As a company that only opened its doors for business four years ago, Impression (Bolton) is flourishing as a large-format display, event and signage company. Producing a range of graphics and digitally printed products from A4 leaflets to vehicle wraps, building branding and exhibition stands, the company has invested heavily in the latest equipment to meet the demands of these diverse marketplaces.
Initially progressing with Roland, Konica and HP solvent and small-format printing machines for roll-to-roll and small print projects such as promotional work for hotels, colleges and local authorities, it was the arrival of an Oce Arizona flatbed digital printer in 2011 and the recent purchase of an AG/CAD KM627R digital cutting machine that has really progressed the business.
As director, Martin Lyons says: "We wanted to extend the scope of our business and the flatbed UV cure printer with a 2.5m width has enabled that by allowing us to print direct to substrate such as acrylic, Di-Bond and Foamex as well as the printing of window stickers and reverse printing. Whilst this has enabled us to diversify and widened our scope and capacity, it has also enabled us to work in different methods that have reduced our lead times and the cost of printing to make us more cost effective."
Despite opening new markets for the Bolton based manufacturer, the company was sending out a large number of jobs for routing, corner machining and hole drilling. The problem for the eight employee business was twofold. Firstly, with the increasing diversity of its work, the subcontract routing work was increasing and it was becoming more dependent upon external suppliers. Secondly, the company was being asked to conduct bespoke POS projects that it had to turn away because it didn't have the capability.
To address the issue, Impression reviewed the market for cutting tables to drive its business forward. Following an intensive review of the available technologies, the company opted for the AG/CAD KM627R flatbed cutting machine. Lyons continues: "Once we recognised the growth potential and value a cutting machine could add to our business, we looked at our options. The AG/CAD KM627R machine has virtually all the capabilities of a high-end, 'all bells and whistles' machine from a competitor, but at half the cost. It was the logical solution for our business. Furthermore, competitor machines actually run the AG/CAD KASEMAKE software, so we knew we were buying a quality machine with the best available software."
Since the AG/CAD KM627R arrived at Impression in April, it has enabled the company to pass its roll-fed and board printing from the Arizona straight to the cutting machine, creating a perfect synergy between the two machines. Despite only arriving in April, the KM627R cutting machine has made a huge impact at Impression. As Lyons continues: "We wanted to develop our POS business but were constrained by the lead-times, costs and capabilities of our subcontract supplier. This is all a thing of the past. Since buying the machine we have won new business that has increased our turnover and improved our profitability by at least 15%."
Some of the new jobs won by Impression include contracts with clothing brands Henri Lloyd and Dare 2B, creating POS displays. These display units made from boxboard, Correx and Dufaylite can be freestanding shelving and display units that incorporate backlit LED lighting. Without the AG/CAD machine, producing these units would have been impossible for a number of reasons. Firstly, the 18mm thick Dufaylite POS displays couldn't be cut by hand with a high quality edge finish. Whilst in all materials the complex forms, shapes and holes couldn't have been produced by hand to the required accuracy level. Furthermore, hand cutting wouldn't have made the work cost effective and profitable. Finally, with complex assemblies the work would have been nigh on impossible whereas the innovative Kasemake software enables Impression to cut, crease and create folds on the KM627 machine.
Additionally, Impression conducts a considerable amount of aluminium composite material (ACM) work that previously had to be cut by the material supplier to the sizes and shapes required. By having the ability to cut ACM sheets internally to the exact dimensions of the specified job, Impression has improved its lead-times and reduced the cost of the material supplied.
"By using different methods of working and reducing our subcontract costs, we expect the AG/CAD machine to pay for itself within 12 months. Since the installation in April we have already saved the equivalent of 50% of the machine cost," says Lyons.
The AG/CAD cutting machine allows Impression to knife cut as well as conduct routing, creasing and kiss cuts with its numerous tooling options that also include scalpel tools for cutting vinyl stickers. The cutting machine has clearly brought considerable added value to the company, but a key addition has been AG/CAD's Kasemake software.
As Lyons continues: "The Kasemake software is extremely intuitive and easy to use. It is so comprehensive, we are always finding new applications for it. One thing is certain and that is without the machine and the software, we wouldn't have been able to do POS work. The Kasemake package allows us to use templates from its library and manipulate them to create an exact pattern for each and every job. This has also made considerable savings for us. We are delighted with the machine and the value it has added to our business."