Independent Can Racks Up Productivity and Quality Control with Esko’s Automation Engine 10 | Package Design

Independent Can Racks Up Productivity and Quality Control with Esko’s Automation Engine 10 | Package Design

Posted: July 26, 2012 by

Package Design Reader

World leader in the manufacture of specialty tins uses Esko’s advanced workflow server to streamline workflows, increase throughput and efficiency, and tackle complex design and prepress files — while controlling quality

Maryland-based Independent Can (http://www.independentcan.com)  has migrated from the Nexus platform workflow to Esko’s advanced server workflow, Automation Engine 10, streamlining its operation, reducing errors, and automating prepress tasks for dramatic increases in productivity.

Founded in 1929, Independent Can is a world leader in the manufacturing of specialty decorative tins and metal lithography. Its product line has grown from the wholesaling of large cans for fresh and refrigerated foods to an extensive array of items serving a wide variety of markets, including custom-printed cookie, candy and popcorn tins. To uphold its company mission, “To be the best, not the biggest,” the company follows an unhurried and well-thought out plan of continuous investment and innovation.

Independent Can’s prepress department processes approximately 960 files annually, for printing on the shop’s KBA Metal Star six-color press with Trail UV Coater, the only one of its kind in the United States, or its Metal Star II four-color UV press. With two high-speed presses continually ready for action, time to market shrinking, and design files becoming increasingly complex, the need for a more robust yet simplified prepress workflow became apparent.

Automation Engine 10, the backbone of Esko’s Suite 10 packaging and print pre-production software, answered the call. The prepress server, installed at Independent Can in March 2011, provides high-level quality control and increased throughput and efficiency, simplifying the entire file management process and delivering extensive automation for job tracking and prepress functions.  Pre-setting of repetitive tasks, such as trapping and step-and-repeat, result in reduced operator manual control and reduced errors.

Simplifying workflows

“Previously, we were using around 10-12 different workflows—we had workflows for proofing, plating, an initial importing workflow and ArtPro workflows,” says Tim Downey, Prepress Manager, Independent Can. “Now, we have one workflow that we use to output a proof and for dielines; it also generates a low-res PDF for archiving. The workflow is user interactive, asking ‘yes’ or ‘no’ questions. ‘Should I output proof? A dieline?’ The user just answers the questions and the workflow does the rest—it’s all automated.”

A main challenge (with Nexus) was that certain tasks required prepress operators to go back and forth between native Adobe Illustrator, Photoshop files and ArtPro, increasing the amount of time to complete a job as well as the possibility of mistakes being made. With designers building more intricate files with assorted complex elements, not being able to work in the native file became an issue—like when building the transparency of the image to take advantage of the substrate’s (metal) reflectivity.

“When files were taken from Adobe® Illustrator® and Photoshop® and brought into Nexus, the system would choke and wouldn’t recognize some of the filters that were being applied,” explains Downey.  “With Automation Engine 10, we can stay in native Adobe applications.”

Remaining in the Adobe family also saves time when sending files to customers. “There are lots of times customers want a working Illustrator file sent back,” notes Downey. “Before, we would convert the Illustrator file to an ArtPro PDF file, and then export an Illustrator file out of ArtPro. Doing that in ArtPro, we would lose preference settings of the file; there wasn’t a smooth transition for getting the working file to the customer. Now we just send the PDF and a normalized file, and we don’t have to go in and out of Illustrator.”

Managing files streamlined

The entire process of managing files is now very streamlined, as job organization and data management tools allow for fast location of product status and data throughout the prepress workflow. “We are able to keep everything pertaining to the job right there,” says Downey. “We no longer put paper in job jackets—we’re all digital now. All the information relating to the job is in the folder, and anyone in the department can find out what they need to know.”

The process of normalizing PDFs is also much more efficient. When the file was rasterizing through Nexus, depending on the file complexity or size, it could take upwards of an hour to travel through the workflow. With the file now staying in Illustrator or as a PDF, it takes between 30 seconds to a minute to normalize.  “It’s not quite instantaneous, but it’s about as close as you can get to it,” says Downey.

