Standard FinishLine Newsletter Fall 2019

Fall 2019

STANDARD FINISHING SYSTEMS

ACP International

Showtime Update

Cypress Fairbanks ISD Standard Hunkeler/Horizon Roll-to- Booklet system streamlines operations and increases staff morale

Standard Horizon Rotary Die Cutter raises productivity and quality of specialty cable tag applications

The Power of Smart Finishing heads to PRINT 19 and PRINTING United, while Think Smart Factory debuts in Japan

www.standardfinishing.com

Welcome I Contents

Welcome

Contents

Shaping the Future of the Print Industry!

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Customer Snapshot

Recent months have brought excitement and change to our industry, and in no place is this more evident than the evolving trade show landscape. Smaller shows have merged into larger events to meet the needs of printers who are expanding their capabilities. Likewise, new events have emerged, such as the inaugural Think Smart Factory 2019 which just wrapped up in Kyoto, Japan. This unique exhibition showcased a fully automated, working factory from order entry to delivery on the show floor, giving attendees a window into a possible future for their own operations. By planning this event, our manufacturer Horizon has surely moved the industry forward in thinking about automation. Our feature customer in this issue, Delzer Lithograph Company, is a perfect example of this forward thinking trend. They recently completed a transformation of their entire bindery, adding a new press, new capabilities, and a full suite of Standard Horizon equipment. And it paid off. Delzer saw higher productivity, higher quality end products, and increased throughput – all without needing to hire additional staff!

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Cypress Fairbanks Independent School District installs Hunkeler/Horizon Roll-to-Booklet line and virtually eliminates outsourcing

Customer Profile

4-5 Delzer Lithograph Company revitalizes in-house bindery with new Horizon finishing solutions – improving overall throughput

Showtime Update

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Horizon debuts Think Smart Factory event in Kyoto, Japan, and PRINTING United draws large crowd in Dallas, Texas

PRINT 19

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Standard unleashes the Power of Smart Finishing in Chicago and unveils the latest in Red Hot Technology

Similarly, Cypress Fairbanks Independent School District (CFISD) invested in a Standard Hunkeler/ Horizon in-line finishing solution to address their finishing bottleneck and outsourcing costs. Within just the first few months of operation, CFISD saw dramatic results. They were able to turn jobs around faster, improve staff morale, and significantly reduce outsourcing.

Customer Snapshot

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ACP International achieves increased productivity and high quality results with Horizon RD-4055

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In Memoriam

And sometimes, just one machine can transform your entire process for the better. ACP International installed a Standard Horizon RD-4055DMC Rotary Die Cutter and was able to overhaul the production of one of their core specialty products, achieving more consistent quality and greater productivity. With a brand new decade around the corner, we look forward to seeing what new transformations are in store. One thing is for sure – change will be a constant.

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S

David T. Morgan

It is with deep sorrow that we report the sudden passing of our cherished friend and valued member of the Standard Sales Team, David Morgan. Dave joined Standard as a Sales Manager in May of 2000, and built many meaningful and trusted partnerships during his nearly twenty dedicated years with the company. Always a gentleman with a kind word and a big heart, he will truly be missed by his Standard family and the customers, dealers, and partners he worked with over his long and successful career.

Doug Reny ( Left) Vice President of Operations David Reny (Right)

Executive Vice President

Steven Reny (Center) President

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Customer Snapshot

In-line finishing delivers results

The solution begins with a Hunkeler unwinder into the Canon press. Printed output is delivered to a Hunkeler CS6-HS Cutter equipped with vertical perforation capabilities, and then into a Horizon StitchLiner 6000 Digital Saddlestitcher for finishing.

A More Productive Print/Finishing Solution Significantly Reduces Outsourcing. Cypress Fairbanks Independent School District, Texas

Standard Hunkeler/Horizon Roll-to-Booklet line leads to high efficiency and raises staff morale.

