As the first huge semi-trailer pulled up to the loading dock at the D.J. Bordini Ctr. at Fox Valley Technical College, Appleton, WI, a huge grin lit up the face of flexo instructor Steve Utschig.

It's been two years since instructors with FVTC's flexo program confronted the reality that they would lose their old wide-web Carint flexo press, and began laying plans to purchase state-of-the-art technology to replace it. The delivery and installation July 9 of a new 8-color Avanti™ gearless press from Paper Converting Machine Co., Green Bay, WI, was the culmination of 24 months of worrying, planning, and fundraising. And shows what can happen when industry suppliers, instructors and school administrators pull together to turn a potential disaster into an opportunity.

In June 2000, FVTC officials received a letter from the Flexographic Technical Assn. informing them of the FTA's intention to sell the Carint 6-color, CI-press that the association placed at FVTC in 1989. With the flexo program thriving, and both full-time students and members of industry gaining a solid grounding in flexography at this well-placed facility, the prospect of not having a flexo press on the premises represented a potentially fatal blow to the program.

School administrators, after examining a business plan from Utschig and others, made a leap of faith by committing to spend $500,000 towards the purchase of an up-to-date flexo press—hoping to cover the rest of the cost through a capital-fundraising campaign. After receiving proposals from several press manufacturers, FVTC selected PCMC, citing not only the nearby company's reputation as a world-class manufacturer but also their willingness to offer a machine to FVTC at a substantial discount. The deal was struck, and by late summer 2000 the capital campaign was begun.

Then came September 11th, and a drop in the economy in general. While the capital campaign did raise a few hundred thousand toward the discounted purchase price of the Avanti, FVTC administrators had to face the choice of coming up with another $389,000 or—as Utschig put it—"let the flexo program drop from first-rate to second-rate." Thanks to a second presentation made by Utschig and new FVTC vp of operations Dr. Sue May, the school made the decision to fully fund the remaining balance.

After weeks spent taking out the Carint press, breaking up the old floor and repouring several more inches of concrete in preparation, FVTC was ready for the new press' delivery. A small army of specialized riggers rolled, pushed and hoisted the drum, side frames, print decks, and electronics (weighing a combined 32 tons) into place within FVTC's pressroom, which suddenly seemed too cramped to hold all the equipment. During two long summer days, it was all installed, under the watchful eyes of Utschig, various PCMC employees, and several photographers and videographers from both the converting media and FVTC.

"The flexo instructors will receive their training on the press during the third week of August," says Utschig, "and we expect it to be operational the first week in September." That means a new generation of flexo students will get state-of-the-art training on the latest technology. Since the new gearless press will be used as a demonstration unit by PCMC, all the latest equipment and accessories will be installed on it as they become available. "I've been dreaming of this press for two years," says Utschig. "Now, here it is."

Editor's note: FVTC's process of removing the old press, pouring the new floor, and preparing for move-in, as well as the installation of the press itself, has been exhaustively documented and is extremely instructive to anyone contemplating installing a new press. Look for exclusive coverage both in Converting and on our Web site, along with a link to FVTC for the entire presentation. —Melissa Larson