Happy new year to you all and welcome back to the Alphasonics Blog!  So the turkeys been eaten, all the good TV has finished and there are no more mince pies left.  We’re now in 2011.  Now is the time to take a look back on last year and think about how you’d change things.  Much like deciding to go to the gym or spending less time at the pub, many flexo printers will be thinking about how to improve on their production methods.  Maybe not in the same train of thought, but they will be thinking about it.  Trust me. 

Improving best practice methods are essential in ensuring print runs are perfect every time and at this early point in the year, most could say that there is never truly a ‘best best practice’ because there is always room for improvement.  Many think they have perfect procedures but you’d be surprised.  After visiting countless label and packaging printers both in the UK and overseas last year, I’ve learned that there is always room for improvement.  Where I’ve seen the need for this is time and time again the part of the flexo press which is arguably the most important, the anilox.  Many printers, in labels especially, have come to me asking why they aren’t getting the print results and nine times out of ten it is the condition of their anilox rolls. 

It’s unfortunate that the anilox isn’t always given the care and attention that is needed so I’ve decided that I’ll do my bit.  Below are five New Year’s resolutions that will keep your aniloxes clean, allow them to perform well and in turn, make the print production of your press undoubtedly improve. 

1)      Find a cleaning system that is appropriate for your aniloxes. 

Each different kind of anilox cleaning method has its own benefits.  Do your research and get it right.  Every single method has something to offer but there are always draw backs no matter what you may choose.  Look at the benefits and drawbacks to each method and think about the long term. 

If you’re looking to make a rushed decision based on price alone, you may as well take a hammer to your rolls and pour a few thousand pounds down the plug hole.  Consider your own printing capabilities, consider your press and your aniloxes, consider the facts, consider the long term benefits and consider how clean your aniloxes must be. 

The biggest lesson here is not to listen to hearsay or badmouthing that goes on between competitors.  Seek out the facts and you won’t regret it. 

2)      If you are going to bring in higher screen counts, ensure your current cleaning system is compatible.

When you purchased your cleaning system, you would’ve ideally considered your future plans.  If you are looking to move to higher screens, you need to ask a very simple question: Is this good enough to move on with us?  If you have single frequency ultrasonics or a blasting system, you have to take the possibility of roll damage into consideration.  Most methods incur a high consumables costs.  If you have a system that won’t grow with you as a business then it’s back to the drawing board.  If you fail to plan, you plan to fail. 

3)     To derive the greatest benefits from higher screen counts, you need a regime.

Regular and effective roll cleaning is quite simply essential.  There is no other way to say it.  When you’re considering a cleaning system, you need to take into account whether it will allow you to clean as and when you want.  If there is complexity and a long set up time, then I would suggest you give it a miss.  You need a system that will allow you to draw up a detailed roll cleaning plan and stick to it.  The sticking to it is the important bit and is down to you but one thing is for sure, you will not regret it.  It will certainly reflect in your print quality and the awards you pick up because of it.  

4)     Clean between ink changes to avoid layering. 

We spoke about regime in the last point.  A good idea is to clean between every ink change as you can otherwise coat your rolls in a contamination that is extremely difficult to shift.  The range and complexity of today’s inks mean we are finding more and more that traditional roll cleaning methods are struggling at first.  

The reason for this is a kind of cross contamination that occurs when different inks are used on the same anilox without adequate cleaning in between.  We are seeing UV, water based (both filmic and thermal) and in some cases even solvent based inks being run on the same anilox and what we've come across is a layering of contamination that is difficult to shift in one go.  One chemistry may break through one layer but struggle with the next and vice versa.  Luckily, we have Alphaclean 10 which is a chemistry that can tackle this but unless you have products such as this at your disposal it will be difficult.    It is critical that the anilox is cleaned at least between every ink change as thoroughly as possible and you must have a system that will allow you to do this every single time.  Unless you have 100% cleaning 100% of the time, you’re doomed to struggle. 

5)     Finally, share your advice. 

As I mentioned in my last blog entry, the community that is forming across label printing, packaging and all industries utilising flexographic printing is one of the main reasons that this year will be successful.  We’re starting to emerge from a troubled couple of years and I feel that the relationships that are being formed between organisations and experts both online and at trade shows can be credited with helping this to happen.  Also, read publications, blogs and tweets and get the top tips from the industry gurus.  Share your tips and help and in turn you can help bring everyone forward together. This can even start by commenting below.    

