Digital implementation has always been

Top-tier golf provider Titleist packs golf balls in a personalized box, and Odyssey's POP printing plant incorporates cutting-edge, high-speed digital die-cutting technology to not only use roller digital presses to print custom-made point-of-sale display ads. And the development of a quick technical channel to connect to customers' online ordering systems coincides with the needs of Titleist. Odyssey has always confirmed its strength by providing consistent and high-quality packaging products to the world's most famous brands.

When the Titleist needed a personalized box to hold the golf ball, its print broker was almost stumped. Perhaps Titleist is surprisingly described as they have been selling custom-printed golf balls — with an easy-to-use ordering system on their web pages.

However, the company wants online customers to upload their favorite stadium images from the link address, so that they can produce unique products for them to increase their attractiveness.

The Xeikon 50SP's digital press produced Titlet's ready-to-die "PackEdge" carton. The personalized box is printed with golfer's favorite court image.

Duplex Web Press The Xeikon 50D has a unique flash chamber that can print a wide range of hues onto the surface of the substrate suspended on the rollers leading to the flash chamber.

Soon, the agent thought of Odyssey Digital Printing, a nine-year “print on demand” expert. The company is located in Taksa, Oklahoma, with digital printing and digital die cutting as its main business. The 33,000-square-foot facility houses two US-based Heidelberg sheet-fed digital presses, two Xeikon America roll-fed digital presses, and an MGE digital die-cutter, and currently employs 55 people. The commercial and packaging printing company has been using Xeikon America's roll digital presses for some time to print custom-made point-of-sale display advertising (POP). And it has developed a fast technical path to connect to customers' online ordering systems so that these retail outlets from soft drink vending machines to gas stations in the United States can specify the specific requirements of all their orders.

POPs occupy 80% of business

In 2002, 55 employees at Odyssey moved to a 33,000-square-foot facility, expanding the original area by three times to accommodate new large-format equipment. "POP accounts for 80% of our business," said John Roberds, chairman of the company with $6.6 million in assets. The two advertising agencies represented eight self-service food chain stores and occupied most of Odyssey's business. There are two Heidelberg company Quickman DI 46-4 printing systems for newsletters and large-format POP printing, and two Xeikons presses—50D and 50SP.

“Our main goal is to change the way customers look at print, and convenience is the number one advantage,” said Roberds. From a broader perspective, it is the use of digital printing to integrate end products, making this wish possible.

"Most of the year, the factory has implemented a two-shift system. The print resolution of two dry-color digital presses is comparable to a 2,400-dpi Plate-making machine," Roberds said. The Xeikon 50SP can print on one side, while the full-duplex 50D printer can print on both sides of the register at the same time. Odyssey uses Xeikon equipment for web, vinyl, polyester, and polystyrene printing. The maximum thickness of the ink layer on a 16-pt (g/cm3) board is 27 lbs.


In a digital environment, MGE's Type I digital die-cutting machine uses optical technology (including software and cameras) to obtain high-precision registration.

Feeding heavier rolls of substrates (10- to 16-pt rolls) for the press can complicate the printing process. "When the substrate is very thick, the process of color ink fixing will be different from that of thinner substrates," he said. He also emphatically explained the challenge of using Xeikon technology to deal with the problem. “After the color ink is transferred out of the ink tank, its particles should always be consistent when it reaches the “substrate”, and the registration is accurate.”

Short version packaging orders are strong

Maintaining the reliability of the color ink during the printing process is critical. Digital presses do not require the usual gears and mechanized registration systems that are common on traditional presses, but registering on digital equipment requires specialized techniques. The auxiliary system for the production of customized short-form packaging containers for Titleist custom-customized golf packages is based on a system for producing CDs and home video tape (VHS) packages. An off-line integrated roll coater can apply a protective layer on the surface of the substrate prior to digital die cutting. The unique I-die die-cut digital terminal solution from Mikkelsen Graphic Engineering - MGE transformed a large number of mixed printing and packaging rolls into a single packaging unit.

"Short-lived - up to half a dozen types of golf boxes, CD shrink sleeves and VHS boxes - is an easy task," Roberds said.

Based on MGE's unique "visual" technology, the digital die-cutting system consists of Zund's die-cutting tables, friction wheels, computer system files that set the die-cut shape, and black registration points that can be printed on the packaging printed by Xeikons. MGE camera system consists of. A large number of barcodes are stored in die-cutting software to identify the packaging design drawings. In order to solve the inconsistencies caused by the repeated printing in the digital realm, the software and the camera together determine the location of the first registration point. Then, either CAD or Adobe Illustrator software is used to automatically adjust the die cutting parameters to compensate for all non-registered or image stretch conditions and to send instructions to the die cutter head.

"It only takes two minutes to change the die-cutting machine, and a sheet-fed press takes 30 minutes," Roberds cautioned. Odyssey used Xeikon/MGE's digital die-cutting machines to perform other complex tasks, including a poster with a beverage graphic placed in front of the soft drink machine to highlight a box of special products or images with a special die-cut pattern; for specific Applied special-shaped magnetic sheet.

The web width of up to 20 inches and the unlimited length is an important feature of the Xeikon roll press, Roberds said. "This means that the customer's product is not limited by the special paper size. Because of its roller feed nature, the 50D is very versatile. Odyssey was recommended to Titleist because of our fully digital production process, and Titleist is on a single order. The deadline for delivery is three days," Roberds said.

Titleist occupies 75% of the custom golf market, offering diamond grade “PackEdge” products to its customers. Its cardboard boxes are printed with golfer’s favourite court images. Odyssey receives 40 to 50 such orders every week on average, so automating the workflow is critical. At the beginning, in order to meet the special requirements of each client, graphic files were created on-site by Titleist artists. Now, orders are sent by e-mail from the customer's sales staff. The box's surface graphic file is in PDF format, and the box and package files can be uploaded to FTP. Since this work needs to maintain its consistency in terms of design, most of the die cutting is done on the Series III standard die-cutting presses provided by Preco Industries. "This is our heavy-duty equipment," Roberds said. "But it's very productive."


Source of information: packagingdigest china


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