As the third largest school district in Texas, the Cypress Fairbanks Independent School District (CFISD) has more than 117,000 students across 91 campuses consisting of 56 elementary schools, 18 middle schools, 12 high schools and 5 special program facilities. The district has more than 16,000 employees and is the only district in the state to be ranked in the top three most effective and efficient districts in Texas by the Education Resource Group for each of the last six years. At CFISD, administrative expenditures account for only 1.8% of the operating budget. For a district of this size and caliber, CFISD’s printing resources are a critical asset. An efficient print shop can deliver both significant value to the district as well as contribute to a better bottom line. That’s the mission that Derrek Thompson, Print Center Manager for the district’s Janie Scott Print & Production Department, has undertaken since he joined the organization 10 years ago. “For a district this size,” he says, “we have quite a small department with only 12 employees. But we deliver a huge amount of printed material to the district with this talented staff.” The district has six toner-based printers/copiers and four small offset presses. “Our problem was that our finishing department couldn’t keep up with the output from our copiers and presses,” Thompson explains. “We would have pallets of paper sitting around waiting for finishing, and we often had to outsource work to meet deadlines – in fact, as much as $250,000 worth of outsourcing annually. We knew we needed to take action to continue to

dealer LSS Digital seamlessly installed the Hunkeler and Horizon components of the system and now provides ongoing maintenance and service for the front and back ends of the line.

“Although it has only been five months since installation,” Thompson says, “the results have been dramatic. We have virtually eliminated outsourcing, and operation of the line only requires two people instead of the three or four we required before. Now at least half of our work goes through that line, basically paper in and finished booklets out. As an example, one recurring job we do used to take us 54 hours to complete. Now we get it done in 9 hours!” He adds that since the system got up and running, it has basically run itself, with two people taking finished product off the end of the line, boxing and labeling it, and getting it ready for distribution. In this more productive working environ- ment, morale among the staff has skyrocketed. “We just got through the school year start-up,” Thompson says, “and historically that time period has been extremely stressful for us. This year, with our new Canon/Hunkeler/Horizon line, staff is working at 100% instead of 110%, everything is calm, and it doesn’t seem like a rush. The troops are much happier, and this is a much more pleasant place to work. Not only have we saved the district money by virtually eliminating outsourcing, we are meeting our deadlines. But for me, the improvement in the work environ- ment for my hardworking team is the biggest plus of all.”

do our best to serve the needs of the district.” In-line Hunkeler and Horizon solution reduces costly finishing bottlenecks at CFISD.

Thompson and his team determined that a roll-fed inkjet press with in-line finishing would be the best solution to their dilemma. “We looked at solutions from three different printer vendors, who all basically recommended the same in- line finishing choices. Ultimately, we decided to go with the Canon Océ ColorStream 3900 digital color printing system. And since we had already had a Horizon StitchLiner 5500 Saddlestitcher for some time – and had very good experience with it – we chose to work with Standard Finishing and Canon to configure an in-line solution that would best meet our needs.” CFISD installed a Standard Hunkeler/ Horizon Roll-to-Booklet line last April along with its Canon 3900. The solution begins with a Hunkeler unwinder into the Canon press. Printed output is delivered to a Hunkeler CS6-HS Cutter equipped with vertical perforation capabilities, and then into a Horizon StitchLiner 6000 Digital Saddlestitcher for final finishing. Houston-based Standard

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Customer Profile I

Delzer adds new capabilities to bindery

The BQ-480PUR has allowed Delzer to bring high-volume perfect binding capability in-house. The binder offers advanced automation including adjustments for roller height, nipping height, and amount of side glue.

Delzer ended up retiring most of its older equipment and acquiring newer, more modern solutions to meet their bindery needs. The company now runs a Standard Horizon lineup which includes saddlestitching, collating, large-format folding, die cutting, and perfect binding with in-line trimming.

The quick turnaround time from one job to the next on the Standard Horizon StitchLiner Mark lll allows for book- let production at a faster rate for both short & long runs.

The combined BQ-480PUR and HT-80 line features fast set-up and changeover for variable book production, ideal for book-of-one as well as long runs.

Bindery Transformation Delivers for Delzer Lithograph Company. Third-generation, family-owned commercial printer in Waukesha, Wisconsin

Improves speed, quality, and productivity, while better controlling costs and schedules.

Founded in 1949, Delzer Lithograph Company is a third-generation, family- owned commercial printer located in Waukesha, Wisconsin. The company prides itself on delivering “commercial print done right.” As part of an overall transformation for the business, President Michael Delzer and his team acquired a brand new Komori 8-color HUV perfecting press in 2015 to complement the Konica Minolta digital presses they use for short-run on-demand work. The company also offers wide-format printing, mailing, sophisticated kit

could better control the cost.”

