FTA Excellence in Flexography Awards Recapped

FTA
TODAY
Printers
Pushing
Limits
FTA Excellence in Flexography
Awards Recapped
By Robert Moran
2011 EXCELLENCE IN FLEXOGRAPHY
ALL MEDALS GIVEN
Gold
Silver
Bronze
39%
34%
27%
Flexo’s Finest Work
• FIRST guidelines are allowing converters to maximize potential.
• Entries with crisp color and tight registration scored
highest when printed using extended gamut.
• Top-of-the-line equipment provides the freedom to be
creative in designing packages.
• The newest presses are capable of excellent registration, while advances in plate technology are allowing
printers to expand the tonal range.
• Package buyers are demanding better understanding of the final printing method from designers. Designers who understand the process produce better
results.
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2011 EXCELLENCE IN FLEXOGRAPHY
ALL MEDALS GIVEN
Gold
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39%
FTA
TODAY
2011 EXCELLENCE IN FLEXOGRAPHY
% GOLD MEDALS BY CATEGORY
Wide Web
Narrow Web
Mid Web
Napkins
Paper Board
Combined Corrugated
Preprint
Envelope
Students
Newspaper
Graphic Design
F
17%
22%
14%
1%
1%
7%
5%
10%
5%
1%
17%
2011 EXCELLENCE IN FLEXOGRAPHY
% SILVER MEDALS BY CATEGORY
Wide Web
Narrow Web
Mid Web
Napkins
Paper Board
Combined Corrugated
Preprint
Envelope
Students
Newspaper
Graphic Design
ormally identifying flexography’s finest work isn’t easy.
The 39 judges of Flexographic Technical Association’s
2011 Excellence in Flexography Awards competition
took nearly 3 days to evaluate 620 print samples for their
degree of difficulty and level of execution. They deemed 146
worthy of recognition and awarded 35 medals in narrow web
(a high for its category), 25 in wide web, 15 in graphic design,
15 in envelope, 12 in mid web, 11 in combined corrugated, 10
in preprint, 9 in students, 6 in napkins, 4 in paperboard, 2 in
newspaper and 2 in self-promotion. Gold medals comprised
39 percent of the awards, with silver accounting for 34 percent
and bronze 27 percent.
Familiar names adorned the boxes, cartons, containers,
labels, envelopes, pouches and other forms of packaging
under review in the amphitheater and brand-speak filled the
air, making it clear that leading consumer product companies
embrace flexo in large numbers. Counted among the advocates: Miller, Coors, Dial, Enfamel, TyalorMade, O’Lay, Oak
Hill, Yankee Candle, Tide, Nature’s Recipe, Kaytee, Downy,
Kingsford, NutriSystem, Biore, Doritos, Cape Cod, Godiva,
Degree, Huggies, Cattlemen’s, Nestle, Nissan, Moosehead
Lager, American Express and Volvo. For a complete list of
award-winning firms, see “The Winners’ Circle,” on page 19.
17%
24%
2%
6%
4%
8%
6%
9%
6%
2%
16%
2011 EXCELLENCE IN FLEXOGRAPHY
% BRONZE MEDALS BY CATEGORY
Wide Web
Narrow Web
Mid Web
Napkins
Paper Board
Combined Corrugated
Preprint
Envelope
Students
Newspaper
Graphic Design
15%
22%
7%
5%
2%
7%
10%
10%
7%
0%
15%
In the end, the following entries stood apart from the rest,
capturing the highly coveted “Best of Show” in their respective classes:
• Publisher’s Printing Co. for the Autumn 2010 cover of
Alpinist 32.
• Sunshine Plastics Corp. for Midnight Indulgence Chocolate Fondue Wrapper.
• Cellotape Inc. for Syntax Spirits Vodka Label.
• Encore Envelopes, Ltd. for Harry Potter Envelope.
• Label Technology Inc. for John Frieda Frizz Ease Overnight Repair Packette.
• Lewisburg Container Co. for Duracel My Grid Charge
Pad for Cell Phones.
• SCI for Crisco Pure Peanut Oil.
• Clemson University for The Phoenix Label.
• GOLDENera Group for Kellogg’s All Bran.
PACKAGING’s PACESETTER
Judges’ comments proved enlightening. Many drew parallels to FFTA’s 2011 Annual Forum theme, Setting the Pace for
Packaging Excellence, and declared that the print samples
they evaluated are a testament to exceptional packaging and
flexography as its print production process.
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“We actually had to examine a
few samples very closely to ensure
they were indeed flexo-printed,”
says Scot McLeod, Robbie Fantastic
Flexibles, who judged degree of
difficulty for the wide web line and
screen classifications. “We are seeing much more color in the samples
submitted. Increased saturation,
higher line screens and tighter registration are very common.”
