Duplicator, Digital press, Offset Blend

[tsprinter]

I own a small commercial shop with 2 one color offset presses, 1 two color offset, and purchased a Ricoh c900 last year that we now have approx a million clicks on. I would like to automate more printing for things that don't run well on the Ricoh (envelopes, textured stocks like linens & laids, letterhead, longer run forms, etc.) in order to save labor costs. Considering a 2 color duplicator for forms & envelopes but haven't seen any good solutions for letterhead and the like. What would you consider the best blend of equipment? I would also like to hear best solutions for automating finishing, such as slitter/cutter/creasers, etc.

What would the perfect shop look like if you could start over with a decent capital budget?

 

[Craig]

Sounds like our shop! We have a Ricoh HQ9000 duplicator and here is my only problem with it. The ink NEVER dries! We print our job sheets on it and the oil or moisture from your hand will smear the ink. If I could solve that problem I would use it more.

I have a nice 19" (used) cutter and RB Sun business card slitter. All creasing is on our folder with Tri-Creasers. We also have offline bookletmaker.

My next update will be a programmable cutter.

 

[Al Ferrari]

Give some thought to the notion that automation is a solution for repetitive processes and not a replacement for skilled work. So, as you develop your business ask yourself to what extent can you rely on unskilled employees.

Al

 

[MailGuru]

Ok tsprinter. For the duplication process, take a look at some RisoGraph equipment. It's ink-based (as opposed to toner-based) so, should be able to do the linen/laid/letterhead & envelopes. It's also very reasonable cost-wise. Anther option would be to look at something that is using the new Memjet technology. It's fast & the color is pretty good. As for finishing, we use Duplo equipment (booklet makers & a slitter/creaser). All of the above equipment is on the low-end of the cost scale (much less than your C900 is costing you). Hope this helps.

 

[tsprinter]

Thanks for the input! Al, my thoughts on the labor issue is to transfer skill sets from multiple press operators that can also assist with bindery to more graphics skilled personnel that can also operate the digital equipment, perform bindery or finishing tasks, etc. I may be a bit naive (thus the reason for the thread before making changes) but I think I could have less head count but more versatility, while speeding up some of the printing processes through digital production.

I totally agree with automating repetitive tasks which is why I'd like to hear the group's opinions on which printing/finishing/bindery solutions have given the biggest bang for the buck. I have an offline Duplo booklet maker with collating tower, hydraulic cutter (non-programmable), GW HS numbering machine, etc. but would love input on how to strategically plan and prioritize my capital purchases based on your experiences.

 

[MailGuru]

We tried in-line booklet makers hooked to our digital presses, but, we eventually pulled them and now all finishing is offline. This has significantly increased our production and throughput. In-line booklet making is just too slow. Here's why: While most digital production press manufacturers will tell you that their equipment will run any substrate at rated speeds, what they won't tell is that it won't run mixed-stock at rated speeds. When we produce booklets, the outside cover is 80# gloss cover, while the inside pages are 60# gloss text. Most tonoer-based digital presses will need to pause when switching between the two stocks to adjust the fuser pressure & temperature for a thinner or thicker stock. So, our solution is to run the covers on one of our printers while running the inside pages on another one. Then they are "married" in front of the offline bookletmaker.

As far as personnel goes - we run a small shop (15 or so people) producing a large volume (about 20 million pieces per year). All of our employees wear multiple hats. Graphic art also merges data and runs printers, printer operators also work in bindery, data processing and programming also work in Graphic arts, etc. Me, I'm everywhere from data processing to programming to printer operator to running cutters/folders & inserters. The side benefit of cross training your people is that they now know and understand what's going to happen to the product through each stage of production. This enables them to proactively see and correct a problem in their home department before it goes to the next.

 

[printfinisher]

Hi Tsprinter,

Duplo has a range of Duplicators. They are very easy to use, environmental friendly (soya based ink) and economical DP - U950 (Digital Duplicators) | LinkedIn please click on the link to know more... In the U series of our Duplicators we have integrated lot of new features. Have a look at it.

We have DC family of Slitter/Cutter/Creaser and now even with embossing and perforating module.. DC-745 can perform all the above functions in one pass. DC - 645 (Slitter/Cutter/Creaser) | LinkedIn
Have a look at it...