PCR-FSC (30% recycled fibers) – This material is ideal for use in wine, spirits and beverage labeling applications where an authentic and artisanal look is desired, as it has a kraft brown shade to it. Bulldog Studio used this material to create the craft beer bottle label design.

“We designers have a responsibility and a duty to use materials of this kind. The industry is progressing. Suppliers have more and more options for using sustainable materials. Having a range of recycled papers with this much personality and quality, that are hyper-specialised, is amazing for us designers,” Miguel Angel del Baño from Estudio Maba, comments on their experience in using UPM Raflatac’s label materials. “It allows for high-quality projects, which to some extent is not often the case with recycled papers,” Albert Puigdemont at Estudio Puigdemont Roca adds. “I was pleasantly surprised by the print quality, especially in the area of relief and stamped finishes, the ease of adherence, fixing and raising. It looked as if it would never be possible to have elegant, high-class recycled paper for premium products. But now, we can say that papers of this quality do exist. The Rêverie 3 series from UPM Raflatac has managed it,” Sergio Aja Iglesias, Estudio Calcco concludes.

“Responsible sourcing is in our DNA here at UPM Raflatac. Thanks to our sustainable supply chain, we are able to offer designers FSC-certified labels that have varying percentages of PCR content, suiting any requirement. Rêverie 3 was already an extraordinary range due to the use of the recycled content. However, what the designers have done with the materials, has truly taken it to the next level. It just shows what can be done when high quality materials are combined with creativity. This collaboration has shown that recycled fiber materials can stand alongside other labels and deliver in terms of both quality and impact,” Eulalia Alcaraz, Business Director at UPM Raflatac comments.

Other partners in the Rêverie 3 Collection include: 
Printer – Gráficas Varias www.graficasvarias.com
Foils and tooling supplied by – Kurz www.kurz-graphics.com
Rêverie 3 folder designed by – Bulldog Studio www.bulldogstudio.es
Bottles by – Verallia www.verallia.com