Adapting to change: PrintLounge powers up with digital production

PrintLounge, an independent, family-owned and operated printer based on Auckland’s North Shore, is celebrating a quarter-century in business this year. 

‘We provide complete print service for corporate clients and small business owners, graphic designers and advertising agencies, marketing specialists and individuals — simply anyone looking for quality print services,’ says Greg Daniel, general manager at PrintLounge. 

The company had long been recognized in the market for its expertise in offset printing, which formed the backbone of its operations. The company primarily operated sheet-fed presses, earning a solid reputation for quality and reliability. 

However, in 2016, it took a significant step forward by purchasing its first Komori H-UV press, a move that marked the beginning of a significant transformation. 

Building on this momentum, the company expanded into the LED-UV printing space, further modernized its digital equipment, and strategically diversified its production capabilities to enter the growing labels market. 

‘We’ve evolved into a commercial packaging company with a focus on digital printing that also produces roll labels,’ says Daniel. ‘When we initially ventured into roll labels, we were just testing the waters with a basic CMYK toner-based machine. However, it quickly became clear that we needed more — white ink capabilities and a broader color gamut were essential to meet our customers’ demands.’ 

Steve Sheppard, owner of PrintLounge, made the pivotal decision to invest in the Durst Tau 340 RSC E LED during the closing hours of Labelexpo Europe 2023 in Brussels. 

‘We needed a machine that could take us beyond the capabilities of our existing label press, which was limited to CMYK and had a restricted color gamut,’ Sheppard explains. ‘We wanted to choose a path that set us apart from the competition, and that’s why we went in this direction. It’s proven to be a successful move.’ 

He adds, ‘With the upgrade, we aimed to expand our color gamut and add white ink so we could print on clear and silver polypropylene stocks, opening up a much broader range of label jobs. Our previous machine served us well, but we started losing opportunities because it lacked orange, green, and white ink, all of which the Durst delivers.’ 

Before purchasing the Durst, Sheppard initially considered another press with a 600 DPI resolution, believing the Durst might be beyond his budget. 

However, after further consideration, he recognized the value the Durst offered despite its slightly higher price point. The press stood out for its superior build quality, 1,200 DPI resolution, extended color gamut, and white ink capabilities. 

‘We conducted extensive research over a nine-month period, which included trips to Australia to inspect various machines in Melbourne and Brisbane,’ Sheppard reflects. ‘During my visits, I met with several printers using Durst machines, including the 1,200 DPI model and an older version. They all spoke highly of Durst’s technology.’ 

Digitalization to meet customers’ demands  

After its installation a few months ago, PrintLounge became the first converter to operate this machine in New Zealand. 

The Durst Tau RSC 340 E LED label press was installed a few months ago to expand its capabilities further. It offers a print quality of 1,200 DPI running at 80m/min, at a native resolution and features Fuji Samba print heads and running speeds of 80m/min CMYK and 52m/min CMYKW. 

‘The speed is incredible, and it directly impacts the machine’s overall performance,’ Daniel notes. ‘Everything has changed — from the stunning high resolution it achieves to the brilliant white it lays down — all at 50 m/min. And knowing we can upgrade it to 80m/min is just remarkable. All we are focusing on now is getting jobs out the door.’ 

According to Daniel, the new press has completely transformed PrintLounge’s operations. 

‘The software powers the machine, and within minutes, we have ink usage data for a quote. Our pre-press team can make color corrections or any necessary adjustments with just the click of a button,’ he says. 

The press is equipped with the new HawkEye auto inspect and correct software, introduced at Labelexpo Europe 2023. 

This system includes a scanner, workstation and touchscreen monitor designed to detect and correct print issues like missing nozzles in real-time, in-line. In the rare case of a printhead nozzle malfunction, the integrated artificial intelligence (AI) automatically detects and localizes the problem without affecting speed. Nearby nozzles compensate by using larger drops, and no additional setup or special test patterns are required from operators. 

Sheppard is also very impressed with the experience of working with Durst workflow. The company pre-press specialists continue to discover new features, such as the ability to create die lines and manage white ink directly within the software. Tasks that are typically difficult with other pre-press software became effortless with just the click of a button. 

We wanted to choose a path that set us apart from the competition, and that’s why we went in this direction. It’s proven to be a successful move

The company, excited about the new machine, shared its enthusiasm with its followers on LinkedIn: ‘Our latest press is now up and running. Our Durst Tau 340 RSC E LED is one impressive machine, upping our label production output and quality enormously. Training is complete, and jobs are flowing to completion. It’s amazing that quality and speed can combine so effortlessly.’ 

