The Caribbean company, with the continual support of Comexi, has acquired an F2 MB flexographic press, an SL2 laminator and an S2 DS slitter

One Caribbean Flexipac Industries and Solutions, a company in Trinidad and Tobago, without prior experience in the flexible packaging sector, has managed to position itself as the leader of the flexographic industry in the country, as a result of the mentoring it received from the Manel Xifra Boada Technology Center (Comexi CTec), specialized in training, advice, and technical process support for the printing and converting sectors of flexible packaging industry. In 2018, the Caribbean company purchased a Comexi F2 MB flexo press, a Comexi SL2 laminator, and a Comexi S2 DS slitter. Presently, two years later, after receiving comprehensive training at both its facility and Comexi‘s headquarters in Riudellots de la Selva, One Caribbean Flexipac Industries and Solutions has obtained the maximum use from these machines.

“Rhett Gordon, the manager of the company, contacted us in 2015, after realizing that flexible packaging, a sector without converters in the country, was the company’s future in Trinidad and Tobago,” explains José Luis Soriano, Comexi’s Area Manager of this zone. Gordon, who until then was dedicated to commercial offset printing, had the complicity and experience of Comexi to start this new adventure. “Together with Albert López, the head of the Comexi CTec, we advised him on the needed machinery began a long process, which has culminated with the commissioning of the first enterely new flexible packaging plant in Trinidad and Tobago.”

“The guidance and support of the project, from the moment of the contract signing, has been crucial to the final success of the installation and production entry of One Caribbean Flexipac Industries and Solutions,” says Albert López, who adds that the Trinidad and Tobago company “has worked almost autonomously from the first day it entered production, although at the beginning, the company accomplished this with the support and monitoring of the Manel Xifra Boada Technology Center production advisory team.”

The One Caribbean Flexipac Industries and Solutions production staff received advisory training weeks before the machines were shipped. “As a result, it was possible to foresee and correct varied situations and procedures, guaranteeing that the optimum productive performance curve was adequate in less time than usual,” says Albert López.

One Caribbean Flexipac Industries and Solutions, founded in 2018, is dedicated to manufacturing a wide range of packaging material. The company is part of One Caribbean Media Limited, which is the largest and most diverse media organization in the Caribbean region. One Caribbean Media Limited has businesses investments in newspapers, radio, television, internet, printing and distribution.

“Our relationship with Comexi is truly one founded on the responsiveness and willingness to share knowledge, expertise and experience”, stresses Rhett Gordon, who adds “with a background in offset printing and committment to converting to flexography, the challenge was immense and technology was different. However, Comexi, particularly Albert López and José Luis Soriano, made themselves available and never evaded the responsibility to answer the litany of questions and concerns. They always responded to our emails and never gave up on this transaction.”

Gordon admits that Comexi’s guidance and support from 2015 to 2018 has been crucial, and that presently One Caribbean Flexipac Industries and Solutions “is well on its way to becoming the supplier of choice for all the major local manufacturers that externally source their packaging to Central America, India, China, and the USA”. To conclude, the manager of the Caribbean company claims that “the equipment of Comexi has performed to our expectations and technical support has been excellent. Furthermore, ongoing training and access to numerous Comexi CTec facilities have also meet all expectations. Within 12 months, we expect to begin discussions regarding the purchase of a second flexo press, and have no intentions, while I am involved, on seeking alternative equipment.”

The equipment of Comexi

The Comexi F2 MB press is an advanced machine designed to satisfy the medium run print needs in the flexible packaging sector of the retail and wholesale channels. This flexographic press shares the patented FLEXOEfficiency concepts of ergonomics and accessibility, as well as the level of performance and robustness with the rest of the Comexi F2 range. Moreover, all of this is integrated with a simplified drying system design. Irrefutably, the Comexi F2 MB is a high performing and productive machine.

The Comexi SL2 design, due to its uncomplicated ability and state-of-the-art controls, is the ideal short and medium run laminator for a wide variety of materials, as well as the perfect solution for solventless lamination. This machine has been designed to comply with productivity concepts and operation simplicity. The Comexi SL2 possesses an extremely intuitive environmental nuance and has an exclusive applicator head design, which consists of complete motorisation, the use of metering sleeves, and the option of incorporating automatic change turrets.

