Direct Corrugated Press Solution Will Goss, Day International, Inc. FPPA, March 14, 2006.
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Transcript of Direct Corrugated Press Solution Will Goss, Day International, Inc. FPPA, March 14, 2006.
Direct Corrugated Press Solution
Will Goss, Day International, Inc.
FPPA, March 14, 2006
Day International Charter
Day is a leading designer, manufacturer and
marketer of highly engineered, consumable
image transfer products for the graphic arts
industry and fiber handling products for the
textile industry
Day International History
Offset printing blankets first manufactured
M.A. Hanna acquired Day
M.A. Hanna sold Day to American Industrial Partners
Varn and Accotex acquisitions
1,475 Day associates operate in 37 facilities worldwide
1945
1960
1995
1999
2000Custom Solutions acquisition
Today
Dayton Rubber and Manufacturing Company founded
Renamed Dayco Corporation; auto tire business sold to Firestone Tire & Rubber
Auto hose and belt business sold with Dayco name; renamed Day International GSC Partners and SG
Capital Partners acquired Day
Rotec acquisition
NDI and IPT acquisitions
Produced first printing rolls
1905
1936
1986
1987
2003
davidM acquisition
1997
1998
Packaging Industry
• Packaging Growth= ~ 5% = $120 Billion– Cautious Economy/Consumer Spending– Asia/Latin America Strong Growth– Oil Prices: Moderate Negative– Europe some Growth
• Forecast– Small Bull Marketplace– Strong Productivity Growth– Moderate Capitol Investments
Packaging Market Sectors
Percent of Total Market
72%
13%
10%
2%1%2%
Flexo
Litho
Gravure
Screen
Letter
Others
Packaging Segments
Percent of Market
Flexible, 20.7
Multiwall, 3
Labels, 10.2
Corr/Pre, 31
Fold Cart, 13.4
Envelope, 3.2
Can/Glass, 18.5
Corrugated/Folding Carton
• “Low End” Graphics: ~70% and falling– Brown Box– Thick Plates, Relief: ~.070”- .150”– Typically 1-3 colors
• “High End” Graphics: ~30% and rising– Smooth Board Stocks– Thin Plates, Relief: ~.025”-.060”– 2-4+ colors
Objective
• Develop an integrated system that utilizes an integrated carrier/cushion stock and combines the image transfer element via a direct digital workflow into a composite press ready corrugated construction.
Features
• Complete Integrated Article– Carrier Sheet with cylinder attachment mechanism– Cushion Layer(s)– Image Transfer Element (potentially replaceable)
• Photopolymer(s), Liquid and/or solid materials usable
• Direct Digital Curing of image transfer element– Day Patent #’s: 6,855,482 & 6,976,426– Other Patent Applications Pending
Cross-sectional Diagrams
Direct Digital Image Transfer Element
Value Added Technology to End Users
Element Current Art New System
Workflow •Complex
•Mostly Analog
•Simplified
•Digital
Components •Individual plate, mounting tape, carrier w/cushion
•“Stacked” tolerances
•Integration of all components
•Total Thickness tolerance
Technical Choices
•Component Vendor selection based on trial and error
•Integration of properties for application requirements
Registration •Varies with accuracy of mounting & analog system
•Digital imaging direct to carrier gives ‘perfect’ accuracy
Print Quality •Varies with all components
•Unpredictable until used
•Pre-determined by system design for application
“Plate” Quality •Analog •Digital
Summary of Benefits
• Lower Labor & Error Elements– Elimination of several steps in workflow– Efficiency of Digital Workflow
• Higher Quality– Improved Tolerances & Image Registration– Higher Print quality and predictability
• Potential Reusability– ‘Reimageable’ integrated support components
Questions?
Thank You for Your Attention!