Digital Printing for Folding Cartons? What's out there? Second Report: Dotrix Modular

This post is the second coming out of my meeting with the Independent Carton Group (ICG) at their quarterly meeting in Atlanta.  For more on that meeting, and a broader introduction to this post, see my Nov. 10 post.

In that prior post I talked a bit about the HP Indigo presentation given by Ray Dickinson.  The Indigo was one of four currently available single pass systems that were shown with folding carton applications, the others were Xerox’s iGen4, Kodak’s NexPress, and the topic of today’s post, Agfa’s Dotrix Modular.  The Dotrix is the only UV inkjet option of the four….more on that later.

Kristof Dekeukelaere, Sales Manager for the Dotrix gave the first day presentation including an overview of the Modular and his view of the carton market and where digital printing systems fit in.  Run lengths decreasing, pressures on turnaround time and efficiencies, and all the supply chain efficiencies were discussed…all the arguments that have been the mantra for digital print….the difference here is the audience.  Instead of speaking to a group of label printers, who are the most savvy converters when it come to digital printing….they have been dealing with hearing it from the podium since the mid 90s….this audience is full of carton printers….a relatively new market for digital…and they were listening, most not for the first time either.

Kristof described how the crossover point between digital and conventional is shifting out to longer runs (which is a very general term) as digital systems become faster and more efficient.  The main savings coming from minimal changeover time for digital systems…if the substrates is the same the graphic change is immediate….no plates or inks to change.  One of the comments that he made, and one that I have been stating for some time now, is that digital printing in general and for cartons in particular, has now risen past the novelty, sales sample runs, test markets, and mock ups stage.  It is now ready for true production….my caveat is….if your work mix is right!  It still is not for everyone.

One of the highlights of the two day cram session….intense learning for the ICG members….was a field trip to Digital Packaging Solutions (DPS) in Atlanta.  A division of Master Graphics, DPS purchased and installed a Dotrix Modular and provided all of us with a very interesting tour of their facilities capped off with an impressive demonstration of the Modular in action.  For many this was their first look at a single pass digital press and most were impressed with the robust “real press frame” that was the core of its construction, “this is a real press” was uttered more than once that I heard….

With a web width of 25.6 inches (65 cm),…by the way the repeat is infinite…, speed of 105 linear ft per minute (about 32 meters), and the ability to handle board thicknesses up to 24 pt, the Modular has the potential to be true production systems for folding cartons.  Currently it is configured with a CMYK ink set, the Modular is soon to have an extended gamut solution adding Orange and Violet to the SPICE (Single Pass Inkjet Color Engine), which is a field upgrade….  The DPS system also had an in-line sheeter that can be inserted for roll-to-sheet needs or taken out for roll-to-roll needs.  It also had a pair of UV flexo stations on either side of the digital engine for adding white or coatings.  All-and-all the folks at DPS put on quite a show and even gave each visitor an individualized die cut folder that was….you guessed it, printed on the Modular….I give high marks to Aamir Anwar, CEO of Master Graphics and our host for the tour, and his staff who were excellent ambassadors of the company.

Kristof Dekeukelaere showing the Dotrix Modular at DPS in Atlanta (yours truly is on the far right)

All the vendors hammered home their solution’s ability to match colors and some to “match offset and flexo quality”.  While this is true to an extent, everyone has to make those judgments for themselves especially when it comes to using different ink sets like UV inkjet and toners while trying to match offset or flexo inks.  In an e-mail response to my first post…actually to a comment to that post… a friend of mine suggested that we all have to keep the marketing hype at a manageable level….granted, while one persons match is another persons “close-but-no-cigar”, we need to understand that printing is a craft trying to be a science.  And I have to remember….this is why this blog is here….thanks Bill for helping me to keep that in mind…and thanks Jan for the comment.

To add further value to my hoards of readers, here is a link to a Dotrix Modular video on YouTube

…I will do this whenever I can.  Let me know how it works for you.   Also, thanks to all of you how have sent me e-mails and called wishing me well with the blog, and a real big thanks to those of you who have broken the mold and posted comments….keep them comin….and the biggest thanks to all those who have tuned in to the blog in the first week…this is real validation to the importance of this topic to our industry….

ONE LAST NOTE: I’m looking for a catchy closing phrase that will become an icon for the blog. “Keep those cards and letters comin…” just doesn’t cut it. Any suggestions? Email me at Kevin@karstedt.com or better yet, post it as a comment.   You are also invited to follow me  on Twitter at www.twitter.com/DigitalKevin