The Comexi S2 DS slitter is a compact and fully electric machine with an ergonomic design. It permits adjustments and manoeuvres the slitting after the material has proceeded. The NIP system, which separates tensions, enables the machine to use various tensions while rewinding and unwinding. Quality and quantity are not incompatible with the Comexi S2 DS, due to the high productivity which is achieved by acceleration ratios. All of this is accomplished through reaching top speed at a quick rate. Operation with this slitter is straightforward and intuitive, due to tools such as the PC Touch-Panel, which is used to set the pace of the machine, and store production data.

The Technological Center of Comexi uses new technologies to perform demonstrations and stream training for its clients

The Manel Xifra Boada Technology Center, Comexi CTec, specialized in training, advice, and technical process support for the printing and converting sectors of flexible packaging industry, has adapted its methodology of production support in order to implement and remotely monitor improvement and efficiency programs. Remote Serviflex, the resulting modular program which offers the integration of all optimization tools, detects and minimizes inefficiencies, improves processes, and enhances machine operation. This program, on average, renders a 10-30% improvement, regarding customer.

Remote Serviflex allows customers to optimize changeover time, reduce color adjustment waste, increase printing speed, and eliminate unexpected cessations. Through Comexi Cloud, the most innovative digital platform that assists customers with improving the performance of their plants, production data is analyzed to understand work systems and detect improvements. Furthermore, the use of Comexi Smart Glasses, a remote communication system that allows information sharing, in real time visibility, between field technicians and support departments, promotes the implementation of efficient methodologies, training, and operational support.

This modular program, which includes consulting, coaching, online training, webinars, virtual guidance, streaming demo, and redesigning of standard operations, is divided into and developed through three modules: monitoring, operation Improvement, and consolidation and new targets.

The Comexi CTec also uses new technologies to conduct live streaming webinars, which guarantee personalized group learning and attention in real time. Process managers and professionals, who wish to learn and deepen their knowledge, are the target audience of these courses. Training workshops in lamination defect solutions, printing defect solutions, color management, and flexographic printing production efficiency have been given in various languages, including Spanish, English, French, Portuguese and Russian. Thus far, these courses, which will continue throughout the upcoming months and expand to include other topics, have been taught with success, in reference to participation, which averages an attendance of 14 people per course.

Furthermore, Comexi CTec streams personalized demonstrations for customers, which has replaced face-to-face demonstrations. Due to current circumstances, travel is impossible, and demonstrations cannot be performed at Comexi facilities. These machine demonstrations are conducted with the custom designs sent by clients, and the most up-to-date Comexi technologies, including Smart Glasses.

The project implementation of a complete conversion plant is highlighted, as are the new training courses, which showed an increase in the number of attendees at both Comexi CTec and the facilities of customers

The Manel Xifra Boada Technological Center, Comexi CTec, maintains its line of growth, as is visible in the results of 2019, which showed a contracting increase of more than 15%, particularly in reference to all its service areas, including the project implementation of a full plant conversion and training courses. Noteworthy, is the exceptionally significant increase of attendees, in courses held at Comexi as well as those conducted at the facilities of customers.

Last year, CTec, a specialist in advice and technical services for the impression and conversion of the flexible packaging industry, exceeded, for the first time since its creation, over 200 participants in training courses at its Riudellots de la Selva (Girona) facility; the total number of participants was 208 for 2019. Furthermore, the Technological Center has seen participation in technical and advanced training courses increase, with the enrolment of 177 students, the highest number of participants since being offered in 2010.

“Since 2018, we have maintained, with high added value, the manner in which we conduct specialized training and demonstrations,” says Albert López, head of the Technological Center, who assuredly values the increase of clients who have trained at CTec as those who have participated in one of the personalized formations, which was more than 30. The number of companies relocated to Riudellots de la Selva, in order to participate in exclusive sessions also increased.