That decision led to a discussion with Standard Finishing and their local dealer Precision Graphics. “We have an older Standard Horizon bookletmaker that we use in our digital department,” Delzer says. “But, as part of our discussion with Standard Finishing, we visited their outstanding demo center in Boston and immediately saw an opportunity to transform our entire bindery as well.” During the visit, Standard Finishing staff demonstrated all of their equipment and, according to Delzer, were very patient in explaining everything and taking time to fully

With their new BQ-480 (L to R): Randy Kornuth - Bindery Manager, Tim Weske - Vice President Operations, Jim Polzin - Vice President Sales, and Michael Delzer - President.

assembly, finishing, fulfillment, distribution, and warehousing.

understand the company’s needs. “They presented options that would fit our budget and could do what we needed to do,” he says. “The more we thought about it, we realized that this was an opportunity to look at our whole complement of finishing equipment and determine what made sense to upgrade. They were proactive and made it very attractive for us to look beyond

“With the new quality and capacity our Komori press provided us,” Michael Delzer notes, “we decided we needed to bring high-volume perfect binding in-house. With closures and mergers, there was only one trade bindery in the area we could trust with our work, and we wanted to bring that work back in-house so we were not reliant on their schedules and

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Changeovers and set-ups are quick and easy on the AFC-746F large-format folder using the intuitive, color, icon-based touchscreen. The system allows for up to 47 automated

With the printed materials in place, Danny Ortiz, Digital Finishing Specialist, makes simple adjustments to the Standard Horizon RD-4055 Rotary Die Cutter before running the application.

adjustments and runs 30% faster than its predecessor.

The AFC-746F pallet-feeder allows for the loading and processing of thousands of sheets directly from the press. No heavy lifting and working of the sheets.

The RD-4055 is prepped for a custom job, which now takes Delzer considerably less time thanks to the system’s ability to automatically scrap the hang hole.

method was to die cut those on sheets and manually scrap the hang hole. That took a great deal of labor; in fact, since we print millions of these things, the ability of the new die cutter to automatically scrap out that hang hole has saved us hundreds, if not thousands, of hours. It turned a marginal job into a very good job simply by automating that manual task.” Delzer also notes that the pallet feeder on the AFC-746F Folder allows for the loading and processing of thousands of sheets directly from the press for smooth feeding without heavy lifting and working of the sheets. “With its fast changeover and fully automated set-up for multiple fold types, this folder runs 30% faster than its predecessor.” Delzer likes to joke with his staff that Santa brought them a lot of new toys for Christmas in 2018, as all of their Horizon investments, first with the new Komori press and then in the bindery, has had not only a huge effect on our productivity and profitability, but has also had a significant impact on employee morale,” he says. “In addition to the new equipment and jettisoning older equipment, we modernized our facility and changed the way we look and feel about what we do. It’s exciting for our employees. It makes them feel proud to come to work and proud of the type of jobs we do. Those are the kinds of things you hope happen when you make investments like these. We also used it as a springboard to set expectations even equipment was delivered to the new and improved bindery that December. “Transforming our operation and making these

what we were initially thinking about. One of our key goals was to be able to increase our bindery efficiency and output without the need to hire additional staff.” Delzer ended up retiring most of his older equipment and acquiring newer, more modern solutions to meet his bindery needs. The company now runs a Standard Horizon lineup which includes saddlestitching, collating, large-format folding, die cutting, and perfect binding with in-line trimming. They improved speed, quality, and productivity right out of the gate, while reducing both the plant footprint and physical demand on their operators. Delzer is thrilled to now have perfect binding capabilities in- house with the BQ-480PUR Perfect Binder and in-line HT-80 Three-Knife Trimmer. The combined solution features fast set-up and changeover for press. They are equally impressed by the lightning-fast make- ready of the StitchLiner Mark III Saddlestitcher. The quick turnaround time from one job to the next allows for booklet production at a faster rate for both short and long runs. “One of the most significant benefits from this transformation of our bindery department,” Delzer says, “is that it enabled us to increase our overall throughput without the need to hire extra staff. The systems all have a common user interface and are very easy to use. That made it easy for us to cross-train staff if we needed, for example, to add a shift.” Delzer especially appreciates the efficiency of the RD-4055DMC Die Cutter. “We have a recurring project that involves a cutout of a hang hole for cards that go in retail spaces. Our old variable book production, ideal for book-of-one as well as the long runs coming off the Komori

“One of our key goals was to increase bindery efficiency and output without hiring additional staff.”

higher in a positive way, and our people have responded. That’s been an important side benefit to the whole thing. And the excellent partnership with Standard Finishing and Precision Graphics helps to keep it all working.”

