Packaging manufacturing companies face three challenges
Lackner pointed out that three major challenges are looming, bringing a shadow of uncertainty to offset printer operations. First, skilled press operators are elusive, but they are essential, possessing the expertise to master the intricacies of offset lithographic sheet-sheet presses.
"I know getting the workforce is a challenge," Lackner said. "But I want to talk about much more than that. This is the practical skill required to run offset, lithography, and sheet-fed presses. There are not many places you can go to get training in how to operate a printing press. So skill dilution, especially when you embrace technology, becomes a bigger problem. It will be an ongoing challenge for the industry as a whole, ourselves and the organisations that support the industry to train and develop their employees to master the printing process.
"This is going to be a bigger problem in the future," Lackner added. "When I talk about the need to embrace technology, modern offset presses also have all the attributes, where there are multiple systems for cleaning the press, plate hanging, registration, and so on. We use technologies that make it easier to run the equipment, but operators need to understand the basics of printing, such as how to set up the roller, what the rubber cloth does, and understanding dot gain. Understanding these technical aspects can help operators troubleshoot when problems arise is a challenge. This could be the difference between a "news operator" and a "news man" : a news operator would say I know what buttons to press; The press will say I know why you pushed those buttons."
Second, packaging printing faces a relentless regulatory rollercoaster that requires constant vigilance and adaptation. "You have to make sure you comply with existing regulations," Lackner added. He gives an example from when he first started in the industry. "Most printers used alcohol in their printing solution," Lackner recalls. "No one in North America does that today; If so, they better manage their own environmental compliance." He explained that as technology advances and environmental issues shift, packaging printing companies have to deal with ever-changing rules and guidelines, from chemicals to processes. Similarly, it's important to have a team with strong technical skills so they can "tackle these challenges with more modern chemical approaches."
The third challenge, he explains, is also an opportunity. This challenge requires an environmental overhaul of packaging manufacturing in search of relevance. "Our entire industry is still working to promote sustainability," Lackner said. Noting that lithography operations typically print inks on fiber-based materials, Lackner said, "I don't think we've done a good enough job of advocating for paper and paper-based or fiber-based products. We need to better educate the masses - the public - about our sustainable practices and the sustainable use of our products. We need to tell them that for every tree cut down for paper, three are planted through managed certified forests. Fibre based secondary packaging is not evil!"
Strategies to overcome challenges
To educate the public and promote sustainable practices, Lackner suggests that packaging manufacturers should actively engage in public awareness and awareness campaigns. By emphasizing the sustainable nature of paper packaging and dispelling misconceptions, companies can encourage consumers to make environmentally friendly choices. Lackner also stressed the importance of working with industry organizations and participating in sustainability initiatives to drive positive change and create a better future.
By working together, industry organizations and packaging and labeling processors can also develop effective strategies to overcome workforce challenges and stay ahead of regulations in the evolving packaging industry. That's because partnering with organizations gives packaging manufacturers access to valuable resources, networking opportunities, and industry insights.
Lackner also encouraged processors to take advantage of certification roadmaps offered by many organizations. "For example, we make sure our employees are aware of the G7 methodology, we spend a lot of time training our employees, and we've also built what we call 'Folding Carton 101' and '201' courses in-house."
However, processors who don't have the in-house resources to build the same type of programs as Colbert's packaging should not be intimidated. Technical seminars organized by industry organizations provide a platform for companies to learn about the latest trends, technologies and best practices in offset printing operations. In addition, these organizations often have specialized staff overseeing regulatory actions at the state and federal levels. Being an active member of these organizations can help ensure that owners and managers of label and packaging processors and printers are aware of upcoming regulations. Membership also enhances the association's overall advocacy capacity when regulations may be misguided, or when stakeholders outside the industry need further clarification or education on packaging manufacturing issues.
Build capacity to ensure future success
Investing in new equipment is an important aspect of optimizing offset printing operations. The packaging and printing industry is capital-intensive, there is no doubt about it. Investments in new technologies are costly, and don't be short-sighted when making these investments. The cost of trying to catch up with industry advancements is almost prohibitive, so continue to reinvest in the business to keep the technology ahead of the industry.
As an organization, Colbert Packaging uses meeting the future needs of existing customers as the primary benchmark for evaluating the return on investment in equipment upgrades. To this end, Colbert Packaging uses a collaborative approach. "We have a great sales team, and we work closely with them," Lackner said. "They have a great relationship with our customers." Through collaboration between production and sales departments, Colbert Packaging can develop forecasts, budgets and capital acquisitions that allow processors to meet customer needs and respond flexibly as challenges arise.
"When we get to 80 to 85 percent capacity on five days a week, we get very nervous," Lackner said. "So when we get to that point, we like to reinvest because there's always some emergency, quick turnaround, new product launch or other event that challenges our capabilities."
One of Colbert Packaging's most recent investments is the eight-color RMGT 1050 LX 8-color UV + IR press, installed at Colbert's facility in Elkhart, Indiana. Explaining the driving force behind the investment, Lackner said, "We specifically chose eight-color presses because when we evaluated them, we found that many of our customers had multiple jobs, and we now produce them in one go."
Five - or six-color presses may be considered a standard investment for other packaging presses, but Colbert Packaging's customers are increasingly engaged in complex packaging operations. The work required multiple paper walks on Colbert's packaged six-color press. However, this process is not fully effective and does not support Colbert Packaging's growth strategy through capital investment.
Install the new RMGT 1050 LX, a state-of-the-art press that enables Colbert Packaging to efficiently perform seven - or eight-color jobs at a time on a variety of substrates, from lightweight offset paper to cardboard. The press's AGT Combi Chiller monitors and controls the ink system temperature for printing speeds up to 17,100 sheets per hour. When conventional inks need to be run, the Eltosch UV 4-3-3 oven and infrared drying unit for curing UV inks start the drying process. In addition, Colbert's packaged UV dryers feature four press UV lamps that can be reinstalled between units to facilitate the drying of trapping colors as needed.
The full closed-loop color spectrophotometer can also measure colors in detail and coordinate real-time adjustments, providing precise color management and ensuring that each job meets customer specifications without Colbert Packaging having to interrupt print production.
Cultivate a winning culture
Continued capital investment is the cornerstone of shaping an offset printing business that stands the test of time. Peeling back the layers of this vibrant story, however, reveals a profound truth - the road to success doesn't just stem from cutting-edge devices.
Instead, package printers and processors must harness the power of passionate teams. By establishing a culture of engagement and continuous improvement, label and packaging processor owners and managers can develop and continuously nurture work environments that not only embrace innovation, but inspire a genuine desire among employees to reach new heights in individual and collaborative performance. At that point, the printing company can work the magic of the skill and passion of a true printing professional.