Paul Teachout, Harper Corporation of America, who judged degree
of difficulty for mid web, paperboard
and napkins, adds, “The level of excellence and consistency continues
to grow each year. It is a strong testament that the guidelines provided
by Flexographic Image Reproduction Specifications and Tolerances
[FIRST] continue to allow converters
to maximize their potential.”
“As an industry, we really have
made some great inroads in
overall package appearance and quality,” says Ed Dedman,
Graymills Corp., who judged level of execution for mid web,
paperboard and napkins. “I am blown away by so many of
the samples—the sharpness, print quality and overall ‘pop’ is
amazing!”
Other judges point to the flexo industry’s progress, elevated
quality and consistent performance, noting comparisons to
results previously considered the sole purview of gravure.
Cori Devlin, DuPont Packaging Graphics, who was charged
with rating level of execution for wide web line and screen
entries, says, “I noticed improvements in ink’s adherence to
Judges, Wide Web Line and Screen Work: Front row, L-R: Bill Malm,
Harper Corporation of America; Cori Devlin, DuPont Packaging
Graphics. Back row, L-R: Dan Dietrich, Inometa AKL Flexo; Scot
McLeod, Robbie Fantastic Flexibles; José Soler, Comexi; David Story,
Farnell Packaging, Ltd.
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paper. Also, several printers appear to be using screening
technology to lay down white.”
Dianna Winfrey, Sun Chemical, preprint and corrugated
level of execution judge, adds, “The print production process
and exceptional packaging was excellent in all areas. The
quality was outstanding for flexo—gravure quality.”
“It’s amazing that flexo continues to push the envelope
and simulate litho-type quality of work,” says Scott Ruscetta,
INX International. He examined envelope, student, newspaper and promotional entries. “Based on information shared
about setup, print and production, these entrants clearly used
leading-edge technology.”
Judges, Mid Web Paperboard and Napkin: Front row, L-R: Paul
Teachout, Harper Corporation of America; Catherine Whitaker, Asahi
Photoproducts; Mark Hemans, Huhtamaki. Back row, L-R: Ed Dedman,
Graymills Corp.; Greg Horney, Rock Tenn; and Curt Smith, Luminite.
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Judges, Narrow Web: Front row, L-R: Bill Enright, Mark Andy; Cayleigh
Nichols, Prairie State Group; Don Earl, Overnight Labels. Back row,
L-R: Doug Nelson, Carol Harrison, CTS Industries; Bob Loescher,
ACTEGA-WIT.
Judges, Wide Web Process: Front row, L-R: Karen Daniels, Georgia
Pacific; Thomas Klein, tesa tape. Back row, L-R: Bart Wright,
Colormasters, LLC; Dale Cargal, Sealed Air Corp.; Jean Engelke,
Kodak; and Dan Reilly, Flint Group.
Judges, Preprint and Combined Corrugated: L-R: Scott Gehrt, FVTC;
Tony Falcone, Temple-Inland; Tim Esselman, Castle Rock; Maureen
Armstrong, Smurfit Stone; Dianna Winfrey, Sun Chemical; and Bob
Dauses, Mark Trece.
Judges, Envelopes, Students, Newspaper and Self-Promotion: Front
row L-R: Andy Schipke, Winkler & Dunnebier; George Brigham,
Worcester Envelope; Michelle Surerus, Appalachian State University.
Back row, L-R: Mike Taylor, ALC Group; Bettylyn Krafft, Phoenix
Challenge; Scott Ruscetta, INX International.
Dale Cargal, Sealed Air Corp., degree of difficulty expert
for wide web process work, notes flexo’s expanding range.
“We’ve seen screen counts often hitting the 133 to 175 range
and we saw a few 220 screens. Printing is getting more complicated and graphics are getting more creative in achieving
smarter capabilities,” he says. “Several exceptional labels
came across the table this year. Extended gamut is moving
forward.”
Dan Riley, Flint Group, who judged level of execution for
wide web process jobs, is impressed with the samples’ crispness and tonal range, but notes where improvements might
be made. “One thing entrants should concentrate on next
year is registration. It has knocked some excellent submissions out of the running.”
Still, the entries reflect some of the best flexo printing in the
world, says Cayleigh Nichols, Prairie State Group, narrow
web, degree of difficulty analyst. “These samples showcase
just how far flexo has come as a commercial printing process.
The samples rival other printing processes that have long
been established as higher quality.”
Tom Newmaster, William Fox Munroe, long-tenured graphic
design critic, agrees. “[Several entries] represent some of
the best designs that I can remember. With the right mix of
design, prepress and printing, flexo can deliver some of the
most effective packaging in retail.”
