Digital Printing - a difference maker in launch of Windows 7

In late 2008, digital print specialist Mediaware Digital Ltd. of Dublin, Ireland, saw a business challenge and opportunity as Microsoft was seeking a folding carton producer for its Windows 7 software launch. Mediaware proposed a new workflow enabled by the Gallop digital print packaging line jointly developed by Xerox and Stora Enso.
The timelines behind this successful application are impressive, to say the least. Once Mediaware got the nod from Microsoft, it had just six weeks to ramp up. Microsoft, after all, was not going to change its software launch date, so Mediaware and technology partners Xerox and Stora Enso had to meet the October deadline. In a six-week time frame, the team built out the 8,000-sq-ft facility in a secure, climate-controlled environment, tested the IT infrastructure, appropriately staffed the organization, and met Microsoft’s delivery expectations.

Microsoft wanted a solution that would speed its supply chain, handle short runs for many countries, and reduce the overall cost of packaging in multiple languages. Mediaware chairman Simon Healy and the team at Mediaware recognized the benefits of digital technology. Working closely with Xerox, Mediaware successfully introduced a new digital workflow approach that helped them capture the Windows 7 folding carton converting assignment.

Because the workflow is built around a digital printer, it enables lower minimum orders, less waste, less storage, and quicker time to market. An added benefit gained is more secure printing because Mediaware prints a unique code on each carton, allowing item-level tracking worldwide. The total solution prints a precise number of cartons per job, cutting the risk of counterfeiters gaining access to legitimate packaging.

“Early on, we also saw it as a more sustainable process,” says Healy. The environmental advantages of digital printing for folding carton packages include reduced ink and substrate waste from make-ready and die-cut scraps. “We’ve found,” adds Healy, “that digital technology eliminates surplus inventory and overruns as well as plate production, saving the environment, budget dollars, and physical space.”

Demanding specifications

Today, Mediaware delivers two sizes of folding cartons for Microsoft. The material used for them is Stora Enso’s 330 gsm Ensocoat board, which has been newly improved to provide a superior visual appearance. Microsoft’s specifications were demanding, requiring printing a stream of short runs of glossy, full-color, folding cartons in dozens of languages. Production had to begin in time for the launch of Windows 7 in October 2009, and it needed to satisfy Microsoft in terms of price, quality, environmental footprint, security, and integration with Microsoft’s workflow. The first step in the carton-production process is printing, which is done on the sheet-fed Xerox iGen4 digital printing press. The material is coated inline with a water-based but high-gloss formulation. This addresses Microsoft’s requirements for “green” chemistry and a sleek appearance.


Next stop in the inline process is the CTi-635 in-line coating system, supplied by Epic. It features CoatTech Anilox coating technology similar to systems used in-line on offset presses. Precision anilox roller and doctor blade produce consistent coating results on long or short runs.

Run lengths at Mediaware vary greatly, from just 5 cartons to around 2,500. Total volume, which now is also attributable to other customers besides Microsoft, varies but is currently between 10,000 and 15,000 cartons per day.

After printing and coating comes a Stora Enso buffer/stacker followed by a unique DC 58 die cutter, developed by Stora Enso in partnership with Kama GmbH. The die cutter operates at up to the twice the speed of the iGen4 digital printer, so it can handle hot foil stamping and die cutting and still keep up with the printer. The buffering stacker line integrates the printing and coating section to the die cutter and allows printing to continue even if the die cutter is offline.

Mediaware also needed to integrate with the client’s workflow and supply chain to deliver what was needed, when it was needed, and in the exact quantity required. Mediaware and Xerox developed a software solution that provided close coordination between production and consumption as well as the ability to operate with “lean” supply chain manufacturing principles. Utilizing Xerox’s PrintCise software, Mediaware’s own proprietary ArcLink program, and the Xerox Automated Packaging solution, Mediaware created a system that could accept orders via the Internet, print in multiple languages, quickly switch from one language to the next, and produce small batches with relevant consumer information. This digital packaging solution significantly reduced minimum order quantities. The inline finishing meant that Mediaware could produce customized packaging cost effectively, without having to stop production and manage offline equipment.

Workflow of the future

The competing bids for the Microsoft contract offered solutions bound by the old rules of conventional analog offset print technology. Competitors relied on the old business model, printing short runs in analog for the best unit price they could offer and storing excess prints for possible use with later orders.

