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DTG Printer – Six Functions to Take Into Account With Almost Any DTG Printer.

Deltabach, our prime-flying commercial print house based here, has reported a substantial upturn running a business following its adoption from the latest generation LED-UV curing system from Air Motion Systems. The AMS XP9/17W unit was retrofitted to the latte art printer earlier just last year but, as Deltabach Director Marc de Jong explains, it wasn’t before the final quarter that the chance of the brand new system to alter his business became fully evident.

“Our primary basis for purchasing the AMS LED-UV technology ended up being to boost the efficiency and productivity of our B1 press,” he shares. “It took us a little while to find the balance of consumables right and adapt our practices and processes, however the numbers reveal that this primary objective continues to be realized. In the year prior to the upgrade we printed 24 million sheets; that rose to 30 million, pro rata, during our transition period and today, once we maintain our current amounts of output, we will hit 36 million sheets this year. This is certainly without any variations in shift patterns, increases in manpower or electricity use and with added savings on such things as spray powder, which we no longer use.”

The rise in productivity is essentially the effect of three key advantages of the AMS LED-UV curing technology.

First this year, after a three-year period during which its turnover had quadrupled to €6 million, Deltabach made the decision to switch its B2 press with all the B1 Heidelberg CX 102. However, the extra costs incurred in changing formats at pre-press and bringing in a bigger guillotine flow line meant their budget would not stretch into a long delivery for that press. The compromise became problematic in reality: “It resulted in we had been only capable to run at 12- or 13,000 sph (sheets hourly) when coating and also this was obviously not satisfactory coming from a commercial standpoint,” says Marc de Jong. “With the AMS system we don’t must coat, and then 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 are therefore ready for fast printing in the reverse side and downstream processing:

“This doesn’t just mean we can easily promise better turnaround times to our own customers,” explains Mr de Jong, “it has a major affect on our pressroom practice. Previously, on turn-and-tumble work, especially where uncoated or smooth papers were involved, the operator would output eight plates because the job would have to wait - maybe overnight, or even longer - before the piles might be turned and placed back throughout the press. Naturally, then another 10-20 minutes would be lost in obtaining the settings to the appropriate levels… now we simply turn and go on. By trying to quantify that - it’s amazing. Additionally, it gives another dimension to your planning since the timings have become predictable.”

As well as the third factor is one that is certainly often cited, but perhaps without its full ramifications being appreciated:

“By eliminating spray powder we not only make life easier about the press and in the bindery, and increase the product to the customer, our company is boosting the production time seen on the press,” shares de Jong. “We accustomed to take three hours following per week to de-powder the press, along with the same was true of a lot of the finishing machines, given that is not really required it becomes more available production up-time. All of this factors in to our profits. We also save dexmpky56 to a hour each day as the LED-UV inks overnight inside the ducts, and much more time in the coating unit, where we used to have to alter plates and tidy up between different jobs.”

The impact from the changes on workflow is clearly visible in the a4 uv printer wherein a large floor space is marked out into eight ‘lanes.’ It was formerly the marshaling yard where pallets of print were held and shuffled since they waited to dry before turning and reverse printing, or moving to post-press. It now acts as a buffer zone for print that is certainly immediately ready for the upcoming process, leaving a good amount of free space for, possibly, the following press investment.

With around 70% from the business being with agencies, brokers along with other printers, production efficiency is essential for Deltabach to guard its margins whilst keeping its prices competitive. The added features of the AMS LED-UV technology can also be helping win business. As de Jong continues, “Many from the major brand owners and designers specify a necessity for coating as standard procedure. We now have been able to indicate them that the is no longer necessary when utilizing our system… we actually placed our product among those using their other suppliers plus they couldn’t see the difference. This was the green light for AMS LED-UV.”

In another instance, the rewards happen to be more dramatic. A serious national lottery company was utilizing a spread of print houses to offer its countless tickets for mailing to potential entrants. The A4 sheets are printed on G-Print together with the personalized ticket information on one side and the lottery company’s solid red corporate ID around the other. Consequently, the waviness of your papers from the coating, and slippage from the spray powders were causing mayhem in the mailing house:

“When we switched for the AMS system we supplied our quota as always, but without telling the buyer of the change in production,” explains de Jong. “It had not been prior to they called us in since their mailing house was demanding for all the tickets to become supplied like this. Their machines had never run very well. They may also notice that the caliber of the solid was better, too, and the truth that we are now able to supply at such short notice meant we won the entire contract.”

Now Deltabach is exploring other elements of the rewards that this AMS LED-UV brings. For just one of its property agency clients it can be already printing ‘SOLD’ stickers which had been sent for screen printing as they are on non-absorbent stocks, and tests are under method for innovative POS, packaging and promotional gifts on unusual substrates who have added-value to build better margins. Mr de Jong sees this being a separate enterprise, that will be directed at direct customers inside the region:

“We can look at any display, promotional or printed requirements the individual might have so we will supply. As far as our commercial printing services are concerned, Air Motion Systems’ LED-UV has created a huge difference, like waving a magic wand over our business. The designers love the product quality along with the texture of our print, we compete on price and we are obtaining a reputation because the go-to supplier for quick turnaround work - even the same day - that’s pretty difficult to beat.”

For Air Motion Systems, European Managing Director Carsten Barlebo reports, “Deltabach’s experience is a perfect instance of just how the AMS LED-UV solution can improve performance in the press and the way this, consequently, can energize the full production process. As well as being entirely mercury-free, another significant benefit of the AMS option is our patented Dynamic Collimation system, allowing Total Flexible Lamp Positioning within the press and can make it the best choice for retro-fitting and re-commissioning as required. Because of this any print company having to improve its efficiency and increase capacity has a investment path that does not necessitate outlay over a new press.”

Deltabach was founded in 1970 by de Jong’s father as being a spin-out from the stationery in plant he managed for any newspaper publisher in Leiden, between Amsterdam as well as the Hague. Although still dedicated to commercial stationery print, it always championed new technology and was among the first adopters of CtP and MIS systems within the Netherlands. When expansion forced relocation for an eco-friendly business park in Nieuw-Vennep, even closer to Amsterdam, in 2007, a sales partner was appointed to produce 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 this year triggered the unusual decision to switch the B2 press with a new B1 Heidelberg CX 102.

Marc de Jong comments, “We hadn’t designed to move out of the Leiden area, but there are no suitable options available there. Because it been found, the transfer to a brand new high-tech, eco-friendly building continues to be perfect for us; it’s a fantastic environment to welcome our high-end corporate clients, agencies, designers and print brokers into … they never fail to be impressed. We had been also fortunate we chose to not specify a long delivery with IR drying if we made the move to B1. It had been the constrictions imposed by that press configuration that led me to investigate alternative solutions as our business developed. I produce a reason for after the latest innovations by checking the trade media in the United States, and so forth, so when I check out AMS LED-UV I had been impressed by the claims for eliminating powder, increasing speeds and also the sheets being ready for immediate back-up printing or finishing; I wasn’t considering the capacity to print on awkward stocks or plastics. All of the reports looked good so that we made enquiries and Wifac, the agent for Air Motion Systems in the BeNeLux countries, arranged some site visits for people. Whenever we saw it functioning we were convinced that AMS LED-UV was the correct choice for people like us.”

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