Craftline Printing — The Finishing Touches

Pictured from the left, Larry Lengacher, vice president and general manager of Craftline Printing, along with his mailing and fulfillment manager, Darrell Stahly.

J.D. Prater, shown on the left, and Kevin Johnson put the finishing touches on a job.

Supplier Partnerships

So Lengacher had planned to go with two Nexpresses, but also ended up with the Kodak Prinergy workflow system, InSite asset library and Web-to-print storefront solution. “If Kodak has it, we own it,” he quips. “I didn’t buy a Nexpress as much as I bought a partnership,” he adds. “We wanted to expand our variable data capabilities into a much higher speed from where we were. We needed to have the volume capabilities.”

With the new Nexpresses in tow, Craftline Printing found itself in need of a finishing system that would ensure mail integrity, as well as produce L-perf reply cards for the millions of direct mail products it produces. When VDP campaigns feature reply cards or need to be produced on heavier stocks for mailing, they require perforating and scoring, Lengacher notes.

They have to be trimmed down to final size, pushed through the folder, sent through a mailing system and either tabbed or glued.

With all of the required steps, opportunities for disaster abound. Thus, the Craftline exec found a good fit with its Rollem TR Die-Score system, which can provide the L-perfs, score, trim, fold and glue while maintaining mail integrity. It gives Craftline the capability to run variable printing jobs through the Nexpress—in mail sortation order—into a single postpress finishing operation prepared for postal verification. By performing multiple finishing processes in one machine, Craftline is able to eliminate added labor costs, improve production and increase profits.

The TR Die-Score system also has the advantage of easy changeovers for different layouts. For example, a 20×5.5˝ mail piece printed two-up can be edge-trimmed, slit down the center, folded and edge perforated to create five coupons.

“Rollem provided us with that single operation instead of four operations, where the mail integrity could have been lost in any of those,” says Lengacher. “Now, we take the printed output off the Nexpress, put it into the preloader in presort order as it comes off, and run it through the Rollem system. It comes out the end in mail sortation order, ready to go into mail trays.

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