Mediaware, on the other hand, put together a workflow of the future. It’s integrated with Microsoft’s order entry, manufacturing, and delivery operations, and it was critical to meeting and exceeding expectations and requirements. Here is the basic sequence for each of the hundreds of folding carton print jobs Mediaware has delivered to Microsoft since October 2009:

• Initially, Mediaware takes a forecast from Microsoft and downloads the artwork from Microsoft’s global repository into Mediaware’s document library within the Xerox PrintCise program.

• ModusLink, Microsoft’s tier 1 kitting partner in Waltham, MA, places an order to Mediaware in the form of a .CSV that automatically generates a component of the overall bill of materials.

• The .CSV file is dropped into Mediaware’s MIS system. Mediaware’s proprietary ArcLink program automatically generates a work order and places it into PrintCise. • PrintCise automatically retrieves the artwork from the library, adds variable information (country of origin, printer ID, and bar code verification), and drops the job on the iGen4 digital printer complete with a job ticket.

• The iGen4 feeds via Internet Printing Protocol (IPP) back to PrintCise the status of the job in real time.

• After printing, coating, die-cutting, and gluing, weight verification acts as a final quality control to confirm that the appropriate number of folding cartons was produced. PrintCise outputs a value to a weighing machine. If the value meets the actual weight, a delivery label is released. If not, the job goes into quarantine for evaluation.

The Mediaware workflow is so automated that human hands normally do not touch the carton until it is ready for insertion into the folder/gluer. The jobs are segregated into two queues, one for each carton size, limiting the need to change the settings on the folder/gluer.

No hard copy order

There is no hard copy order. As with other Web-driven print applications, this means that there is no need for intervention from customer service representatives when jobs are released from Microsoft. According to Healy, “We can complete a job from the initial email order to the completion of die cutting in less than 45 seconds.” With its internal IT group, PrintCise, and the Xerox Automated Packaging Solution, Mediaware has basically developed an automated Web-to-print folding carton business. Plus it comes with sustainable packaging benefits.

“Our system cuts the waste associated with conventional folding carton converting, including overruns and inventory obsolescence,” says Healy. “While we can’t quote exact dollar amounts, we have clearly delivered substantial cost savings to Microsoft.” Healy also emphasizes that while this is a business solution that has met Microsoft’s expectations, it has tremendous viability for a broad range of folding carton applications from retail to pharmaceutical. “Pharmaceutical companies, in particular, have some of the same business needs that top software companies have,” says Healy. “They have a regular use of small-format cartons, they sell internationally, and they have a high need for secure print.”

“Digital, print on-demand packaging meets the current cost cutting and lean manufacturing initiatives but it also creates opportunities for increasing customization and targeted marketing, such as the packaging for retail chains or for seasonal products,” says Pekka Tommola, director of Stora Enso Digital Solutions. “The ability to coat aqueous formulations for companies needing FDA approval for use with food and drugs opens the way to use the Gallop line for example in the production of chocolate boxes or pharmaceuticals packaging.”

As for the Microsoft Windows 7 project, it proves once more how critical a role packaging can play in helping brand owners achieve their objectives. Mediaware’s Healy sums it up nicely.

“We listened to the brand owner and knew that we could not compromise on quality or appearance. We needed to prove that our solution would work.”

This story is adapted from a case history report written by InfoTrends, Inc.

Digital printing process, quality control (I) – Digital printing, quality printing – printing industry

As well as today’s CTP and digital printing, printing industry has undergone a continuous process of change. However, no matter how the printing industry changes, people’s attention is none other than the transmission and reproduction of graphic information. Therefore, graphic and text information to evaluate the quality of reproduction and use of effective means of quality testing and control, has always been extremely important. Then, when the printing industry from the DTP, CTP to all-digital network production process, how should we carry out quality inspection and control? This article will discuss the issue. The main print production process Twentieth century, the rise of the DTP 7 80′s technology enables the printing plate technology has greatly changed.