Serviflex, the advisory and training service that Comexi CTec performs at the facility of a client, increased in number by 16 during 2019, reaching 57 since the company began offering this service. In regard to industrial demonstrations and tests, during the second half of last year there was a considerable increase in those dedicated to Offset Technology; in 2019 there were 255.

The Turnkey Project: An Upward Trend

One of the principal novelties of 2019 was the turnkey project, through which constant advice is offered to the client from the beginning of the process, and culminates when both parties achieve the desired result. “At CTec we support customers from the moment they acquire the project to the final productivity phase, offering customers permanent training”, summarizes Albert López. The project begins with the definition and implementation of a new business model, continues with the definition of the action planning program, the monitoring of the business implementation phases, and culminates with the analysis and monitoring of results, in reference to production. The employees of the customer receive training both at the beginning and throughout the process.

New Training Courses and Online webinars in 2020

The primary innovations to Comexi CTec training courses for 2020 include a prepress course, offered in July, and an additional laser slitting operational course, offered in October; the language of both courses is Spanish. Furthermore, two formations, a technical colour seminar and an advanced lamination session, have been scheduled for October at the new Comexi Technological Center, located in Miami, USA.

There will also be advanced sessions in flexographic printing (language: Spanish and English), lamination (language: Spanish, English and Russian), as well as slitting (language: English), solution of printing defects and standardization (language: Spanish), fundamentals of flexographic printing (language: Spanish), practical maintenance course (language: Spanish and English) and a technical color seminar (language: Spanish, English and Russian).

Furthermore, Comexi CTec has scheduled various live online streaming webinars, which guarantee personalized group learning in real time. Process managers and professionals, who wish to learn and deepen their knowledge, are the target audience of these courses. The next formations are Lamination troubleshooting (April 22nd), Troubleshooting: Gosting efect and Back trapping (April 24th), and Colour Management (April 29th).

A hundred professionals from 30 of the sector’s most important companies in Argentina, Paraguay and Uruguay know first-hand the advantages of this system

The extended gamut printing system was the main point of interest of the technical seminar that Comexi, a global leader in the flexible packaging industry, held in Buenos Aires on May 10^th. At the event, a hundred professionals from 30 of the most important Argentinian companies in the sector, as well as those from Paraguay and Uruguay, had the opportunity to learn first-hand the main advantages of this printing system, due to the speech giving by Yago Luling, Technical Advisor of the Manel Xifra Boada Technological Center, Comexi CTec.

“Today, this is a subject that is of interest to most converters, but many of them do not know how to move forward in extended gamut,” says Manuel Muntadas, Comexi’s regional representative for this area. Muntadas emphasizes that the intervention of Luling “was one of the most interesting for all the attendees”. Taking all of this into consideration, José Luis Soriano, Comexi’s Area Manager in Latin America, points out that given the reality many converters are evaluating the possibility of implementing the extended gamut in their plants. He states that “Comexi wanted to explain the complexity of this implementation, the advantages of the process, and also its limitations, which in many cases are not clearly defined.”

Soriano, who was in charge of welcoming all the participants to the event, intervened on different occasions throughout the seminar to talk about Comexi’s innovations in flexography and digital services, as well as everything related to the offset technology with central drum, an aspect that also generated a lot of interest among the attending professionals. Albert Torrent, Brand Manager of the Slitting Business Unit, detailed everything associated to this technology and automation in the conversion processes, while Yago Luling took the floor again to discuss colour management in flexography.

The technical seminar, organized by Comexi, had the collaboration of the company’s different partners, such as Siegwerk, Apex, MacDermid and Tesa. The representatives of these companies also gave interesting speeches that pleased the attendees.

“The balance of the day was very positive. The customers were very satisfied with the technical level of the presentations offered”, says Manuel Muntadas, who adds that “Comexi’s perception as a global technology and service provider has been reinforced as a result of the seminar. The attending professionals greatly appreciate events such as these organized by the suppliers of the machines. We have received very positive feedback from the attendees congratulating us both for the great power of convocation and for the organization of the day itself.”

