Mark Andy has demonstrated the productivity potential of its Digital Series HD HighSpeed 1200 through an eight-hour production shift that completed 10 jobs, encompassing 25 SKUs and 873,000 finished labels, with a single operator.
Compared with conventional flexo, the hybrid press reduced total production time by 83%, makeready time by 91%, and material waste by 88%, resulting in a 28% reduction in production costs.
Combining digital flexibility with flexographic printing and inline converting
According to Mark Andy Product Manafger, Ben Luly, “Converters aren’t simply looking for faster presses. They’re looking for ways to produce more jobs, manage increasing SKU complexity, and reduce the time and resources required. By combining digital flexibility with flexographic printing and inline converting, we’re able to reduce the steps required to complete a job and significantly improve overall production efficiency.”
Mark Andy utilised a seven-colour version of the hybrid press, operating at 480 feet per minute with 1200 dpi resolution. The press had two flexo print units before the digital engine to print WW while the remaining four process colours and two special colours were applied digitally (CMYKOV). Embellishment and further converting were also carried out in a single pass.
The results demonstrate that productivity extends well beyond maximum printing speed. Job preparation, changeover requirements, workflow efficiency, and the ability to complete multiple production processes in a single pass all influence how much finished work a converter can produce during a shift. Hybrid Technology Supports Changing Production Needs
The label market is facing a growing number of SKUs and an increasingly diverse range of orders. At the same time, production consists of shorter runs that require frequent artwork changes. Flexo remains a proven solution for longer runs, while digital printing offers flexibility for short-run jobs. Hybrid technology combines the advantages of both methods, allowing the way an order is produced to be tailored to its specific characteristics.
With the Digital Series HD HighSpeed 1200, converters can combine flexo printing for selected colors or coatings with digital printing for variable artwork, extended gamut colours, and versioned production. Inline embellishment and converting further streamline the workflow by reducing the need to move work between separate pieces of equipment.
The ability to maintain production speeds of up to 480 feet per minute while delivering 1200 dpi resolution also expands the range of work that can be produced economically using digital technology. This allows converters to evaluate additional mid- and longer-run applications for hybrid production while maintaining conventional flexographic equipment for jobs where it remains the most efficient option.
The result is greater flexibility in how converters allocate work across their production floor, with opportunities to improve capacity utilisation and reduce overall production costs.
A measurable approach to pressroom productivity
The Digital Series HD HighSpeed 1200 provided specific data on production under conditions characteristic of a printing business operating in the commercial market. It is precisely the combination of these parameters that matters to companies seeking ways to increase productivity. The impact is not only on the time taken to complete a single task, but also the ability to efficiently handle a printer’s diverse portfolio of orders.
For Mark Andy, these measurable improvements reflect a broader commitment to helping customers build more productive and profitable operations through technology and application expertise aligned with their specific business needs.
See the press in action here: https://go.markandy.com/e/990852/JAqVsDUZqq4/26jfrn/1579445482/h/kF84dPZVm7-H9KDvS7WkCU0xBispO3zVzxHsIYfrfdo