Allpak/Trojan, an award-winning printing and packaging company located in Seattle, installed a KBA Rapida 142 56-inch six-color plus coater sheetfed press in early 2011, reports the printing press manufacturer. This new press compliments an existing KBA Rapida 142 56-inch eight-color sheetfed press with coater and hybrid UV capabilities operating with the KBA Qualitronic II inline sheet inspection system installed in July 2005.
“Growth from our existing large format work had developed to the point where a second press was required,” says Wayne Millage, president of Allpak/Trojan. “After reviewing our product mix, we decided that a six-color plus coater would be the right configuration to support this growth. Based on our experience with KBA’s service and support, combined with the quality and productivity improvements that we have experienced, it was clear to us that our initial view of KBA as a leader with a proven track record in the large format market was an accurate assessment. In order to be a leader and an innovator you must be partnered with and supported by the best suppliers, which we consider KBA to be.”
Significant increase in production capacity
In order to ensure enough room for the new large-format press, Allpak/Trojan needed to remove two existing 40-inch presses in its pressroom. “We’ve found that our KBA presses are so productive that down-stream equipment needed to be added to handle this new capacity,” says Millage. “Although we removed two presses and replaced it with one press, we have significantly increased capacity while keeping manning at existing levels or even slightly less than before. Our customers will benefit in the increased production capacity now available from us.”
In addition to increasing capacity, Allpak/Trojan is gaining greater savings and quality and providing benefits to its environmental commitment. “The savings in paper from a 56-inch sheet compared to a 40-inch sheet surprised even us,” commented Millage. “Technically the 56-inch sheet is twice as big as a 40-inch sheet but we typically get 125% more product on the larger sheet size. Quality is quite important too and what we get from our KBA presses is rock-solid predictable and consistent quality from sheet number one to one million,” says Millage. “The new KBA press allows us to continue the high level quality our customers have come to expect from us. And we can rest assured the quality level will match what they’ve come to expect form our existing eight-color KBA.”
Reduced waste equals environmental benefits
Allpak/Trojan’s commitment to the environment was maintained with the new press installation. The firm has significantly reduced waste, according to Millage, especially make-ready waste with the new Rapida press. The wash-up chemistry and ink waste was brought down considerably with the addition of the automatic ink dispensing as well, he recalls.
“As a high production facility it was important for us to be comfortable in the knowledge that we could install a new press and get up to full production as quickly as possible,” says Millage. “Ever since our first KBA press was installed, we have been extremely impressed with how quickly and efficiently the KBA installation team works.”
Founded in 1950, Allpak/Trojan provides high-end commercial printing and innovative packaging solutions. Allpak/Trojan also offers in-house graphic and structural design; point-of-purchase displays; pack and assembly services; all under one roof.
KBA North America is located in Dallas, Texas and a member of the KBA Group. Established 194 years ago in Wuerzburg, Germany, Koenig & Bauer AG (KBA), the parent of the KBA group, is the oldest and second largest press manufacturer worldwide. KBA's banner, 'People & Print', reflects its dual focus as a leading innovator for print entrepreneurs. The group's product range is the broadest in the industry; its portfolio includes commercial and newspaper web presses, sheetfed offset presses in all format classes, special presses for books, inserts, banknotes, securities, metal-decorating, smart cards; CDs and DVDs plus inkjet and other coding systems. For more information visit the company's web site at www.kba.com