Trapping, too, has become simplified running Automation Engine 10. “We did upgrade the server that was running Nexus before we bought Automation Engine 10, but it didn't fix a lot of the problems,” notes Downey. “We deal with a lot of agencies and they get as creative as possible and the files are pretty complex. The trapper would have problems; it wouldn’t know what to do with some areas. So we would have to delete what the program did and manually do it. Now, it’s all automatic, and instead of it taking us 20 minutes to trap a file, it’s done in 2-3 minutes. Occasionally we edit that traps, but 85% of the time it traps just fine.”

Mistake-free production

Automation Engine 10’s extensive quality control tools allow the prepress department to run “an environment that is more mistake-free,” says Downey. The Viewer module lets the prepress operators find errors early in the workflow—95% of mistakes are caught ahead of time. “We can compare the customer-supplied file to the one we are working with, making sure all the corrections are applied,” Downey explains.

Automation Engine 10’s automated imposition or step-and-repeat reduces the need to prepare impositions manually. “We used to manually step-and-repeat in ArtPro,” recalls Downey. “Now we take the engineering drawing, type in the stepping data, get a ticket and it is automatically stepped. When setting up a job it takes about a minute to enter the data; if it’s a difficult job it takes another four minutes — if it’s a one-color job maybe it takes 30 seconds. All told, a job usually takes under 5 minutes; it used to take us 20 minutes. Also, we are making fewer mistakes, because we are catching them earlier during set-up, before we step-and-repeat.”

Since the Automation Engine 10 implementation, everything is faster, says Downey. “We are trapping faster, stepping faster,” he says. “We have no paper trail—instead of spending time looking for paper we are double-clicking on a folder to find info. It all adds up.”

Job turnaround times have been reduced by a full day, from five days to four, and even the most complex projects are running smoother. “A couple of times a year we receive a job from a high-profile customer,” notes Downey. “The job always choked on Nexus—it would take days to get fixes to run through. We just completed 5 jobs for them, and were able to stay in Illustrator to build the files. There were no issues—it all went very smoothly.”

Looking ahead, Downey hopes to be able to take advantage of Automation Engine 10’s advanced JDF-based MIS integration capabilities, tying in the company’s administrative systems and prepress production for an even more efficient process. Independent Can is not at that stage—yet. “We know Automation Engine 10 is MIS capable, but our company’s MIS software is not,” says Downey. But, we're ready whenever the company makes that move. Automation Engine 10 has simplified our workflow, and offered us another QC element to rely on. We’re able to manages jobs and files a lot more efficiently.”

About Esko (www.esko.com/)

Esko is a global supplier of integrated solutions for packaging, sign and display finishing, commercial printing and professional publishing. Esko products and services help customers raise productivity, reduce time-to-market, lower costs and expand business and improve profitability.

Portfolio

Esko is the worldwide market leader with software for artwork creation, structural design, pre-production, workflow automation, quality assurance and online collaboration. Esko solutions support and manage the packaging and print processes at brand owners, retailers, designers and packaging manufacturers.

CDI flexo computer-to-plate imagers and Kongsberg digital finishing systems complete the portfolio for the packaging, label, signage and display industries.

Enfocus, with its suite of PDF tools for graphic designers and print production professionals, is part of Esko.

Facts & numbers

Esko employs around 1200 people worldwide. Its direct sales and service organization covers Europe, the Americas and the Asia Pacific region, completed by a network of distribution partners in more than 50 countries.

Esko is headquartered in Gent, Belgium, and has R&D and manufacturing facilities in five European countries, the United States, China and India. 

Editor’s Note: This post was shared by a member of the Package Design community. Do you have news to share with our readers? Click here to learn how you can become a contributing member of the Package Design online community.

ORIGINAL ARTICLE - http://www.packagedesignmag.com/news-from-our-readers/independent-can-racks-up-productivity-and-quality-control-with-esko-s

Company Name: 

Esko

Company Website: 

http://www.esko.com

TIN STAGES A COMEBACK

Below you will find excerpts from Tin Stages a comeback. An article by written by James  Krouse

"Metal packaging, at one time, dominated store shelves. From cans to metal tins, the packaging was durable, protected goods from being crushed, and sealed in freshness. While cans have remained a staple of practical packaging, metal tins were relegated largely to occasional holiday container for cookies. Today, however, metal tins have seen a bounce back due to some of the inherent advantages of the material as well as unique applications leveraging its advantages to redefine entire product arenas.

