Print Project SA
Be Water My Friend
Introduction
• Printing World
• Print Chain
• Printing Technologies
Print chain
Brand
Design
company
Printing
Printing elements
Manufacturing
Printing Technologies
• Offset (High quality, medium printing
speed)
• Rotogravure (Good quality, hihg printing
speed)
• Flexography (Low quality, medium
printing speed)
• Others…
Our Company
1.WHAT
2.HOW
3.WHERE
4.Current situation
1. WHAT
Integral rotogravure process for all kind of
customers (packaging, edition,
decoration...) offering customers a quick
commitment between response and
quality, at market prices.
1. WHAT
• What does “integral process” mean?
Print Project SA is able to handle the
whole process, designing the product
image for the Brand and engraving
cylinders with advanced methods and
equipment.
2. HOW
Integral process:
- Graphic design
- Engraving
2. HOW
Graphic Design:
Split the product image colour into several basic
colours, as many as inks are going to be
used in printing process, because each ink
will require one cylinder
Repeat that basic colour image along the
cylinder
2. HOW
• Graphic Design Equipment:
• 3 working stations
– Hardware MacIntosh G4, G5.
– Artpro sofware
• HP plotter 8500 pps. (Low resolution, big
format)
• Printer EPSON pro 7600. (High resolution)
2.HOW
• Engraving process
• Material to be engraved is a cylinder property
of printer.
• Cylinder can be re-engraved with diferent
designs
• Process is diferent depending on cylinder
status (new, old)
2. HOW
• Machinery:
– Engraving
•
•
•
•
•
•
•
3 digital engravers Helio Klishograph.
2 Chrome baths Chromstar.
2 Copper baths Bolstar.
1 Nickel Iron bath Combistar
1 CFM k. Walter
1 rectifier Polishmaster
1 Testing heaford
How cylinder looks like
Alternative #1 New steel
bases: Nickel iron bath
Combistar
Alternative #2 Old cylinder:
Dechrome bath
Common process:
Copper baths Bolstar
Copper rectification
(Polishmaster)
Engraving (Helio
Klishograph)
Chrome bath Chromstar
Final polishing: CFM
Printing proof: Heaford
machine
• Quality check with real printing
conditions:
– Material
– Ink
– Engraved cylinder
– Print process parameters
3.WHERE
• Print Project SA is located at 10 km
south of Barcelona, in Viladecans (Prat
del Llobregat).
• Established in 1993.
• Weakness: Long transport distance
afects on price and delivery time.
4. Current situation
•
•
•
•
Sales
Annual Acounts
Competitors
Market
4. Current situation Sales
(thousand €)
2001
2002
872
600
420
532
400
444
Base copper
16
8
8
8
8
8
Graphic Design
60
60
60
60
60
60
948
668
488
600
468
512
Engraving
Total sales
2003 2004 2005 2006
4. Current situation Annual
Profit & Loss
1.200.000
1.000.000
800.000
600.000
EBT
inmov+financ
400.000
other
personnel
material
200.000
0
2001
-200.000
-400.000
2002
2003
2004
2005
4. Current situation
Competitors (year 2005)
4.500.000
4.000.000
3.500.000
3.000.000
2.500.000
EBT
inmov+financ
2.000.000
other
personnel
1.500.000
material
1.000.000
500.000
0
Zrba
-500.000
M.grab
Grabac
Jan.esp
Tecgraf
SPH
Jan.Bu
Rdinsa
Gcilsa
Print Project
HM
4. Current situation Market
• Spanish market is estimate in 90.000
cylinders per year, steady.
• Our market quota is between 1 - 2 %
decreasing every year
10 OM Decisions
•
•
•
•
•
•
•
•
•
•
Goods & service design
Quality
Process & capacity design
Location selection
Layout design
Human resource and job design
Supply-chain management
Inventory
Scheduling
Maintenance
10 OM Decisions
• Goods & service design
 Print Project SA was born with the goal of providing
customers full response in their needs.
 Its designing capability is assured by the high tech
equipment.
 On the other hand, an optimal cost-quality balance is
pursued.
10 OM Decisions
• Quality
 An extraordinary effort by the company aquiring the best machinery
allows Print Project SA to guarantee the quality of all its products.
 Therefore, all the cylinders produced are tested under electronic
microscopes to verify them.
10 OM Decisions
• Process & capacity design
 The production of Print Project SA is focused nowadays in
the grave process. This technology supplies a great part of
the market.
 With high capacity computers, the design capability is also
guaranteed.
 However, our proposition for new service is to provide the
firm a bigger capacity by introducing a paralel technology:
Flex.
10 OM Decisions
• Location selection
 Being a little company, Print Project SA have only a
single location, near Barcelona.
 The proximity to Barcelona, the 2nd biggest city in
Spain, guarantees a complete and fast response of
transports and providers.
 However, the long distance from Barcelona to many
parts of Spain is one of the main weaknesses of the
firm.
10 OM Decisions
• Layout design
 Print Project SA is a small company, with a simple
organization which involves 2 main sections:
• Design
• Production
10 OM Decisions
• Human resource and job design
 The company staff is formed by 10 people. Originally
formed by 16 people.
 7 employees in production, 3 in design.
 One of the main basis of the firm is its well trained staff,
which allows to make value-added products.
 Our proposal for new service is focused on taking more
advantage on the current staff.
10 OM Decisions
• Supply-chain management
 Print Project SA commitment of fast delivery of its
products begins with the reception of the raw
material. A well structure net of providers is
needed.
10 OM Decisions
• Inventory
 As long as Print Project SA works individually with
each customer, and its work sector is quite
concrete, inventory needs are not a big problem.
10 OM Decisions
• Scheduling
 The quick response and delivery is one of
the main worries of Print Project SA.
 The Location seems to generate problems
in this subject.
10 OM Decisions
• Maintenance
• The company tries to give fast and efficient
after sale service to all the costumers.
• However, the hard quality controls minimize
the devolutions and the maintenance
problems.
What about future?
• Alternatives:
– Automatic line
– Diversification (Flexo)
– Sale the company
– Close the company
Automatic line
• It needs less employees so decrease
price cylinders in productions higher
than 400 clynders per year.
• Problem: Our company only produces
around 1000 cylinders per year. We
cant aford it.
Diversification (Flexo)
The engrave market is stable, it had been
the most quality print technology but
nowadays Flexo is growing (digital
quality, low peices)
Diversification (Flexo)
• Objective:
– Offer costumers others print elements for
diferent print systems with similar graphics
results
– Optimize our excessive personal and
design equipment working in both
techniques.
Diversification (Flexo)
• Production & capacities
– Investment necessary: A laser polymer
engraver (Helio Flex, about 400.000 €)
Diversification (Flexo)
The raw material this time will be “polymer
tablets”, and it costs 120€/m2 .
Basf and DuPont can sell to us.
– The machine has a procces capacity of 30
polymers/day
– Sale price: 200 €
Diversification (Flexo)
• In less than one year we will have
amortized our investment.
• This seems the real alternative to grow
up the company.
SOURCES
• Accounting data
• “Registro Mercantil” which is public. Offered digitally with a
suscription in www.axesor.es
• Machinery
• Hell gravure systems (German manufacturer)
– www.hell-gravure-systems.com
• Photogravure process
• The subsidiary of Janoschka (www.janoschka.com) in Alzira
has helped us with some useful information.