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Dealer News I Innovationdays 2017 Showtime Update

Envisioning the future. Think Smart Factory 2019 is a consortium of Japanese manufacturers in the print industry who champion the idea of the fully automated “smart factory.” Members of this group include Canon, Fujifilm, goof, Horizon, HP, JSpirits, Konica Minolta, Resologic, Ricoh, Screen, and Value Machine. TSF2019, organized by Horizon, was designed to highlight the transformative power of innovation and automation and present a vision of the future of the print industry.

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New event draws high interest among those in digital print market

Think Smart Factory Debuts in Kyoto, Japan. From November 11-13th, the Standard team, along with other print technology leaders and industry professionals, traveled to Kyoto, Japan for Think Smart Factory 2019 (TSF2019). The inaugural event was sponsored by leading digital print vendors, software providers, and Standard Finishing manufacturers Horizon and Hunkeler.

Designed to be a completely innovative trade show event, TSF2019 offered attendees a truly unique experience. In lieu of vendor booths, the 43,000 square foot show space was transformed into a fully automated working factory from order entry to shipping and delivery. Horizon’s solutions, which Standard distributes in North America, were used for finishing processes. Every system in the hall was connected via a digital workflow, and automatic transport, in-feeding, and off-loading were incorporated to demonstrate a true “smart factory.” During the 3-day show, attendees were also able to sit in on live demonstrations, seminars, and panels from industry leaders, print vendors, and technology innovators. Standard closed out a busy October with a trip down to Texas for PRINTING United! The inaugural event, organized by SGIA and NAPCO to build upon the original SGIA Expo, brought over 650 exhibitors and thousands of print professionals from all industry verticals to the Kay Bailey Hutchison Convention Center in Dallas. Standard’s latest and most popular solutions were on display, including the Horizon StitchLiner Mark III Saddlestitcher with the new VAC-L600H collating Standard and Partners Highlight Finishing at PRINTING United. October 23 - 25, Dallas, Texas

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Special Thanks to...

Cobblestone Graphic Equipment Co. showcased the Standard Horizon AFC-566FG Folder, CRF-362 Creaser/ Folder, RD-4055DMC Die Cutter, and SmartSlitter RMGT Graphic Systems North America featured Standard Horizon’s StitchLiner Mark lll Saddlestitcher PDS Equipment highlighted the Standard Horizon BQ-480 Perfect Binder Screen Americas presented the Standard Hunkeler Gen 8 Roll-to-Stack Solution

towers, the BQ-480 Perfect Binder, the RD-4055DMC Die Cutter, and the robust Hunkeler Generation 8 Roll-to-Stack line.

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The next PRINTING United show will be held from October 21-23, 2020, in Atlanta, Georgia.

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PRINT 19

Another Year, Another Successful PRINT Show! PRINT 19, October 3 - 5 in Chicago

Attendees discover the Power of Smart Finishing in Standard’s booth with a wide array of finishing solutions handling a diverse range of creative applications.

A focus on linking creativity to technology.

Held from October 3rd to October 5th in Chicago, PRINT 19 drew attendees and exhibitors from across the world to the print industry’s longest-running event. This year’s PRINT show focused on the nexus between creativity and technology and featured dozens of educational sessions, curated tours, and networking events. In Standard’s booth, the largest display of feeding and finishing solutions at the show, attendees were treated to demonstrations in die cutting, perfect binding, and more. All of the Horizon and Hunkeler equipment featured in the Standard booth was

Air-Suction Collator. The VAC-L600H builds upon the successes of past VAC collator models by improving air flow, expanding size capacity, and increasing efficiency to allow end-users to process a wider variety of media and applications. Combined with the Mark III, the VAC-L600H is capable of producing 4.725" x 3" small-format booklets, 9" x 12" landscape booklets, large-format calendars, and more. Hunkeler’s award-winning Generation 8 modules were also on display as part of the powerful Roll-to-Stack line. The Roll- to-Stack is available with Standard’s second “RED HOT Technology” winner of the show, the LS8-30 Long Stacker. The LS8-30 Long Stacker allows the Roll-to- Stack line to support the widest range of formats on the market, from

VAC-L600H

StitchLiner Mark lll

HOF-400

LS8-30

designed to highlight the transformative power of advanced automation across a range of applications. Equipment on display included the Horizon StitchLiner Mark III

Roll-to-Stack Solution

full-bleed 4" x 5.5" postcards to sheets as large as 22" x 30" (B2+ format) at speeds of up to 590 feet per minute.