Package designers and brand owners can take advantage of tinplate's unique packaging properties taking a cue from innovative applications that range from cat nip to software to adult entertainment products. Manufacturers can help along the way to help designers realize the full benefits of this time-tested form of packaging.

Unique appeal

In most retail product categories, tinplate is such a unique packaging material that it automatically gains attention. Often, this can rejuvenate not only a brand but an entire product category. The famous tin for Altoids mints is a good example. Although the tin package was used for the product since the 1920s, it was widely introduced in the U.S. in the 1980s and the unique metal tin along with a quirky ad campaign quickly launched the product into widespread success. Today, dozens of product categories are taking advantage of the "something different" factor in metal.

Cosmetics and personal care products are another good example of a product category that is taking advantage of the unique properties of metal. 

"Gourmet foods are still, by far, our largest product category," says Neil DeFrancisco, v.p. of sales at the Independent Can Company (www.independentcan.com) in Maryland. "Retailers in any sector are looking to get the most bang for their buck out of shrinking shelf space and demands for less packaging from retailers. Tin packaging can provide that quite well." 

 There are a number of applications that take full advantage of metal's unique look on store shelves. Bosch, for example, has launched a new line of handheld, cordless power shears in a custom metal tin. The container features an irregular, tube-like shape decorated in light green and silver.

Life after purchase

While many designers may be focused on leveraging metal's properties for initial sale, most manufactures point out that consumers often consider the use of a package in their home. A Google image search under "Altoids Tins," for example, reveals a huge trend in reuse for the package for everything from storing paper clips to creating custom MP3 players and portable speakers.

The reusability factor is a plus for brands looking to extend their image, promote the longevity of a product, and to give consumers an option of not throwing away a package.

Package uses and reuses also play into concern for the environment. As retailers and consumers call for less packaging, metal packaging is answering the call. The material is 100% recyclable, over and over, and recycled metal uses less energy to process than new metal does. Design flexibility can also impact the environment, as Independent Can's DeFrancisco points out. "We're seeing more and more requests for tapered designs of metal buckets which can be nested during transportation before they are filled, " says DeFrancisco. "A small change like this can reduce fuel and other transportation costs."

Challenges and benefits

For many designers, working with metal for the first time can present some challenges in execution and changes in thinking. Color, for example, plays differently on metal as opposed to paper.

"The PMS guidelines are based on paper and come out much darker on metal," says DeFrancisco. "We can do several things to accommodate for this effect, but there is a learning curve for designers. In addition, designers often don't know about all that is available to them with metal. We can selectively print a background color so the natural color of metal shows through or use a variety of varnishes in combination to highlight a design. "

In addition, tinplate can be manufactured with different properties to enhance a design such a pebbly textured varnish that is often used in combination with a printed label. There are so many possibilities with tins that most manufacturers point out that working with the material is more of an art than a science.

"We can do so much in the way of varnish combinations and coatings on the same package, " says Neil DeFrancisco. "That, in combination with embossing and printing, can really make a brand pop. We employ people who work with designers to help them achieve their vision but also leverage everything that tinplate packaging has to offer. For many designers, it's like working with a brand new medium even though it's been around for hundreds of years."

Getting back to basics

Tinplate packaging has been, for years, a staple of holiday cookies and candies, and although this form of packaging has clearly evolved to other applications, some of its basic benefits still apply.

Neil DeFrancisco points out that, although there are some new technologies they still build on the basic benefits of metal packaging. "We've seen the advent of six color printing and we're seeing concentric dot technology that can produce nearly 300 dpi print clarity, but many of the basic features of the metal like shaping, embossing, and varnishes are really new for designers in many markets, " Neil DeFrancisco explains."

Excerpts quoted from the original article written by James Krouse. James Krouse served as a consultant and writer for the packaging and printing industry for the past 10 years, covering package design for food and beverage, pharmaceuticals, and a wide range of retail goods

LIZ CLAIBORNE TRUSTS INDEPENDENT CAN TO PRODUCE PASTEL HUES THAT EXTEND THEIR CURVE PERFUME LINE

The Curve brands of men's and women's fragrances are tied irrevocably to the rectangular tin cans that enclose every product in the line. When Liz Claiborne wanted to introduce a limited run line extension called "Curve Wave" for the summer season, they relied on their partners at Independent Can Company in Belcamp, MD.

