Technology and Automation Drive Value at Kelly Box

Last quarter Corrugated Today published and a really great article about Kelly Box and Packaging that focused on our production capabilities in our Fort Wayne facility.

Find the article here.

The article captures our commitment to driving productivity and value by investing in technology and our people.

Exploring Digital Print - Excelagraphix 4200

When we attended the SGIA Show last October we ran across a little digital printer that has been getting a lot of publicity lately: The Excelagraphix 4200.

The Exclagraphix 4200 has some intriguing specifications:

1. Small format digital printer that prints up to 42 inches (1.067 meters) wide on substrates up to 5/8 inch  thick. 
2. Uses aqueous dye inks and prints directly to porous substrates that are receptive to water based inks, or aqueous coated substrates for optimal print quality.
3. Runs 1600 X 1600 dpi at a speed of 6 inches (15.24 cm) per second or 12 inches (30.48 cm) per second at 1600 X 800 dpi resolution. 
4. The print output per hour is up to 12,600 sq. ft. (1,090 m2) at 1,600 X 800 dpi and up to 6,300 sq. ft. (545 m2) at 1,600 X 1,600 dpi.
5. Uses an Adobe PS3 software RIP with Xante's iQueue workflow software.
6. There are many variables involved, but they estimate the operating costs for ink and the print head at 100% coverage (25% use of each color and use of the print head) to be approximately $0.22 per sq. ft. and $2.37 USD per m2.

We were intrigued and thought this might be a great tool to help us develop some of our processes as well as to expose our customers to some of the benefits of digital printing. We decided to put this machine through our product evaluation process and sent them over some files and a stack of corrugated.

We took the best sample from the Excelagraphix and compared it to the best sample we had from Sun and the Excelagraphix print quality was significantly better. So much so, that the customer we are working with rejected the Sun sample, but would accept what came off the Excelagraphix. 

So it passed the quality test... almost. This machine uses aqueous inks, which is a significant problem because the inks do not sure and will run when exposed to water. This is certainly not a production machine, but it can be used for some short run production.We are working with the manufacturer and we are going to run a test to see if the operating environment impacted the performance of the machine. We should get those back by the end of the month. Then we have to evaluate the cost of operations, capital investments and other factors. Interesting option at the low end of the market.

Exploring Digital Print - Sun CorrStream

Sun Automation is on the verge of developing a true industrial inkjet platform that will perform at speeds that will compete with analog flexographic printing. 

Digital Printing has the potential to be a game changer in our industry. 

Digital technology eliminates the needs for make ready registration, mounting, ink mixing, print plates, make ready color matching, not to mention the ability to serialize the boxes and convert to alternative designs on the fly.  

When this technology works it will truly impact the way we can serve our customers and how they will reach their customers. We are excited about how we might use this technology to serve our customers.

Here is what we have learned about the Sun CorrStream: 

1. The technology works.
2. The machine produces a decent print quality (300/600 dpi) at a pretty good speed 180ft/min.
3. It is a simple, rugged and robust platform. It is designed as an industrial tool.
4. It has a highly modular design to account for upgradeability and serviceability.
5. RIP software and File handling is relatively easy and straightforward.
6. Color matching systems are excellent and simple to use.

On the other hand they are not quite ready for market.

1. The machine is priced very high. Which doesn't matter except...
2. The machine uses 48 heads, and at payback utilizaton the heads need to be replaced every 2 years.
3. The heads are currently priced at an unworkable price each.  
4. The print quality is currently well behind flexo and not comparable multi-pass machines.

So what to think?

1. This technology definitely follows Moore's Law: The speed/performance will double and the cost will halve every 18 months.
2. This machine is a proof of concept for Single Pass Digital Inkjets.
3. When the costs come down and the print quality improves this will be the platform for our industry: NO DOUBT!
4. The cost curve is moving toward them.
5. In 3-5 years theses machines may very well be a dominant player in the market place.
6. They already showed us the impact of new ink formulations that will be coming in the next year that radically improves the overall quality of the print.
7. This is a corrugated-centric solution geared to sheet plants. 

Over the next few weeks we will be looking at additional platforms for digital print. Stay tuned.

Digital Printing Update - Chasing the Hype

Over the last few months we have been looking very closely at the current status of direct digital print in the corrugated packaging industry.

Gartner Hype Curve

There has always been a great deal of hype about this technology for many good reasons. It holds tremendous promise to radically impact our industry and more importantly our customers. 

But like most new technologies it is following the Gartner Hype curve. At this moment we are just past the trough of disillusionment and finally on the slope of enlightenment. 

Is the technology finally more than just a sample maker or POP maker?

We decided to develop a strategy to assess two critical factors affecting the adoption of this technology in our industry.

1. Is there are market for digitally printing packaging?
2. What is the current capability of the technology?

To truly asses if things have changed we decided to focus on the box side, as it is pretty obvious that the technology is working for the POP segment. We wanted to find something that was currently being run at decent but not crazy volumes and that had a strong graphic element. We found a perfect candidate and they agreed to let us explore the current state of this nascent technology for producing boxes on a production scale.

For there to be a digital market in packaging the technology would have to compete with multi-color flexographic printing and offset lithographic printing laminated to corrugated sheets in three key criteria:

1. Quality
2. Speed (Productivity)
3. Cost 

Over the next weeks we will share with you the results of this project as they unfold.   

KBPC Indy Hosts 2015 Kick Off Event

The KBPC Indy plant hosted the the Annual kickoff event. It was a chance to see the Indy facility and to review a very successful 2014 while we planned for an exciting and successful 2015. 

Joe Gorman supplied the younger members of the team with first aid kits to help them patch the wounds they were about to receive in the budget process, while the younger team members put together a kit of Senior Citizen Aids for the old men in the room. (Strangely they included me!?!)

 Awards were given, food was consumed, the plant was toured and budgets and zeroes were established for the coming year. 2015 promises to be another record setter!