Whether you think you’ve got it right or not, there is always room for improvement.  My tips are based on what I’ve seen in the past year and probably the five biggest tips that I’ve been dishing out to printers.  You can be a huge printing outfit or you could be running one tiny press, it all works the same.  Once you get the condition of your anilox right, the rest will follow.  You’ve got to use it or you’ll lose it. 

Since taking on the role of Sales Manager for the UK and Ireland here at Alphasonics, I have noticed certain things about the label industry.  Some of these things I had a slight awareness of before becoming so involved, and some elements have smacked me right between the eyes.  Some things I have found to be extremely positive and have actually made me feel encouraged and at times privileged to be part of this recovering and dare I say it, thriving offshoot of print that is powering into the future.  While this encouragement gives me great hope for where the industry is going and what it may mean for me personally, I cannot help but be aware of murky undercurrents that needlessly hang around the collective necks of the flexo printing community - in all formats.    

 I'll start with the positives.  After being present at the Ipex exhibition this year (my first real taste of a printing show), I couldn't help but buy into the buzz and excitement that envelops shows of this nature.  Obviously, Ipex is a different animal to Labelexpo and other shows relevant to flexo, but I was bitten by the bug.  I knew printing was something I wanted to be part of and I knew it was something I could succeed in. Since then, travelling to places such as Finland and South Korea, I have met some interesting and thoroughly enthusiastic people who are striving to move not only Labels, but Flexo and printing and packaging as a whole forward.  On this note, the product development I have seen in my short time has simply astounded me.  Being lucky enough to be representing Alphasonics at DScoop Asia earlier this year was an absolute privilege and getting a taste of the future though HP's trailblazing Indigo press and their unrivalled support to their channel and media partners filled me with a great sense of happiness in that I was now part of a progressive industry and while it is not necessarily great news for flexo press manufacturers, you cannot deny the potential for progress that these presses symbolise for even label printing.  Again, that is my opinion, do with it what you will.  

What has probably struck me the most however is the varied support networks that social media is now opening up.  In bringing Alphasonics into this new networking frontier is something I wanted to focus on in my marketing role.  This blog, our twitter feed and LinkedIn profiles are opening doors to meet people that share our thoughts, values and passion for what we do and why we do it.  This ‘Why?’ element is what is leading to this explosion of tweeters and bloggers that are becoming Gurus in their own right through their willingness and ability to share their thoughts and ideas using these online platforms.  People such as Danielle Jerschefske, Joann Hines and Mark Spaulding are the bench setting trailblazers through their dedication in sharing their vast expertise and in turn creating topics for discussion and debate within the online arena.  Even press manufacturers are getting in on the act and our friends at Nilpeter and Edale are embracing tweets as a great communications tool.  Even Label Experts from India are now flying the flag for their respective markets through this medium which in itself is a great development.

Basically, what I am trying to say is that there is not only a great sense of community within Flexo, but a great support network also.  Friendships and associations are being forged in new and exciting ways and as a young person who has been quite familiar with social networking for quite some time, I can honestly say that I am immensely impressed with how the flexo industry and printing at large has taken to this.

So let’s a get a bit more close to home now.  At Alphasonics, I must say that I could do a lot worse for my first role.  It's a great company with great staff, a great list of agents and clients and is a company that is well liked because of the strength of their product and brand.  The latter two in this list are the secret to its success.  Without a great product, any brand is useless.  I feel Alphasonics stands for quality and dedication to solving the problems of Flexo printers and has done for a long time.  I have enjoyed contributing to this strength and also enjoyed moving into the sales side of  the business and what that entails for me. 

However, in moving into sales, I have noticed things that have actually made me feel uncomfortable and in many ways, shocked me.  It is something I am coming up against more and more as I am meeting Label Printers both in the UK and elsewhere.  What I am referring to is the flat out dubious tactics employed by auxiliary equipment suppliers to the flexo industry, especially by cleaning equipment manufacturers. 

Now, I know what you are thinking dear reader: ‘But that’s the business you’re in.  Surely you know your business environment?  Shut up new guy and get on with it.’  Well, yes I was aware of what I would come up against when I took the role on and not for one second did I think I was in for an easy ride.  I was even warned for what might come but I was really not prepared to meet customers who have been told flat out lies about the product I am selling and as such have made assumptions about Alphasonics and even myself. 

The more experienced businessmen and women among you will now be thinking ‘What’s his problem?  That’s life.  Get used to it.’  I’d even say it was fair to say that.  What isn’t fair is that many of these other manufacturers and suppliers are simply basing their pitches on lies and deceit.  When Alphasonics, a company that has been around for twenty years and has gained the recommend status of many of the major press manufacturers as well as having customers that have a long and expansive list of print awards and accolades to their name are coming up against criticisms that are quite frankly untrue, we have to look at the problem in detail. 