DTP is the beginning word processing system mainly to solve the prepress part of the process; to the early 90s, the printing industry into a more mature stage of color desktop publishing, desktop publishing in this period has gradually developed into a process process. CTP is the output of digital prepress an extended form. With the CTP plate prices continue to fall and the related technology continues to mature, to the mid-90s, CTP system has entered a practical stage. “Digital printing” is essentially the digital pre-press to printing, after printing an extension. For digital printing, there are currently no unified view. Broadly speaking, the so-called digital printing, is stored in the computer in the text, images and other data in digital form with a recorded media, then transfer this information to the media, then the printing substrates. Currently, digital printing can be divided into two ways. First, the complete elimination of printing plates, electronic imaging, or ink-jet technology directly imaging the full significance of the media digital printing, such as HPIndigo and Xeikon digital presses introduced; The other half with the printed version of the digital presses, such as the Heidelberg DI (Digital Imaging System) printing press. The latter could be summarized as in the machine CTP. Different degree according to digital, the existing printing technologies can be classified into the following four means of workflow. 
  1. CTF process: DTP CTF traditional press printing
  2. CTP process: DTP CTP (computer to plate off) traditional press printing
  3. Semi-digital printing process: DTP semi-digital printing (computer to plate in the machine) print
  4. All-digital printing process: DTP print digital presses we have the first CTF process known as the traditional printing process, the digital process known as the back three.

Printing quality control elements and control tools. Print print quality is the combined effect of a variety of exterior features. Replication technology from the perspective of print quality should be a “faithful reproduction of the original” as the standard, whether in traditional or digital printing process flow should be achieved on the faithful to the original printed copy. For printing there are four control elements: color, level, clarity, consistency. 
  1. Color is the basis of product quality, product quality directly determines the advantages and disadvantages. Color printing control or management is always a hot research and analysis professionals and key technology.
  2. The level tone that the color shades of the image recognizable changes in steps. It is the foundation to achieve accurate color reproduction.
  3. Definition refers to the clarity of image detail, including the three aspects, the clarity of the image subtle level, the clarity of the image contour edges and the clarity of image detail.
  4. Consistency is uniform, which includes two aspects. On the one hand refer to the same batch of printed ink in different parts of that area of ink of different degree of consistency, the general field with vertical and horizontal print density to measure the degree of consistency, it reflects the same time, print out the stability of different parts of printed matter.

The Still Used Printing Machine

Unit Goss Community Web Press
This press is well-suited for producing newspapers, newsletters, advertising circulars, catalogs and magazines. Publications can range in size from signature to metro. We stock roll widths of 29 and 34 inches in both newsprint and Hi-Brite. We also have 34 inch 50 lb. white book stock available.

Miehle-28
This is a 2 color press for printing larger format jobs. It can print up to a 20" x 28" piece in 1, 2 or 4 color process printing. It has a stream feed, so it is capable of running up to 10,000 IPH. Its high pile delivery allows large jobs to be completed more quickly.

Heidelberg KORD
The Kord is a single color printing press capable of printing a variety of jobs, from business cards and stationery to full color brochures up to 18" x 25".

Heidelberg GTO
This is a 2 color press for printing small to medium format jobs. It can print up to a 14" x 20" sheet. It is an excellent press for producing 11x17 inch sheets for making 4-page newsletters and brochures. It is capable of very high-quality process color printing.

Ryobi 3302M
A two-color offset press that produces high-quality printing. It uses a V-shaped five-cylinder system that enables tight registration control. Its many automated features and plate preregister system make for efficent and cost-effective operation.

Sculpteo the 3D printing service and why we love them

3D printing

Okay, so you've got a printer at home. It's probably colour, and maybe it has a scanner built in, but I bet it doesn't print 3D models. Yes, I said 3D models.

3D printers are my new favourite things - through a process of squirting and layering they are capable of making three dimensional models from a computer design but unfortunately at $3000 for the cheapest models, they are just a squeak out of my price range. 

Print company Sculpteo had the good idea of buying one and then taking commissions from people to print their work for them. Send them a computer file of your three dimensional design and they'll "print" it out and mail it back to you. Based in France, they cater for European customers and as of today, for any in the USA. 

So you'll need 3D imaging software to make the model, and of course, you can't just design a house or a Harrier Jump Jet, there are size restrictions: between 2and 10 inches. But otherwise, cute idea right?
Sculpteo also point out though that you can get some free 3D imaging software online...

"Google provides a free, easy to use application called Google Sketchup. This tool allows you to design everything you want in 3D, through an intuitive interface, and offers free 3D models for download."

Sounds good eh?

Prices depend on various factors:
"Our price is based on your choice of material, monochrome or colour printing, and object size & shape. It is calculated automatically once you have selected your printing parameters, before confirmation of your order. A quantity discount applies based on the volume of the object. You can increase or lower the final price by adjusting each of these 3 factors."

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