THE FLYING PRESS INSTALL THE FIRST DUPLO INLINE TRIMMER
10 Aug 2010
The Flying Press have installed the UK's first DKT-200 trimmer to their existing System 5000 bookletmaker, resulting in an inline three-knife trimming solution saving the company "up to 100 man hours on one job alone".
The Oxfordshire-based company has undergone a strategy of 'continual upgrade' of Duplo bookletmakers over a period of twelve years; starting with a DBM-100 in 1998, then DBM-200 in 2003 and finally the System 5000 in 2008.
Managing Director, Stuart Cope explains this growth; "We started with a 6 tower suction system from Duplo, and the modularity of their systems has allowed us to steadily improve our bookletmaking capabilities without breaking the bank everytime."
"Our business has a customer-first ethos coupled with a passionate drive for continual improved efficiency. We are a large company, with only 6 employees, and our trust is on our plant list to deliver and cater for our customers' demand. The addition of the extra two knives on the bookletmaker just seemed natural to us."
Cope first saw the DKT-200 at this year's IPEX exhibition and it is an extra module which trims all open sides of a booklet removing the need to pre-guillotine printed pages before collating, saving both time and money. Forming part of Duplo's System 5000, the new unit trims the head and foot of completed booklets, brochures and other business collateral. The online trimmer is capable of producing up to 4,500 A5 books an hour or 9,000 books an hour when fitted with the optional gutter cut knives.
Flying Press' policy for low overheads, low labour and low cost has enabled them to remain extremely competitive in both the litho and digital market. They have grown 32% between 2009 and 2010, and have been able to compete in the short run market, 'taking business from local digital printers because of our low prices'. As Stuart explains, the introduction of the DKT-200 was a major part of this efficiency drive.
"We have a magazine job three times a year, which means we are literally flat out for two weeks non stop. With the new three knife trim bookletmaking line, we have saved 30 man hours every time we run the job. That is nearly 100 hours saved, on one job, per year".
As well as the clear business benefits, the operators are also very happy with the new investment. Justin Bury, Finishing Manager explains; "The benefits are two fold. We save so much time by going straight from press to bookletmaker. Not only does guillotining take time but in clamping down on the sheets, it takes the air out of the stack, so we used to have to fan the sheets before placing them into the towers. On the other side, it is the quality finish. By trimming all three open edges in one process you gain a naturally squarer book. Our customers are commenting on the difference."
The Flying Press have also enhanced their finishing capabilities with the purchase of Duplo's new DB-280 Perfect Binder. The first perfect binder ever purchased at the site, it has replaced the former glue pad/staple/tape process that was used. Not only has it improved the look of the perfect bound books, it has speeded the whole process up.
"Gluing and padding is very time consuming. With the new binder we can now turn a job around the same day as opposed to the next day, plus the finish is far more professional. Within ten minutes it is out the door. The DB-280 has been a catalyst for a very quick organic growth for our perfect binding, with repeat business and referral work growing due to the improved service."
For the future, The Flying Press are looking to expand via acquisition, and have recently bought a one and two colour stationery printer in the local area. It is clear what Stuart's plans are for this new venture.
"I will do what I have done here. I will start with a blank sheet of paper, understand the customer's needs and ensure they receive the best service possible, using whatever machines are required. I believe that modern print is less about 'fine art' and more about being a business; and this philosophy has served us well and enabled us to grow."
Contact: Samantha Mee
International Marketing Communications Manager
Telephone: +44 (0)1932 263 900
Email: samantha.mee@duplointernational.com
Download: TheFlyingPress.pdf
Images: The Flying Press Duplo DKT 200 Stuart Cope.zip