‘Since we installed the Durst, we have brought back in-house a number of customers that we previously had to outsource to other label companies,’ notes Sheppard.  

Finishing to match print quality 

To meet the demands of new business and the increasing volume of orders, PrintLounge recognized the need to upgrade its finishing equipment to match the exceptional quality of its print output. 

This decision was driven by the growing importance of high-quality finishing, a need that brands have consistently emphasized. 

In response, PrintLounge carefully considered its options and ultimately decided to invest in A B Graphic’s Digicon, a decision they have never regretted. 

Daniel highlights the superior performance of the Digicon. ‘It’s an excellent piece of equipment with superb engineering, amazing service, and outstanding accuracy and speed,’ he says. 

This praise reflects the machine’s technical capabilities and the reliable support provided by A B Graphic. 

Daniel adds that the company’s confidence in the Digicon has led to the acquisition of another unit. ‘We’ve just purchased another machine from the Digicon Lite 3 Series, which will be arriving soon,’ he says. Sheppard echoes this sentiment, expressing excitement about the company’s second ABG machine. 

‘Our first machine has exceeded all expectations, which made it the obvious choice for us when it came time to invest in a second unit,’ Sheppard explains. ‘While we explored other options, we firmly believe that ABG offers the perfect solution for our current needs, as well as the future growth we anticipate in the label and packaging markets. This investment reflects our commitment to both quality and innovation, positioning us for success in a rapidly evolving industry.’ 

Looking back, Daniel reflects that when PrintLounge began developing its roll label section, they didn’t fully understand the requirements—everything was completely new to them. 

‘We thought that one Digicon would suffice for our converting requirements. It’s laughable now, but we quickly realized that something more nimble was required to keep up with production,’ he says. 

This ultimately led the company to invest in a Daco DT250, a table-mounted slitter rewinder. The decision to choose Daco Solutions was largely influenced by their close proximity to ABG, shared values, and numerous positive recommendations. 

‘This, along with the Digicon, managed our converting for a year until we realized we had outgrown both, prompting us to invest in another piece of finishing equipment from Daco Solutions,’ adds Daniel. 

The Daco PLR350 turret slitter rewinder was the answer, allowing PrintLounge to take jobs directly off the Digicon and finish them, as the company could now handle a 350mm web. 

Diversification is key to survival. You can’t keep doing the same thing or you’ll fall behind

‘The arrival of the Daco PLR350 was two weeks behind the arrival of our second Digicon and it has been revolutionary. For instance, we have one particular job that would take 1.5 days to slit and rewind. This is now accomplished in 4.5 hours,’ notes Daniel. ‘The arrival of the Durst Tau RSC E LED last year made us re-evaluate our conversion, as the output from that press was so much higher than that of our previous printer. I think that the Daco PLR350 has given us breathing space, and we are where we want to be for now.’ 

Diversification is key 

As PrintLounge continues to innovate and expand, its strategic investment in digital technology, including the Durst Tau 340 RSC E LED press, reflects a commitment to staying ahead in an ever-evolving market. The company’s dedication to improving its operations, from print quality to finishing, ensures it remains well-positioned to meet the growing demand for high-quality labels and packaging. 

PrintLounge is setting a strong foundation for continued success in the competitive label and packaging industry, focusing on diversification, operational excellence and customer satisfaction. As the company embraces new technologies and refines its processes, it is not only keeping pace with industry changes but actively driving them, reaffirming its role as a forward-thinking leader in New Zealand’s print market. 

‘We’re definitely focused on diversifying here at PrintLounge,’ Sheppard explains. ‘Looking back 10 years, we didn’t have a digital offering, but now it makes up a solid double-digit percentage of our turnover. Diversifcation is key to survival. You can’t keep doing the same thing, or you’ll fall behind. 

‘Like many businesses, we started as a conventional printer, and now we offer commercial print, packaging, digital printing and roll labels. Our move into roll labels has been one of our best decisions, especially with the label market growing here in New Zealand.’ 

Labels and label-related products have become a significant focus for the company, growing exponentially and making for an exciting and rewarding journey. Looking ahead, the next step will likely involve enhancing label embellishments. 

‘This is an area we’ve been considering for some time, but the key questions are what to prioritize and how to approach it. We’ve always prided ourselves on being innovative, and we’re eager to bring that spirit to the next phase of our growth,’ concludes Daniel.