The first Curve package was introduced in 1996, with a green tinted can for the men's fragrance and a blue tinted can for the women's. The recent introduction of the Curve Crush line was designed to appeal to a younger audience than the cosmetic company's flagship Curve brand, and Independent Can supplied the hot pink and gray metal tins to house the Crush fragrances.

Paul McLaughlin, creative director at Liz Claiborne, explains the appeal of the tins as differentiating in more ways than just presenting a category-defying material. The bright fluorescent lighting in most department stores helps illuminate the shiny colors on the smooth metal, which also reflects "shadows" of nearby darker objects. McLaughlin believes that the tin has an inherently stronger appeal to a younger audience.

Independent Can was able to determine color schemes and develop new tooling in a very short period of time in order to meet Liz Claiborne's launch date of the Crush project. "Independent Can was selected as the vendor for this project based on their reputation for print quality and reliability," says Michelle Barreres, director of packaging at Liz Claiborne. "We both maintained a continuous line of communication every step of the way on this critical project. The results have been exactly what we expected."

The four-color offset printing process uses UV inks and a UV curing system. "Colors had to be created, then matched across all media," explains Neil DeFrancisco, senior sales representative at Independent Can. The can is only one part of a complete retail strategy that includes the perfume the can, the bottle itself, the nozzle tab, the protective insert, advertising, collateral, and gift boxes. Independent Can's technical team in lithography developed a several-stage process that involved hand-mixing the inks as well as curing and varnishing stages.

Liz Claiborne's expectations were also high for the Curve Wave seasonal line extension. In both projects, they confirmed color approval on press, trusting that Independent Can's production would match the quality of the samples they ran. The Curve Wave cans were run on a machine that is the first of its kind in metal lithography in the U.S. The Bauer & Kunzie Metal Star II printing press with "continuous grip" was able to achieve the tight registration on this six-color printing job.

The colors for the Curve Wave packages were inspired by the ingredients of each fragrance. The women's orange glow comes from the citrus emphasis and the men's green shimmer comes from the aquatic hints in the fragrance. DeFrancisco was well aware of the weight of brand expectation that came with the responsibility of extending the signature Curve brand to both the Crush and Wave lines. "The brand almost seems identified with the tin," DeFrancisco explains, ultimately very pleased with the results. "I think the men's colors are spectacular."

Independent Can Company
Ryan D. Huether
Vice President of Business Development
Originally Published by: http://www.packagedesignmag.com/content/liz-claiborne-trusts-independent-can-produce-pastel-hues-that-extend-their-curve-perfume-lin

Independent Can Company Captures Print Excellence Awards

Independent Can Company Captures Print Excellence Awards

July 26, 2012

Independent Can Company was again recognized for excellence in print quality by the International Metal Decorator’s Association (IMDA). The award was presented to Independent Can Company at their annual conference held this May. Each year the IMDA conducts a quality contest with entries from around the world, to recognize the skillful achievements of metal lithographers. Independent Can Company, for many consecutive years, has won the prestigious “Award of Excellence” and “Best of Category” in Specialty Packaging, as well as Signs and Displays.

The “Award of Excellence” for Specialty Packaging was presented to Independent Can Company for the Nestle Turtles® Limited Edition Holiday Tin. The Turtles® tin also earned a “Special Judges Award” from the Printing & Graphics Association Mid Atlantic (PGAMA) in March of this year. Independent Can was also presented the IMDA “Best of Category” for Signs and Displays with its printing of the “Fender Guitar” metal sign produced for Desperate Enterprises.

Over the past decade Independent Can has invested heavily in the latest printing equipment specifically designed for high definition printing on metal. The company has hired technical experts to direct this highly specialized print operation. “We are constantly looking for process improvements in order to meet the expectations of our customers,” said President and CEO, Rick Huether.

XXX
For more information contact Ryan D. Huether, Vice President of Business Development, Independent Can Company, 1300 Brass Mill Road, P.O. Box 370, Belcamp, MD 21017-0370, Phone: 410-272-0090, Fax: 410-273-7500, e-mail: Ryan@independentcan.com, web: www.independentcan.com.

