By Contributing Editor Melissa Larson
OH label printer with global customers adds a Mark Andy Performance Series press to greatly expand its quality, productivity and technology.
When you're running a successful 24/7 tag and decal printing operation, buying a new flexo press to run clear films may seem counterintuitive. But for president Gregg Trebnick of Trebnick Systems, it's all part of his five-year plan.
"We always have a five-year plan in mind," says the upbeat and forward-thinking entrepreneur. "Our durables and tags business is doing so well, yet we're always asking ourselves on each new order, 'Is there a different material that can do a better job?'" Eyeing unsupported-film applications, and perhaps even flexible packaging, Trebnick decided to purchase a Performance Series P7 narrow-web flexographic-printing press supplied by Mark Andy. It was installed in December 2009.
Privately held and family-run, the Springboro, OH-based printer has been in the label business for 15 years and employs 20 people, including part-timers. Its operation includes an in-house art department capable of revising original advertising-agency artwork, although 100 percent of platemaking is outsourced.
"Due to increased business, we've hired four new employees in the last
five months," Trebnick says.
Two older 6-color, 10-in. and 13-in. Nilpeter narrow-web flexo presses handle the thriving business in tags, decals and primary product labels, many of which incorporate Valeron[R], DuPont Tyvek[R] and Kimdura[R] high-performance films. Labels and tags that stand up to harsh environments and hazardous materials are touted as a Trebnick specialty. Through a worldwide network of distributors, the converter supplies its products to a variety of end-use markets, including chemical/industrial, pharmaceutical, consumer food and retail.
Providing the right adhesive for the job is another strength. Trebnick offers permanent, removable or repositionable adhesive labels for many substrates including high-temperature, wood, drum, plastic, steel and even glass surfaces. Custom top coatings for thermal-transfer, laser, dot-matrix, inkjet and direct-thermal printing are also available.
Trebnick's demonstrated ability to turn out drum labels, decals, warning labels and other outdoor products requiring durable materials has brought the company increasing overseas business. In fact, according to Gregg Trebnick, the majority of his business in 2009 was derived from customers in such far-flung locations as Saudi Arabia, Dubai, South America, China, India, Japan and Europe.
Taking his time
Unlike most successful converters who have specific jobs in mind for a new press and want it up and running as soon as possible, Trebnick is in no particular hurry to start cranking out large print jobs on the P7. Rather, he is carefully analyzing which print jobs and customer prospects are best suited for the capabilities of the new press. Also, he's determining which ancillary equipment (sheeters, rewinders, etc.) will best help the P7 reach its full potential.
That said, Trebnick has already seen some success with the P7. Orders are in process which will result in up to $400,000 in incremental business for the converter.
Launched at Labelexpo Europe last fall, the Mark Andy Performance Series P7 press has been sold to 12 customers worldwide so far. Trebnick Systems' model, an 8-color, 17-in. version with a final UV-curing station, is only the second P7 purchased by an American company. Maximum print speed is 750 fpm. Important features include:
A print-station design that allows the operator to set up a single station in less than a minute.
An inking system that combines several steps into one quick motion.
Automatic pre-registration and re-registration.
Servo-driven infeed pacing; independently servo-driven plate cylinder and impression roll; and servo-driven die station with 360-deg registration management.
VariPrint feature for extensible substrates, which reportedly ensures perfect registration on virtually any stretchable substrate.
Instant remote diagnostics with an Internet connection.
Printing of anti-counterfeiting work is one of the P7's most important capabilities. "It has a registration tolerance of +/-0.002 in., so that it will do both overt and covert anti-counterfeiting systems, as well as cold or hot foil," Trebnick says.
While the P7 is said to be ideal for short runs with its rapid changeover capabilities and automatic pre- and re-registration, Trebnick also sees the press's high-speed benefits for longer runs. "We're finding out that there is no order too big with the speed of this press," he continues. "Super long-run orders are a capability of the P7 that older press technologies cannot compete with on our specialty substrates, film, paper labels and synthetics."
Global savvy
Gregg Trebnick has learned the tricks of the trade that are necessary to supply international customers from his headquarters in Ohio. For instance, he sends print samples for customer approval before the job is run, opened a line of credit to even out cash flow, and has the customer pay for shipping.
"We have a different way of doing things," Trebnick says, "and we've even walked away from business.
"All press operators are unmanaged; they are their own supervisor. The only requirement is to have a sign-off. Bill Parsons, a senior operator with 26 years of experience, places requisitions for the press operators."
A professed "self-taught" converter, he sees running uncoated and unsupported films, at high speeds, as the next technical hurdle to be overcome. "We bought the [Mark Andy] press for three main reasons. For higher quality, for more productive press operators, and to advance our level of technology. Flexo is going to be a big part of our future.
"We've never been a 'me-too' operation, and with the new press, we're even less interested in commodity products," Trebnick says. "Our motto is 'one job at a time.' We've doubled our warehouse space, and thanks in part to the new press, we're ready for whatever comes along."
Specifics:
Melissa Larson
TREBNICK SYSTEMS : Springboro, OH
OPERATIONS : Pressure-sensitive label printing and finishing
PLANT SIZE : 18,500 sq ft
EMPLOYEES : 20
MAJOR EQUIPMENT : 8-color, 17-in. Mark Andy Performance Series P7 narrow-web flexo press; 6-color 10- and 13-in. Nilpeter narrow-web flexo presses; one Rotoflex DLI 330 offline diecutting machine, one Kor inspection rewinder; one 16-in. CTC turret; two B. Bunch fan-folders; 24-in. one Markwith fan-folder; two J.M. Heaford platemounter/proofers; one Teco tabletop inspection rewinder.
MORE INFO:
CONVERTER:
TREBNICK SYSTEMS , 866/229-0601, www.trebnick.com
SUPPLIERS:
MARK ANDY, INC. , 636/532-4433, www.markandy.com
NILPETER , 513/489-4400, www.nilpeter.com
VALERON STRENGTH FILMS , 800/825-3766, www.valeron.com
DUPONT TYVEK , 800/448-9835, www2.dupont.com/Tyvek/en_US/index.html
NEENAH PAPER (KIMDURA) , 678/566-6500, www.kimdura.com
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