Our Customers' Stories
New CtP water pre-press room - new quality of Duni paper elegance
Duni is the world's leading supplier of products in the "everything to set the table" industry. The company's history began in 1949 with the production of a waxed paper cup and paper napkins. Today, Duni has about 2,400 employees, and the group's headquarters are in Malmö, Sweden. The company is listed on the NASDA Stockholm Stock Exchange.
Key values: innovation, quality, safety and high environmental boothards.
Duni has its own paper mill in Skapaforsch, Sweden, and two of its own factories: in Bramsche (Germany) and in Poznan. The company began its operations in Poland in 1993, installing 6 machines and employing 20 people at the time. 1998 was a breakthrough year. The company moved to new premises, increasing the number of employees to 100 and the machine park to 17. In 2005, a new production hall was added for more machines. Today Duni Poland has 36 machines producing napkins, plates and displays, and employs more than 450 people.
In order to ensure increased production efficiency and minimize the negative environmental impact of photopolymer printing plate production, Duni Poland decided to switch to CtP technologies. The process of searching for new technological solutions tailored to the organization's needs has begun.
Our existing CtF equipment for exposure and development was old. This was causing increasing problems in purchasing spare parts and servicing these devices.
We also implemented our ink-jet solution, which proved more expensive than we anticipated. We often used an external pre-press service, but in situations of time pressure or the need for quick file changes, this model also failed. Rising environmental boothards, the need to reduce chemicals, energy savings in the production process, and the need for greater flexibility in operations ultimately doomed the analog era in our pre-press.
Paweł Leszczyk
Efficiency Manager at Duni Poland
Equipment proposal
In response to Duni's precisely defined needs and expectations, Print Systems prepared a proposal to equip their pre-press with platern CtP equipment for processing photopolymer printing plates. The final offer included the following equipment: an exposure machine with drying sections-EXPOSURE 80, a Quicker SILVER 80 washer, and an Amsky Aura 800S laser with RIP software. This optimal set fully met Duni's investment needs.
We made the decision to cooperate with Print Systems based on a thorough analysis of solutions available on the market. The final choice of supplier was determined by our previous cooperation with the company, based on professional technical support, provision of fast on-site equipment service and modification of the RIP for our requirements and working methods. The price of the solution and the conditions for implementing the technology were also of great importance. The technical support and advice we received both at the planning stage and during the reconstruction of our pre-press proved to be very valuable.
Paweł Leszczyk
Efficiency Manager at Duni Poland
Specification and concrete data
The Exposure 80 plate exposure, drying, and illumination unit is a latest generation processor for preparing photopolymer plates with a maximum format of 660×810 mm, which allows for exposure, drying, and illumination of printing plates. It is equipped with a 7 "inch touch panel for programming and process control, and a cooled backlighting and main exposure table to ensure process stability when processing CtP plates.
The Quicker Silver 80 is a platern and safe water-washed flexo plate washer with a working format of 660 x 880mm.
The Amsky AURA 800S CtP laser uses dynamic autofocus and a drum load equivalent known as autobalance to ensure the highest quality, stability and consistent processing speed for photopolymer plates. The vacuum system of the outer drum keeps the photopolymer plate on its surface, without the need to apply clamping tape to the area outside the plate.
Common features of the equipment are easy operation and quick installation process. Print Systems has conducted individual training of pre-press personnel and provided ongoing technical support carried out by experienced advisors. All devices are covered by warranty and post-warranty service performed by Print Systems at the customer's site.
Investment summary
The results of Duni's new water-based CtP pre-press can already be summarized. Hard production data shows a reduction in pre-press time by about 40%. Every plate comes out error-free the first time, which definitely reduces waste.
The investment has had a positive effect on changing the organization of work in the pre-press room from two-shift to single-shift operation. This generates large labor cost savings. Operators appreciate the higher comfort of die processing. It is now easier for them to control the entire process, which requires less manual activities.
According to Duni, the purchase of equipment and technology is a good investment in line with the company's mission and a big step for increasing the efficiency and competitiveness of production.