Coffee Talk Magazine - Letters to the Editor on "Kicking the Can"

Letters to the Editor

On “Kicking the Can”

Good after­noon.
We are a sub­scriber to Coffee Talk Magazine and we have noticed the “kick­ing” around of steel cans in favor of poly­bags. I’m writ­ing, not because we are a can man­u­fac­turer in the United States who pro­vides tin­plated steel pack­ag­ing to the cof­fee indus­try, but because you may be mis­lead­ing a very envi­ron­men­tally con­scious group of con­sumers to believe that bags are their best pack­ag­ing choice. Showing smashed and soiled cans on your cover was a slap at our indus­try and our material.

Steel is the most recy­cled prod­uct in the US and has an infi­nite life cycle. Steel can be made into another item after recy­cling with­out loss of qual­ity and uses less energy than mak­ing new. Separation from other waste mate­ri­als by mag­net makes the recy­cling process highly effi­cient and lower in cost. There is no bet­ter pack­age for shelf appeal and for preser­va­tion of freshness.

The foils, plas­tic valves, and lin­ers of cof­fee bags make them less recy­clable or not recy­clable. The paper/poly blend excludes cof­fee bags from being con­sid­ered part of paper recy­cling. Cans can be reused. Bags are not. A num­ber of plas­tic con­tain­ers can­not be recy­cled into sec­ondary prod­ucts. Even among those that can be (#1 and #2), once the sec­ondary prod­ucts are used the plas­tic can­not recy­cled again. A good resource for sup­port of the steel can facts that I have stated is this web­site http://steelrecyclingfacts.com/. As a cof­fee mag­a­zine, I’m not sure what is gained by show­ing a bias toward a par­tic­u­lar pack­ag­ing choice. It is not the same as the full page ads claim­ing that steel can is not a good con­tem­po­rary choice. All is fair in marketing.

Donna Sichette
Marketing Specialist
Independent Can Company
1300 Brass Mill Road
Belcamp, MD 21017

POSTED BY:
Ryan D. Huether
Vice President of Business Development
Independent Can Company
http://www.westernspecialty.com
6/4/12


Link to original post: http://www.coffeetalk.com/june12-letters-to-the-editor/?utm_source=rss&utm_medium=rss&utm_campaign=june12-letters-to-the-editor

Advertisments: Lavazza Blue Ground Espresso Coffee

Spring 2012 Whats New

The first quarter of 2012 is now behind us. 2012 has been a unique year so far in many ways.

We almost did not have a winter here in the east and spring actually arrived in February: very strange.
The first quarter was very busy with customers releasing cans at a very aggressive pace. The level of activity and the broad number of industries represented (industrial, chemical, beverage, snacks, food, confections, etc.) shows a true recovery across the board. Thank you to everyone.
Independent Can Company is in an industry that many people consider "traditional, smoke stack, not innovative, old". These beliefs are so wrong. The innovations in the can business are dramatic:

Beverage		Aluminum bottle cans, lighter gauge, fully 100% recyclable and more
Food Sanitary Cans		Shaped cans, lighter gauge, fully 100% recyclable and more
Specialty		Faster concept to delivery of new shapes, sizes and designs than ever before, 100% recyclable, lighter gauge (lower cost)

 

The can manufacturing business is global. Steel mills are located in all developed and developing countries in the world. Can manufacturers are located in these same countries. This is why we participate in organizations and meetings globally. In the past year we have attended meetings in the following countries: Italy (2 trips), England, Germany, Switzerland, Turkey (several trips), China, Dubai and Israel. In the next 3 months we have meetings scheduled in China, Holland and Germany. In addition to attending meetings and conferences we have bought equipment from 6 countries.
Steel: 90% or more of the steel we use is produced in the United States. Unfortunately the global investment in the production of tinplate is being made in the developing countries (China and India). In the future we may have to import more tinplate to meet our needs.
The most exciting development in the past 2 years has been the shift in where tins are being made. In the past 2 years we have begun making tins in our plants in the United States that were previously made in China. We are currently installing and will have a line operational in May that will be directed specifically to replace tins that are currently 100% imported (more to follow).
I hope that you can feel the excitement that we have for the business and the future of the can business here in the United States.

