Alexir makes gains with digital sheet-fed folding carton workflow

The workflow features a Xerox iGen 4 sheet-fed digital press with a Tresu Pinta coater integrated in-line and, near-line, a Kama ProFold 74 folder gluer and Kongsberg plotter.

Capable of printing up to 110 sheets a minute, the 4-color iGen 4 includes an in-line spectrophotometer that automates color adjustments and calibration, automatic density control, and high-definition linearization that eliminates the need for greyscale calibration. Post-print coating through the Tresu Pinta in-line flexo coater provides a layer of protection and enhances aesthetic appeal. A wide range of UV- or water-based finishes are possible that offer identical results to that of analog print. These include matte, gloss, full surface, spot or fine-line effects. After coating, the sheets are wheeled to the adjacent Kama ProFold 74 gluer folder or Kongsberg plotter.

The press and coater cater for a wide array of paper stocks including coated, uncoated, textured, smooth and speciality materials, and sheets of maximum cut size of 364 x 660mm. Alexir specified the line to handle substrates up to 610 micron thickness to meet specialist demands.

Alexir Partnership identified the need to add a digital workflow to its existing litho operation when it faced demand from emerging small food businesses, including farms that aim to sell into specialist niches or local markets.  With its high speed, minimal set-up times, automated features and variable data capability, the single-pass printing and coating line enables Alexir to enter short-run printing markets and offer samples on-demand and personalized packaging. Most jobs run on the line are below 5,000 units, though variable data run lengths can be up to 100,000 units.

Claire Summersby, marketing manager at Alexir Partnership, said: ‘Before we invested in digital capabilities, we would get enquires for runs of perhaps 500 cartons, but our litho-printing operation /was simply too costly for their needs. With the Xerox and Tresu production line and its minimized set-up times, we can give these producers the fast supplies of appealing, high-impact packaging that result in retail listings and sales beyond the farmer’s market.’

Scott Beadell, digital production manager at Alexir Partnership, added: ‘With the seamless integration of the coater in-line with the printer, we achieve the look and feel of the final printed result without extra logistics, material waste and set-up times.  You can see immediately what the final product will look like.’