Saddlestitcher, which combines collating, scoring, folding, saddle- sstitching, and trimming into a single, performance-driven machine. The Mark III was paired with one of PRINT 19’s “RED HOT Technology” winners: The Standard Horizon VAC-L600H

Interested in more from the event? Scan the QR Code to watch highlights from the show, including the Standard booth!

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Customer Snapshot I

A once time-consuming task made simple. Previously, an operator was required to load and unload each piece of media when using steel rule die cutting, but now they simply place a stack of media in the feeder for the RD-4055DMC, place the appropriate die in the machine, and press start. At right, Enieda Albarran, Production Technician, operates the RD-4055DMC at ACP International.

Clean Cut: The Standard Horizon RD-4055DMC Rotary Die Cutter Makes Routine Signs Special. ACP International, Arlington, Texas

Significantly increases productivity, and delivers consistent high quality.

card with holes and rounded corners. Sometimes they can be a unique shape, but typically they are

ACP International makes tags, decals, labels, and signs for utility companies, municipal governments, pipeline companies or any other organization that is required to identify buried and overhead cables. While these might sound like commonplace applications, ACP International has been producing them since 1986, and the company takes great pride in making these signs, labels, and decals as clean

oval. Installers use zip ties through the tag holes to affix them to the appropriate cable.” Other products include reflective letters and numbers used for codes that are placed on telephone equipment or electrical transformers so they can be identified in low light conditions. For Nussbaum, the beauty of the new die cutter is twofold. “We significantly improved our productivity, and the quality is much more consistent. Cable tags don’t have to be the most beautiful things in the world, but it feels good to have a really good clean-cut product.”

Joe Nussbaum, Owner

and good-looking as possible.

“We traditionally used steel rule die cutting in production of our products made from thin-gauge plastic,” explains owner Joe Nussbaum. “You could think of it as kind of a cookie cutter approach to die cutting these shapes. It’s effective, but

somewhat labor intensive since an operator has to move the material into and out of the machine.” About two years ago, Nussbaum’s local dealer, Cobblestone Graphic Equipment Co., introduced him to

Previously, an operator was required to load and unload each piece of media when using steel rule die cutting, but now they simply place a stack of media in the feeder for the RD-4055DMC,

“The RD-4055DMC is so reliable and easy to use. It’s made a huge difference in our operation.”

place the appropriate die in the machine, press start and walk away to perform other, more productive tasks. “The quality is great,” Nussbaum says, “but what really sold me is the automatic loading and unloading of the media. I may be dating myself, but it kind of reminds me of the old Ditto or Gestetner machines, where you make the master, mount it on a cylinder, and it just prints a bunch of copies. The RD-4055DMC is so reliable and easy to use. It’s made a huge difference in our operation.” Nussbaum has been able to transfer most of his thin-gauge plastic applications to the RD-4055DMC, and he still has more capacity available. “This die cutter may not be able to do everything steel rule can, but what it does do, it does much better,” he concludes. “When I get close to capacity on this machine, I would buy another in a minute!”

the Standard Horizon RD-4055DMC Rotary Die Cutter. The RD-4055DMC has dual magnetic cylinders that simultaneously die-cut and crease/score short-run product from both sides of the sheet. It can also perforate, slit, hole punch, and round corner in one process for digital and offset printed sheets, and it can separate waste in the same pass to reduce costly labor steps. “Our requirements are a bit unique,” Nussbaum adds, “not only with respect to the materials we use, but also the shapes we have to cut. The folks at Cobblestone and Standard Finishing worked with us to determine the best settings for us to use and did a great job of training our people.” Nussbaum explains that cable tags are one of the main pro- ducts now being produced on the RD-4055DMC. “These are tags that identify a cable, typically a little smaller than a credit

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