Versatility over a wide range of substrates and adherence to strict quality requirements led Huntley, IL-based Catty Corp. to choose BST Pro Mark's Premius Digital 3 Chip for print-process management.

The company's six-month review of several different inspection systems evaluated each for effectiveness in a wide range of criteria: including the ability to produce foils, foil laminates and colors. Detection of haze and register on complex graphics and unusual substrate combinations was also critical. Premius was the winner.

According to general manager Ron Klint, "We are confident Premius will meet the stringent requirements of our customers and will allow us to continue our 79-year tradition of superior quality and service." Added pressroom supervisor Dan Oddo, "The product is technically superior to other products on the market—evident by the manner in which it outperformed competitive products in trial after trial, test after test."

Catty Corp. has ordered two of the Premius systems, equipped with defect detection and automatic color monitoring. One system will have a 17 1/2 in. by 13 in. field of view in order to accommodate inspection of the company's large repeat areas and 60-in. webs. The two systems will be installed on Catty's newly purchased 26-in. Evolution press from PCMC (www.pcmc.com), and on a 60-in. Bobst (www.bobst.com) gravure press, respectively.

Montreal-based Rosmar Litho has found success with the Ergosa 500 Semi Automatic Packing system for folder/gluers from Conception Impack, St-Jacques, Quebec. Recently introduced by PPCTS (www.ppcts.com), Conception Impack's worldwide sales representative, the Ergosa 500 packer reportedly addresses operator occupational injuries normally associated with folder/gluer lines by organizing, ergonomically, the corrugated case-packing method and eliminating lifting actions.

Not only does the system provide an ergonomic workstation for folder/gluer carton-packing personnel by collecting boxes on a specially designed conveyor, it increases operator corrugated case-packing productivity by facilitating the crating of the boxes, which can allow for the reduction in the number of packing operators, where more than one is necessary, increase folder/gluer speeds and/or allow more time for the operator to conduct quality inspections. The Ergosa 500 is equipped with an automatic case-bottom flap closing system, as well as an automatic corrugated case ejection device.

The Ergosa 500 is compact and can be moved from one gluer to the next. It can be placed inline with, or at an angle in relation to, the folder/gluer delivery section, depending on the type of boxes to be packed. It can handle traditional straight-line boxes in single and multiple layers and/or rows, 4- and 6-corners, double-wall, crash-lock bottoms, 5-panels, and other types of folding cartons and boxes.

Impack specializes in the analysis of work methods and the design and manufacture of equipment for manufacturers of folding carton packaging.

For the flexible package printer/converter who works with extensible films and materials, the fight to prevent defect-rendering process deviations is a continuous one. The key to reliable defect prevention is the converter's ability to measure and make machine adjustments to eliminate unwelcome deviations, including tension transients. Web-process problems can sometimes be corrected simply by installing tension monitoring or control equipment at critical zones on the machine or web press.

While many film printers and converters are busy trying to overcome issues of excess tension, some, like a large gravure printer, suffer from slack web conditions. Dover Flexo Electronics (www.doverflexo.com) helped solve the problem.

Uncontrolled loose web on the printer's two multi-zone multicolor presses was causing the web to "dip a color" periodically, according to the plant's maintenance manager. This potential hazard causes unplanned downtime and lost productivity. As with instances of excessive web tension, the problems could be avoided if operators were able to adequately monitor and adjust for out-of-spec tension conditions on press runs.

The printer started by retrofitting its 36-inch wide-web press (a Cerutti 190 8-color press with lamination zones), with ten Tension Roll® Transducers and FireGuard tension amplifiers. Tension was measured by the transducers, then amplified and displayed at analog meters set up in a single enclosure at the operators' main control panel.

The printer retrofitted a second press (an 1-color gravure unit) with the transducers and indicators. Finally, Dover Flexo supplied a special TLS (tension limit switch) option that triggers alarms at four of the sensor locations when low-tension set points are tripped during print runs.

By continuously monitoring their actual running tension at various critical points in the presses, the operators can make adjustments before a print job is negatively impacted.

Among flexible packagers in the food, beverage, and textile industries, Ultra Flex Packaging Corp., Brooklyn, NY (www.ultraflex.com) has a reputation for state-of-the-art converting technology and print quality. Digital platemaking, a Fischer & Krecke 10-color CI press, and solventless and ultra-barrier lamination capability, speak to the company's technical proficiency.

So when they began experiencing a problem with white ink misting at high press speeds, Catty turned to longtime supplier Harper Corp.(www.harperimage.com). "Harper devised a banded anilox roll with 30-degree cell geometry that solved the misting problem for us," says Zalman Zohar, print manager.

Harper has also helped Ultra Flex evaluate its ink suppliers and systems. As a 34-year veteran of the flexible printing industry, Zohar was surprised how much he learned about the anilox roll at one of Harper's WalkingSeminars™ at its Charlotte, NC manufacturing facility. "I would recommend this program to anyone who is serious about their printing," he says. "Through their technological expertise, Harper has actually enhanced our print capabilities over the years."