The event faced new sustainable printing solutions for the current market trends

Comexi, a global leader in the flexible packaging industry, organized a successful seminar on April 3rd in Belgrade, for Serbia and the Balkans countries. The event faced new sustainable printing solutions for the current market trends; to this end, Comexi sent its best specialists to give high-quality speeches to more than 30 professionals who participated in the seminar. These conferences are in accordance with the experience and knowledge of the Manel Xifra Boada Technology Center (Comexi CTec), which is the driving force behind the flexible packaging sector.

On behalf of Comexi, and for such an important occasion for the company, Carles Rodríguez, (Lamination and Offset Brand Manager), Albert Torrent (Slitting Brand Manager), and Alessandro D’Agostino (Area Manager for this region), were the speakers leading the seminar, along with Nikola Biga and Jovan Stankovic, Comexi’s representatives in Serbia.

Rodríguez discussed the recyclability of flexible packaging by reducing the number of layers and using recyclable materials. He explained, with great detail, high technological coatings for finishings, optical effects, barrier properties, UV filters, COF modification, and a vast array of different applications. The brand manager also spoke about the primary advantages of the CI offset printing technology, a robust machine equipped with an EB ink curing system, which is completely solventless. Its high print quality and quick-change capability, along with the low production cost of plates and automatic sleeve changeover, are some of the principal elements that characterize this innovative press. The Comexi CI8 is the perfect solution for the best time-to-market.

The Brand manager of Comexi’s lamination business unit also commented on new flexo trolley applications, the new holographic KIT for multi-purpose laminations and more sustainable packaging water based adhesives.

Albert Torrent addressed maximizing the use of Slitting systems and Laser applications, connecting current market trends with a laser module integrated with Comexi’s slitters, and decreasing the current production costs through the system’s automation. The Laser system allows converters to quickly and easily differentiate themselves from the competition, providing a multitude of applications such as easy open systems, the creation of windows, micro perforations, or the insertion of codes. All of this brings added value to the customer, making life less complicated for end consumers of the packaging. This is a key technology that makes a difference and optimizes production, in turn, following the demands and trends of the market. The system is characterized by control, precision, and speed, allowing for customization, differentiation, and the performance of a wide range of applications and finishes.

Alessandro D’Agostino talked about Comexi CTec as a center specialist in advice and technical services for the impression and conversion of flexible packaging, novelties in flexo technology and the digital service platform, as well as the various Comexi services available to its customers in terms of quality, R&D, processes and systems, and online ordering.

During the seminar there was also an important emphasis on the Comexi Cloud, the most cutting-edge digital platform for the converting sector which is composed of different digital services linked to the machines and the data these machines generate. Production Analytics is the fastest and easiest way to analyse production, understand data and processes, as well as know the job cost of the printing and converting process. This data gives the customer relevant production information enabling them to make the most appropriate decisions. Through the data automatically being taken by the machine, including consumption of energy, inks and consumables, the module provides the total cost per m² printed during a specific period of time. In addition to this, we also have the Comexi Ordering On Line (COOL) service. This new platform for the online sale of spare parts allows for quick identification, 3D and electrical diagrams, faster speed of the order process and security, all with 24/7 service. Another service is Maintenance Assistant, which allows for preventative management of task maintenance. Customers have access to all machine documentation, which is always available and updated.

With more than 60 years’ experience in the sector, Comexi has a wide product range of flexographic presses for short, medium and long runs, which adapt to the market’s most demanding requirements. With the growing demand for sustainable packaging, one aspect should not be underestimated: the equally growing public awareness of how this sustainable packaging is produced. In today’s market there is a clear trend that end users want more ECO friendly concepts for solvent disposal. Nowadays all the Comexi F2 familiy have the possibility to print with sustainable inks: EB, UV LED and water base.

“This seminar has allowed us to show the technology and innovation of Comexi to the most important Serbian and Macedonian companies in the flexible packaging sector”, explains Alessandro D’Agostino, who adds that “the responses have been very positive. Participants have primarily been interested in sustainable technologies such as offset and flexo printing, as well as laser applications to optimize and facilitate the final use of packaging “.