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TECHNOLOGY’S TOUCH
Several judges cite best industry practices and process
controls as contributing to desirable print outcomes. Curt
Smith, Luminite, who judged mid web level of execution,
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sees “hybrid screens in highlights and
vignettes, as well as light impression,
tight registration and good color transfer,” as leading to very positive results.
Mark Hemans, Huhtamaki, a mid
web degree of difficulty judge, adds,
“In-the-round plates were heavily used.
There was a good attempt at lowering
trap tolerances and tighter control of
registration.”
Thomas Klein, tesa tape, who reviewed wide web process entries for
level of execution, was impressed with
printers’ use of double black for line and
process separation, extended gamut
and the integration of silver metallic inks.
According to Mike Taylor, ALC Group,
who judged envelope, student, newspaper and promotional entries, it was
clear that the entrants were comfortable
with using proper tooling, such as anilox
roll line count, digital plates and new
screening technologies. “Density blocks
and dot area scales, along with slur
targets, made it possible to control and
monitor dot gain, impression settings
and registration,” he says.
Scott Gehrt, Fox Valley Technical
College, who judged level of execution
in the preprint and combined corrugated categories, notes the freedom
afforded by top-of-the-line equipment.
“The creativity in the designs submitted
today reveals how great the technology
has changed through the years,” he
says. “Machines are capable of printing
top quality flexo and the winning prints
prove that.”
His colleague on the panel, Maureen
Armstrong, Smurfit Stone, who looked
at degree of difficulty, adds, “Prepress
calibrations for the plates and press
conditions was evident in the top-scoring items.”
Sounding a similar refrain, José Soler,
Comexi, a degree of difficulty judge for
wide web line and screen, notes, “We
saw complex designs for very porous
substrates that are difficult to print. Difficult graphics may register easy on a
substrate, but dot quality is affected on
highly absorbent substrates. On paper,
we saw 100 and 120 line screens. UV
technology was evident in higher-end
work. Screening went very low. I saw
hints of big and important innovations
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in UV and EB coatings and varnishes on
smooth-end films.”
Soler’s counterpart in the process
arena, Bart Wright of Colormasters,
concurs. “The increase in plate and
prepress technology pushes the envelope in what can be accomplished in
flexo. This is the direct reason for the
increase in line screen.”
Judges, Graphic Design: L-R: John McDonald, Brandimage, Desgrippes and Laga; Tom
Newmaster, William Fox Munroe; and Greg LaFond, Matthews Brand Solutions.
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According to Carol Harrison, CTS Industries, narrow web level of execution
judge, the majority of print jobs for narrow web have migrated to digital plates.
“Also, even though four-color and line
jobs are still prevalent, we are seeing
much more eight- and 12-station applications. The rotary screens, the foils, the
builds of varnishes are all technologies
that are becoming extremely popular.”
She adds that they are improvements
to a solid foundation. “We never want to
forget what flexo is all about and what
it means for printing. Two years ago,
the Best of Show was analog plates for
color process. That just shows that we
still know where our roots come from.”
Smart.
COLOR AND KARMA
From ink laydown to tight registration,
clean trappings and well-orchestrated
screens, the effects of evolving technology combine to make packaging
graphics pop. Printers are applying
well-honed talent and skill to deliver
top-notch design and effects. But of all
the elements that affect a package’s
ability to grab and hold a consumer’s
attention, color is among the most critical. Package buyers know this: They ask
for it, and it is often the first thing they
comment on.
Likewise, color drew both the eyes
and comments of FTA’s 2011 Excellence in Flexography Awards judges.
“Color plays a huge role on print results
achieved,” says David Storey, Farnell
Packaging, judge of wide web line and
screen degree of difficulty. “Downstream, EB applications add punch to
the designs, more so than water-based
or solvent-based lacquers.”
Karen Daniels, Georgia Pacific, who
judged wide web process level of execution, adds, “Entries with crisp color and
tight registration scored highest and
were printed using extended gamut,
which is very forgiving in images with lots
of detail. Color management in prepress
is crucial to extended-gamut printing.”
According to Tim Esselman, Castle
Rock, preprint and combined corrugated degree of difficulty judge, color
is crucial to a positive first impression
and should be played up more. “Many
entries showed excellent color combinations. More entries actually could
have used coatings to accent print,”
Harper has devoted an entire division to help flexographic printers and converters
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he says. “Several entries from overseas were using flat-top
dot technology. I noticed very little fluting in any entries. More
than ever, I have seen the use of supported plates in scrap
areas to help in flute reduction. The use of some form of FIRST
specifications for color control attested to printers’ application
of cutting-edge skills.”
