Digi Leaflet, delivering flexibility in the Booklet Label supply chain
Digi Leaflet Technologies has been working with a world-class chemical manufacturer to resolve a number of issues within their booklet-label printing supply chain. The brief to enable them to react to market opportunities, increase manufacturing agility and reduce costs. Their issues are very clearly not unique to them…
Production output limited, increased complexity, excess working capital tied up in stock through
• Long lead-times or late deliveries of printed media
• Cost penalties for ordering small quantities
• High cost items with limited sourcing opportunity
• Loss of control from outsourcing key steps in product supply chain
• Write-off of obsolete printed media
• Reworked finished goods to service “other” markets
• Loss of agility to turnaround urgent orders
As the client brand portfolio had grown the ability to manage the complex product labelling had diminished. Efficiencies in the Supply Chain were a constant objective but it was accepted that as part of doing business set-up costs, adhering to MOQs and managing of old label stock levels were a “fact of life” to grow markets. After all, there aren’t many alternatives to create cost effective booklets and labels, reduce waste and increase flexibility whilst reducing lead times are there, right? Wrong!!
Digi Leaflet Technologies understands how these issues negatively impact on the client’s ability to perform and to maximise opportunity. For example, when producing new packs to meet a specific market strategy, or leverage a valuable product use extension, speed to market and compressing the supply chain is key. Components need to be sourced rapidly, without penalty to ensure maximum benefit is achieved. Historically, booklet printing, with its multi-stage process, complex artworks and many handling points has been unable to react to urgent demands for new formats, short run or short lead time orders and is seen as a major bottleneck.
By exploiting the capabilities of CMYK digital print technology and devising a unique and novel method of folding and forming thin films to create lightweight full-colour booklets, the solution presented as the ‘Origami’ method met all performance goals and delivers true cost benefit with improved agility in the Supply Chain.
The Digi Leaflet Origami machine and its “brothers” in the range delivers operational flexibility, low cost of manufactured product at a lower cost of entry than conventional technologies with a real simplicity of use, allowing the option of in-house production or through existing print and conversion partners. Rapid changeovers between jobs provides the agility and capability to produce small batches to order, cost effectively – in full alignment with today’s dynamic manufacturing trends whilst avoiding penalties and the constraints of traditional MOQ’s.
The patented Digi Leaflet Origami method is ‘disruptive’ and challenges the existing economic model in this converting sector. Having also developed the faster booklet-only system after customer feedback Digi Leaflet Technologies Ltd has realising an even more cost effective unit delivering up to 60 booklets output a minute. The simplicity of the system means that the need for print experience to operate it is negated.
The Digi Leaflet booklet utilises thin-film raw materials to produce robust, lightweight, full-colour CMYK communication formats to effectively deliver your informational requirements. At the same time, the booklet formats coupled with the excellence of Digital Print deliver improved readability for product information whilst permitting the freedom for the designers to produce attractive content within a familiar booklet information flow.
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