The year 2018 was particularly positive for the Manel Xifra Boada Technological Center, Comexi CTec, as it experienced an increase in specialized high value added services performed in its Riudellots de la Selva (Girona) facility. In 2018, CTec, a specialist in advice and technical services for the impression and conversion of flexible packaging industry, carried out 262 demonstrations and industrial tests, 63 training actions (of which 31 were performed at CTec), and 31 service advisories and trainings.

“The sector increasingly demands that our demonstrations at CTec are more personalized and complex. We began using this line last year and will continue to offer it in 2019: demonstrations in which personalization and added value prevail continue to be preferred and the demise of standard tests”, explains Albert López, head of the Technological Center. As for industrial tests, an upward trend has been maintained with respect to previous years and has been consolidated as a highly valued service by the manufacturers of inks, clichés and adhesives.

Training in constant increase

Customized training in our clients’ facilities increased last year, reaching a total of 32 performances in which teams averaging between 6 and 10 people were formed. In CTec, 31 training actions were performed, which included advanced machine training and internal training. The technical and advanced sessions had a participation of 134 people during 2018. It should be noted that customers were very satisfied with these trainings, qualifying them with an excellent score in their ratings (5.3 out of 6 points).

Since Comexi CTec began training in 2010, the number of students that have passed through the company’s facilities, both internal and external, has continued to grow, reaching 1,713 at the end of last year. In 2018, there were a total of 337 students, 21 more than 2017 and 130 more than 2016. “Different clients have shown interest in receiving prepress knowledge. For this reason, we are working on the development of a program that responds to these needs, and our intention is to begin this year”, says Glòria Deulofeu, responsible for training at the Technological Center.

Training courses given by Comexi CTec in 2019 include a lamination course (offered in German, Spanish and English), a slitting and rewinding training program that will include machine operating contents, flexographic printing courses, print defect solutions and standardization (offered in Spanish, English and Russian), maintenance training (offered in Spanish and English), advanced sessions in flexographic printing (offered in Spanish, English and Russian), as well as new editions of the technical color management seminar (offered in Spanish and English).

During 2018 there also was an increase in advisory and training services, known as Serviflex, which Comexi CTec performed at the clients’ facilities. In total, 31 services were given in 23 different companies, with visits that lasted between 1 to 3 weeks. The actions related to rolling and cutting have increased, while for the first time, three services were conducted for offset technology. “Practically 70% of Serviflex is from purchase contracts, which demonstrates the interest in this type of service from customers who purchase a Comexi machine,” says Yago Luling, technical specialist in training and advice.

CTec trainings achieve a record turnout. Due to the success, an extension of the training offer is expected in 2019 with special training sessions in prepress and operational processes

The Manel Xifra Boada Technology Center, Comexi CTec, a specialist in consultancy and technical service for the printing and converting industry of flexible packaging, expands its training range for 2019 with the inclusion of a new course focused on flexographic prepresses. This new advanced technical session, totally innovative, comes up after the great demand of the sector. The training program of this new course is currently being finalized and the dates set for the first edition will be published shortly.

This innovation is added to the training actions that Comexi CTec has scheduled for the following year, in which apart from the successful German laminating course (which will also be taught in Spanish and English) and the prepress session, it plans to improve the training program for slitting and rewinding, including machine operating contents. The training is complemented by courses in flexographic printing, solutions for troubleshooting and standardization (in Spanish, English and Russian), maintenance (in Spanish and English), advanced sessions in flexographic printing (in Spanish, English and Russian), as well as new editions of the colour management technical seminar (in Spanish and English). All the programs planned for 2019 have been updated with the latest developments in the sector.

These trainings, aimed at current and potential Comexi CTec customers, address interested issues related to the different phases of the flexible packaging conversion process. In this sense, it is possible to reinforce customer knowledge and improve the competitiveness of their companies. These training courses are accredited by the University of Girona (UdG) as a specialization course, and for this reason on October 11th, the collaboration agreement between the technological center and the UdG Foundation was renewed.

The director of CTec, David Centelles, stressed that “we are firmly committed to training and our goal is to be the knowledge driver within the flexible packaging business”. In this sense, Centelles has remarked that “constant training is a key tool that allows our customers to reinforce their leadership”.

