New water-based CtP prepress room – new quality of paper elegance of Duni

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Duni is the world’s leading supplier in the field of tableware products. The history of the company began in 1949 with the production of a cup of wax paper and paper napkins. Today, Duni employs around 2,400 people and has its headquartered in Malmö, Sweden. The company is listed on the NASDA Stockholm stock exchange.

Duni owns a paper mill in Skapaforsch, Sweden and two factories: in Bramsche, Germany and in Poznań. The company started its activity in Poland in 1993 by installing 6 machines and employing 20 people. 1998 was a breakthrough year. The company moved to its new headquarters, increasing the number of employees to 100, and the number of machines to 17.

In 2005, a new production hall was added for more machines. Today, Duni Poland owns 36 machines producing napkins, plates and displays, and employs over 450 people. The company’s key values are innovation, quality, safety and high environmental standards.

In order to increase production efficiency and minimize the negative impact of photopolymer plates production on the environment, Duni Poland decided to switch to CtP technologies. The process of searching for new technological solutions tailored to the needs of the organization has begun.

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Paweł Leszczyk, Efficiency Manager at Duni.

Paweł Leszczyk, Efficiency Manager at Duni Poland, mentions the necessity of changes in the technology of plates preparation- “Our previous CtF exposure and development machines were already old. This caused increasing problems with the purchase of spare parts and service of these machines.

We have also implemented our ink-jet solution, which turned out to be more expensive than we expected. We often used the services of an external prepress company, but in situations of time pressure or a need for quick changes in files, this model also failed. Growing environmental standards, the need to reduce chemicals, to apply energy savings in the production process, and the need for more flexibility in action have finally wiped out the analogue era in our prepress room.”

In response to precisely defined needs and expectations of Duni, Print Systems company prepared a proposal to equip their prepress room with modern CtP machines for processing photopolymer plates. The final offer included: exposing unit with drying sections EXPOSURE 80, washout machine Quicker SILVER 80 and CtP Laser Amsky Aura 800S with RIP software. This optimal set fully met Duni’s investment needs.

“The decision to establish cooperation with Print Systems was made on the basis of a thorough analysis of solutions available on the market. The final choice of a supplier was determined by the existing cooperation with the company, based on professional technical support, fast service of devices on site and modification of the RIP software to meet our requirements and working methods. The price of the solution and the conditions for implementing the technology were also very important. The technical support and advice we received at the planning stage, as well as during the reconstruction of our prepress room, turned out to be very valuable.” – says Paweł Leszczyk.

Water-based CtP prepress room

Device for exposure, drying and post-exposure of plates Exposure 80 is a state-of-the-art processor for preparing photopolymer plates in a maximum format of 660×810 mm. It is equipped with a 7″ touch panel for programming and process control, and a cooled backexposure and main exposure table for process stability when working with CtP plates.

Quicker Silver 80 is a modern and safe washout machine for flexographic plates washed with water in a working format of 660 x 880mm.

Laser CtP Amsky AURA 800S uses dynamic autofocus and drum load balancer, the so-called auto balance, to ensure the highest quality, stability and constant speed of photopolymer plates processing. The vacuum system of the external drum keeps the photopolymer plate on its surface, without the need to apply a mounting tape to the area outside the plate.

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A set of new devices at Duni’s prepress room.

The common feature of the devices is easy operation and fast installation process. Print Systems has carried out individual training of prepress staff and provided continuous technical support of experienced Sales and Technical Advisors. All devices are covered by warranty and post-warranty service carried out by Print Systems on the customer’s site.

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Complete staff of Duni Poland’s Prepress Department.

The results of the work of the new CtP water-based prepress room in Duni can already be summarized. Hard production data indicate a reduction in the preparation time of the printing form by approx. 40%. Each plate is made without errors at first attempt, which significantly reduces the amount of waste.

The investment positively contributed to a change of work organization in the prepress room from two-shift to one-shift work. This generates large savings on labor costs. Operators appreciate the greater comfort of plates processing. Now it is easier for them to control the entire process, which requires less manual intervention.

According to Duni, purchase of equipment and technology is a good investment compliant with the company’s mission and a big step towards increasing the efficiency and competitiveness of production.



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