Sincerely,
Rick Huether
President and CEO

 _______________________________________________________________________________________________________

 

Visit our Booth at the Sweets and Snacks Show

 

We have new summer and every day designs for your consideration.  It is not too early to plan for seasonal tins.  We are exhibiting at the Sweets and Snacks Show in Chicago, Booth 781, and will have many of our stock tins on hand. Tins are the perfect eye-catching packaging for confections and snacks.    

 

 

POSTED BY:

Ryan D. Huether

Vice President of Business Development 

Independent Can Company

ryan@independentcan.com

http://www.westernspecialty.com

ZIPPO EARNS PRESIDENT’S “E STAR” AWARD

ZIPPO EARNS PRESIDENT’S “E STAR” AWARD

Pennsylvania Company Earns Presidential Distinction for Export Excellence

WASHINGTON, D.C. – May 17, 2012 – Today, Zippo^®, maker of the world famous windproof lighter with the lifetime guarantee, was presented with the President’s prestigious “E Star” Award by U.S. Commerce Secretary John Bryson. Zippo owner and chairman of the board, George Duke, received the award on behalf of the company at a ceremony which took place at the White House in Washington, D.C. First established in 1961, the President’s “E” Awards are the highest recognition any U.S. entity may receive for making a significant contribution to the expansion of U.S. exports.

"We are deeply honored to have been recognized by the United States government for our continued expansion efforts, especially as we celebrate our 80^th anniversary and approach the manufacture of our 500 Millionth windproof lighter,” said Duke. “While we strengthen our international presence and create jobs domestically, it’s important that we continue to acquaint overseas markets with classic Zippo craftsmanship and quality products. We are anticipating strong growth internationally and are excited about expanding our global footprint even more in the coming years.”

A second-time recipient of this national export award, Zippo first received the President’s “E” Award in 1994 having demonstrated export expansion that was measurable, innovative, sustainable, and which had broad impact. Created in 1969, the President’s “E Star” Award was authorized by the Secretary of Commerce to recognize “E” Award recipients for their continuing significant contributions to U.S. export expansion. U.S. Secretary John Bryson specifically highlighted the company’s recent upsurge in international sales and development of international markets.

“I am pleased to recognize Zippo Manufacturing Company for receiving the President’s ‘E’ Star Award, which honors companies that make significant contributions toward increasing U.S. exports,” said U.S. Commerce Secretary John Bryson. “This Administration is committed to leveling the playing field for American businesses and workers to help U.S. companies build things here and sell them around the world. ‘E’ Star Award winners like Zippo have excelled in this effort, demonstrating four years of successive export growth. It is companies like this that are helping to grow our economy and put more Americans back to work.”

All nominations are reviewed by the “E” Award Committee, which is chaired by the Department of Commerce, and includes representatives of ExIm Bank, the Small Business Administration, and the Departments of Agriculture, Labor, State, and Transportation.

This year marks 50th anniversary of the first presentation of the President’s “E” Award by President John F. Kennedy.  The President’s “E” Award was created by Executive Order in 1961 to encourage U.S. companies to sell their products abroad. 

About Zippo
Zippo markets in more than 160 countries and is one of the most recognized brands in the world. Based in Bradford, PA, Zippo will produce its 500 Millionth lighter on June 5. Each is backed by an unparalleled lifetime guarantee. Zippo’s diverse product line includes lighter accessories; butane candle lighters; watches, fragrance, and lifestyle accessories for men; and a robust line of heat and flame products for outdoor enthusiasts. Zippo also owns the Ronson brand of lighters and fuel and W.R. Case and Sons Cutlery Company, both based in Bradford, PA. Zippo will celebrate its 80^th anniversary in 2012. For more information, visit Zippo.com.

Media Contact

Pat Grandy

Zippo Communications

pgrandy@zippo.com

814-368-2714

Photo Caption: Zippo spectrum finish lighters are imprinted via the auto-engraving process at the company’s plant in Bradford, PA. This model is popular in Zippo’s fastest growing markets, India and China.

POSTED BY:

Ryan D. Huether

Vice President of Business Development 

Independent Can Company

ryan@independentcan.com

http://www.westernspecialty.com