The main culprits?  Smaller companies that produce low specification ultrasonic cleaning systems, masquerading as experts.  By basically deceiving customers into believing their product can do more than it is capable of they are not only selling sub standard equipment but they are also selling multiple hidden risks to flexo printers.  Throughout their periods of insolvency and debt juggling over the years their product has simply remained the same. so in order to compete with our advances and developments, they can only invent fallacies to give their equipment any standing. 

I will be blunt; what manufacturers such as this are making is low specification, low frequency ultrasonic equipment that is at the same level as the equipment that was hanging around in the 80s.  Much like Jon Bon Jovi’s perm this equipment was fine at the time but aged extremely quickly and should be regarded as a mere embarrassing novelty.  Like the shoulder pad and the Reebok Classic, these systems are an unfortunate a hangover of an era that saw equipment emerge and succeed but is now dwarfed by today’s technological advances.  To summarise, the presses have progressed, the substrates have progressed, the plate material and production of the plates have progressed amongst other things yet manufacturers of this cleaning equipment are selling machinery that should really be sent back in a Doc Emmett style Delorean ride to the 80’s to fill a purpose there.  So, what’s the deal? 

For those of you, who are wondering why Alphasonics’ equipment is different, please indulge me while I give you the facts.  Not the speel, the facts.  People started realising that ultrasonic equipment in its low frequency, Dynasty-esque format was simply not up the task of cleaning high screen aniloxes and in fact could cause damage over time and unfortunately we were caught up in this.  It lead David (Jones) to develop dual frequency technology which essentially works in two ways.  Firstly, there is a low frequency setting which is a more aggressive clean that is great for low screen counts and will do the business on heavily contaminated aniloxes.  However, what Alphasonics also has is a high frequency setting which is designed for high screen counts due to its gentle action.  This is the feather duster to the low frequency yard brush and, if I can continue this metaphorical train of thought, is suitable to clean the high screen ‘Finest China’ anilox roll.  Would you clean your finest china with a yard brush?  Go figure. 

This was designed to solve the problems of the flexo printer.  We all know the anilox is the cornerstone of a flexo press and as such must be cared for and preserved.  Dual frequency ‘Alphasound’ eradicates the risk of roll damage through conventional ultrasound and can effectively clean the highest screen aniloxes anywhere, anytime.  To achieve technological advances like this, the highest quality components and highest level of electrical and electronic engineering are required and we have always seen this not as a necessary, but an essential requirement. 

Take this and compare it with a company working out of a room no bigger than your living room and who are simply sub contracting the work to whoever will take it with simply the money in mind rather than the implications for the printer when it comes to the crunch.  I have seen what these systems do to high screens over time and hopefully, you have now too through the roll damage example below.  Surely you can understand my and Alphasonics’ frustration when printers are told there is no difference between the two systems.  It is simply lies and as far as I am concerned is foul play to suggest that these low spec systems can hold a candle to Alphasound. 

What is true is that printers run the risk of roll damage when exposing their aniloxes to this technology frequently.  Even single frequency systems made by Alphasonics is set to a higher frequency meaning even then it is much more gentle on an anilox in comparison. 

As an employee of a responsible manufacturer of ultrasonic roll cleaning equipment, I simply cannot stand by and allow printers to make the mistake of trusting these cowboys.  Their technology simply does not compare.  There is it is in black and white dear readers. 

As I remove myself from the saddle of my high horse, I take great pleasure in reflecting on a great year for Flexo printers whether in labels, packaging or whatever application.  The future is looking bright.  We are ourselves embarking on our fourth R & D project in as many years and we are looking to what the next year brings with optimism and vigour.  I personally would like to see the continued use of social media to cement the flexo printing community online and also to see another year of bumper trade shows as we move into a new and exciting era for printing. 

This hope for the future however does come with a warning in the form of a well known saying: buy cheap...  buy twice.  As we move into a new phase of higher screen counts, better pre and post press production and generally better quality of flexo printing process I would encourage printers and experts alike to look to advanced technologies to compliment this.  If you aren’t careful it could set you back 30 years rather than propel you forward. 

I wish to thank you for taking the time to read the green ramblings of a flexo newbie and wish you all the best for the Christmas period and for the New Year.

Christopher Jones

Marketing Manager/UK and Ireland Sales