Catherine Whitaker, Asahi Photoproducts, a mid web level
of execution expert, adds that new and improved screening
technologies can enhance highlight reproduction. “When these
technologies are set up properly and paired with the right plate
and press conditions, the results are bright and vivid.”
Bob Dauses, Mark Trece, level of execution judge for preprint and combined corrugated, expresses similar thoughts.
“Entries continue to get more complex. The newest presses
are capable of excellent registration, while advances in plate
technology are allowing printers to expand the tonal range.
Many entries are also using varnish in creative ways.”
Greg Horney, Rock Tenn, mid web degree of difficulty
judge, points to the elements that make great color. “There
is a higher demand for attention to details, [particularly with]
spot colors. Coverage on substrates is improving and we’re
seeing less overimpression,” he says. “In process, the ink
strengths are allowing printers to use a smaller dot by using
higher line anilox rolls to achieve smoother, cleaner results to
include shadows and highlights with soft edges.”
Teamwork among printers and suppliers, particularly those
who take advantage of customized educational seminars and
demonstrations, has improved quality, says Bill Malm, Harper
Corporation of America, who examined level of execution in
wide web line and screen, “Everybody is out to learn new,
specialized techniques and everybody is determined to
perfect the offerings and use them to their own competitive
advantage.”
Jean Engelke, Kodak, wide web process degree of difficulty
team member, sees teamwork from another angle. “There
continues to be a mix of in-house graphics techniques and
repro house expertise,” she says. “[Flexographers are] taking
risks. Manipulating software and pressroom capabilities help
to differentiate designs.”
Don Earl, Overnight Labels, a narrow web degree of difficulty judge, notes the contributions of designers. “If the designer understands printing and all the substrates and effects
available, then he or she can design a beautiful label. There
was definitely a difference between the labels and items that
use special effects and color versus those that only relied on
color.”
FTA’s Excellence in Flexography Awards Committee meets over lunch.
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Newmaster agrees. “Packaging buyers are demanding more and better understanding of the final printing method
from the designer. Asking questions
about the reproduction method upfront,
is critical, and based on what I saw this
year, it’s actually happening. When a
designer understands the process—the
limitations and the possibilities—managing the client’s expectations becomes
a lot easier. And, the results are always
better as well.”
He adds that those who concentrate
their efforts on appealing to their target
markets had the most success. “Color,
typography and imagery were focused
on the core consumer, without trying to
be all things to all people. That delivers a
superior result. Many of the gold winners
and especially the Best of Show winner
exemplify this targeted approach.”
His thoughts echo those of many of
the judges. “Flexography is as good as
all the other printing processes. The
right combination of design, prepress
and printer can deliver high-quality
print jobs.” n
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THE WINNERS’ CIRCLE
For every brand, there is an image-painter—the printing/
packaging/converting partner. The honorees, by and large
FTA members, and their market segment specialties are
instantly recognizable. The winning firms are as follows:
Napkins
NARROW WEB
ENVELOPE
ASL Print FX, Quality Assurance Label, Smyth Companies, MPI Label Systems, Berry Plastics Corp., Regency
Label, Labeltronix, McDowell Label, Paragon Label, Multi
Packaging Solutions, Cenveo McLaren Morris & Todd, York
Label, Dow Industries, Multilabel, Logmatix, J. Ryan Printers, Publishers Printing Co.
WIDE WEB
Sunshine Plastics Corp., Coating Excellence International, Bancroft Bag, Glenroy, PolyCello, Anagram International, FlexStar Packaging, Pioneer Balloon Co., Hood
Packaging, Tufco Technologies, Exopack, The Robinette
Co., Robbie Fantastic Flexibles, Superbag Co., Folmex.
Paper and Design GmbH, Creative Converting.
Paperboard
Master Packaging Inc.
Tension Envelope, Univenture Inc., Mac Papers Envelope
Converters Inc., McKayMitchell, Encore Envelopes Ltd.
CORRUGATED
Allpak Trojan, PCA, SSCC Castle Rock Display Group,
Nampak Corrugated, Bennett Packaging, Great Lakes
Packaging Corp., Wellpappe Auerswalde GmbH, Lewisburg Container Company.
PREPRINT
SCI, Rock-Tenn Co., Packaging Technologies Inc., Menasha Packaging Co.
NEWSPAPERS
Daily Hampshire Gazette, Chattanooga Times Free Press.
MID WEB
Label Technology, Innoware Paper, PERUPLAST, GTECH
Printing Corp., Plastic Packaging, Inc., Golden Era Group.
See a pictorial account of the Awards on pages 21-134.
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