Bennett Graphics installs GM finishing with digital embellishment

For its first investment with GM (Grafisk Maskinfabrik A/S), Bennett Graphics in the US has brought in a DC350Flex finishing line with advanced digital embellishment capabilities to enhance its high-end label products and grow its label business.

Based in Tucker, Georgia, Bennett Graphics was founded in 1968. One of the America’s most highly awarded Commercial Printer, serving B2B, B2C, education and non-profit clients with research, rapid estimation, and ideation; pilot programs, design, prototyping, digital, offset and large format printing. 

In 2015, the company expanded into labels and flexible packaging with the installation of an HP Indigo digital press and a converting machine. This part of the business soon turned out to be very profitable, making great inroads in labels, particularly in nutraceuticals, a market that expanded rapidly during the COVID crisis. 

“Many of our valued folding carton customers had started to inquire about labels, so we seized the opportunity to move into this growing sector. The timing couldn’t have been better. After modest growth in the first few years, the division doubled in size in just three months when COVID hit,” says Adam Seiz, Vice President of Business Solutions and the company’s process improvement expert. 

However, as the label business expanded, it became necessary to re-evaluate the machinery requirements to continue on this growth trajectory. 

“That initial setup served us really well, but after eight years it was time to upgrade the finishing side, so we could better respond to the needs of our customers,” says Adam. “We decided to invest in a new machine that could create more effects, while also speeding up turnaround times and lowering the costs of each label. The GM DC350Flex configured with a JetFX digital embellishment module best fitted that brief.”

Taking embellishment to the next level
Operating at a maximum speed of 262 ft/min (80 m/min) with semi-rotary die-cutting, GM’s DC350Flex line offers Bennett Graphics a versatile solution for converting high-volume digital print. It is built on a modular platform, meaning it could be specified with the options required now and offer the option to upgrade in the future if needed. 

With the smooth integration of the JetFX module, Bennett Graphics can create variable digital foiling, Cast & Cure, spot varnish, micro embossing and other standout finishing effects without waiting for expensive tooling to be made, which speeds up delivery times. 

“The multiple embellishment effects we can create now, such as foiling without using metallic substrates, has taken taking our labels to the next level,” explains Adam. “With digital foiling and Cast & Cure on the DC350Flex, we can start approaching more wineries and other high-end segments, fulfilling the potential of this part of the business. I believe we could easily double turnover.”  

From self-wound to unsupported film lamination
In addition to upgrading its embellishment capabilities, the DC350Flex has also enabled Bennett Graphics to switch from using self-wound film lamination to unsupported films, a major benefit in terms of costs, flexibility, and value-adding opportunities.   

“Moving to unsupported film lamination is a massive benefit, saving both ourselves and our customers quite a significant amount of money,” explains Adam. “The process offers a much more practical and functional solution that allows us to add the effects we want. With self-wound films, there was a distinct limitation to what could be achieved.” 

Impressive job setup times and fast installation
The faster makereadies on the DC350Flex have also impressed the team at Bennett Graphics, allowing them to speed up job turnaround times significantly and save on waste. 

“The speedy setups and changeovers are really important for our customers, because we can get the job done and sent out to them much quicker than before. This means they can implement a just-in-time business model, getting products on the shelf quicker and saving on warehouse costs,” comments Adam. “We can also reassure them that we are doing our bit to reduce waste wherever we can.”

He concludes, “In fact, everything about the DC350Flex has exceeded expectations. Even the speed of the installation was faster than anything I’ve seen before. The machine was up and running in just three days which is unheard of, so kudos to the GM team.”