1,800 professionals have been trained in CTec courses

Comexi has had the Manel Xifra Boada Technology Center since 2010, the year that the first customer service was provided, and supports and transmits its knowledge to the different actors in the flexible packaging industry process. Since its creation, 1,800 professionals have been formed in CTec courses. All its courses are accredited by the University of Girona as a specialization course.

Renewal of the collaboration between CTec and UdG

On October 11th, the renewal of the collaboration agreement between the Comexi CTec and the UdG Foundation was signed, in the presence of Manel Xifra, president of Comexi, and Pilar Marquès, director of the Foundation. This agreement guarantees the quality of the training offered, which is currently aimed at professionals in the flexible packaging conversion industry.

Apex, Esko, Sun Chemical, Dupont, Cauchos Puntes and Comexi joined together in a successful practical session in the Comexi Technological centre to analyse advantages of expanded gamut versus direct colour printing

Better changeover times, waste reduction, ink savings, reduced wash-ups, and higher quality printing. These are just some of the main advantages that expanded gamut (EG) printing system offers compared to direct colour printing. Main key benefits that were showed during the technical day that Apex, Esko, Sun Chemical, Dupont, Cauchos Puntes and Comexi organised all together at Manel Xifra Boada Technological Centre last March.

A total of ten experts from six different partner companies joined in a practical session that consisted of printing a set of planned jobs in continuous simulating a work shift. All these jobs were originally printed in spot colours but for this exercise they were converted into expanded gamut (multicolour) colour separation. Previously the Comexi F2 MP was characterized under agreed parameters of anilox, inks, plate and tape. The target of this exercise was to print in an efficient way and under a fixed quality standards, monitoring step by step relevant specific data in terms of job cost: changeover time, waste material and ink and solvent consumption.

Through these analyses and evaluations, technical specialists have been able to verify that the expanded gamut system increases efficiency and achieves higher profitability and better quality packaging than multicolour system. It offers solvent savings since EG printing only needs seven colours and, therefore, there is no need for wash-up in between jobs. This printing system reduces set-up times and enables to run more jobs, increasing machine uptime and capacity.

As a summary, the more relevant data were a reduction of 60% changeover time, a reduction of 50% of waste material and decrease of 20% in inks cost.

Besides, during the technical day, the experts confirmed that expanded gamut allows to run many shades of different colours at the same time, which results in a reduction of the number of changeovers per day, increasing even more the press up time.

Moreover, with this eco-friendly printing system it is no longer needed to use the press as ink proofer. By converting spot colours to a fixed ink set, colour matching is done during the prepress. Again, it reduces downtimes between jobs and increases productivity. “Demand for shorter packaging production runs for targeted campaigns and product variations is increasing. Printers and converters need to meet these challenges in a time and cost-effective way and EG system is the proper way to achieve it”, explains Comexi Technological Centre Manager, Albert López.

The positive response obtained has prompted the programming of a second edition of this technical session for 2018

Absolute success in the first edition of gravure printing course in Spanish that the Manel Xifra Boada Technological Center has carried out this November.

During four days, attendees – from different regions of Spain – deepened their knowledge in key elements of gravure printing technology, prepress and variables that intervene in the printing process such as inks or materials. In this sense, the course counted with speeches from experts and technicians in the industry of flexible packaging and specific sectors such as cylinder engraving, main materials in flexible packaging, machine peripherals or prepress, among other topics.

The participants were able to know first hand and through theoretical and practical sessions the keys to improve their productivity, the latest techniques in color adjustment and the most effective solutions to avoid printing defects. “We are very pleased with the success achieved, the good evaluations we have received and the interest generated within the sector, above our expectations,” says the Comexi CTec’s Academic Coordinator, Gloria Deulofeu.

In this line, Deulofeu also points out that, as a result of the strong interest generated by this unprecedented session, the Manel Xifra Boada Technological Center has scheduled a second edition of this course, in Spanish, from October 23th until October 26th, 2018. This second training will have more practices, thus responding to the requirements detected within the sector.

The gravure advanced session in Spanish has been one of the main training premieres that the Manel Xifra Boada Technological Center has programmed this 2017, together with the first course of lamination in German that took place in March with a great success of assistance.