Going computer to plate has saved in-plants time and money while speeding up production and boosting efficiency. Find out how you can benefit.
Up until last year, Rutgers University Mail and Document Services handled prepress pretty much the way it always had. Whenever an offset job came through its doors, the 15-employee in-plant went straight to its 3M camera to shoot negatives.
Then, last year, an opportunity arose.
"We were re-tooling the department and we had a decision to make," says Jesse Rambo, director of the New Brunswick, N.J.-based in-plant. That decision resulted in the installation of an A.B.Dick Itek DPM2000 platesetter to output polyester plates.
The in-plant has not looked back.
"Our workflow has really been tremendously improved," Rambo enthuses. The time saved has allowed him to keep almost every job in-house. "Everything stays within us now."
Assistant Director Don Marciano adds that the computer-to-plate (CTP) system saves a half-hour on every plate. From the click of the button, it takes only three-and-a-half minutes to produce a finished plate.
"It saves a lot of time on design work too," he observes. "Our designers don't have to shoot plates."
All across the country, in-plants are unloading their film-based workflows in favor of the cost savings, speed and ease of computer-to-plate technology. According to a recent IPG survey, 17.1 percent of all in-plants have installed platesetters, with an additional 7.7 percent saying they plan to add CTP equipment in the next 18 months. CTP allows them to boost production, store jobs electronically, lower material costs and cut waste.
Frank Savino has realized all of these benefits and more at Yale University Reprographics and Imaging Services, which added an A.B.Dick DPM2000 four years ago.
"You don't have to produce and strip film then process, burn and produce a plate," he notes, adding, "It removes extra chance of human error."
Just the efficiency of the machine, he remarks, is enough to justify having it.
"We're always a step ahead as far as technology," he says.
What About Quality?
Many in-plants opt for platesetters that output polyester plates. Though non-believers are skeptical about the quality and durability of these plates, users encounter few problems.
Savino heard the rumors about polyester plates bending, stretching wearing down and going out of register, but experienced none of this at his 75-employee operation, based in New Haven, Conn.
"The consistency factor is unbelievable," he exclaims. "From one job to the next, the placement on the plate is in exactly the same place."
Jesse Rambo agrees about the quality of work.
"We haven't seen any distortion in runs up to 25,000," he reports.
Both he and Marciano say they haven't had a problem with the polyester plates stretching or wearing down on the press.
Still, just to be safe, Rambo says, "We do watch our count. When we get to a certain point, we generate another plate."
Rambo states that because the design is stored in the computer, the brief amount of time it takes to generate a second plate doesn't cost them much during the run.
Time Is Money
Rambo did a cost analysis before purchasing the platesetter and estimated that the machine would pay for itself in 12 months.
He was wrong—it took eight.
"When you buy a piece of equipment and the return on investment is eight months, that sounds pretty good to me," he says.
Rambo estimates the machine cuts two to five days off every job, since he previously had no platemaking capabilities and had to have plates made outside. With 250 jobs a month going through the in-plant, that's some heavy savings.
Then there are the supply costs. Rambo says a polyester plate costs roughly $7.50 to produce, as opposed to a metal plate which, when produced using the traditional methods, can cost as much as $33.
"Just on the cost of metal vs. poly we've probably saved $40,000, not counting turnaround and quality," he reports.
Russell Gayer, manager of Tyson Foods Printing Services, in Springdale, Ark., reports similar savings.
The 62-person in-plant produces mostly flexo labels for the poultry industry, but does a good amount of sheetfed offset work. Gayer purchased an imagesetter in October and in April started using it to output polyester plates. The results were better than advertised.
"We're getting good quality off it," Gayer says. "We've saved time and saved money."
Gayer estimates that going CTP saves his in-plant eight hours a month and, including parts and labor, will save roughly $26,000 a year.
No Size Restrictions
CTP isn't just for the big guys. The seven-person in-plant at the Millcreek School District, in Erie, Pa., purchased an A.B.Dick DPM2000 three years ago. Printing Supervisor Tim Vargulich couldn't be happier with the equipment.
"Some of my jobs, I bet the prepress [is] cut in half at least, if not more, once the design's made," he says. "That translates into economic savings."
With the money saved, Vargulich was able to take on student projects like yearbooks and recipe books.
The in-plant averages run lengths of 23,000, perfect for a polyester platemaker.
"The quality is excellent," Vargulich declares. The platesetter produces customized plates for both his A.B.Dick and Toko presses, he says, and they fit perfectly.
Possible Drawbacks
None of these managers regrets the move to CTP, but they do indicate a few things to watch for.
"You have to be pretty careful in handling the material," Tyson Foods' Gayer says of polyester plates. "A thumbprint can pick up ink. It's just like handling a piece of film, practically. But, once you get that down in your procedure, it's no big deal."
Rutgers' Marciano advises in-plants to keep the machine clean. He schedules preventative maintenance to ensure the machine runs properly.
Overall, though, managers say the advantages far outweigh the concerns.
"We Love it," affirms Rambo. "We can't imagine going back."
Metal Solution
Polyester plate CTP devices aren't the answer for everyone. When run lengths exceed 1 million, metal plates are essential. That's why Allstate Insurance went with two Creo Trendsetters for its 350-employee in-plant, in Wheeling, Ill. One is used to proof, and the other outputs metal plates for Allstate's six sheetfed offset presses. The in-plant plans to use platesetting equipment for its eight web presses in the near future.
Bob Tierney, director of print operations, says the in-plant experienced dramatic improvements in speed and registration, and significant savings on supplies.
"The biggest dramatic effect is that it is quicker to press," he reports. Tierney estimates a 30 percent reduction of time spent in prepress.
Though the designers experienced a few bumps during the learning process, he says, "as you work through it, you gain valuable experience."
Tierney cautions that when making the transition to CTP, you should take things slowly.
"The most important thing to remember is that it is an evolution, not a revolution," he advises. "You can't do everything at once."
by Joe Ranoia