Digital Magazine

Folder/Gluer Broadens Markets for Contract Converter

A Vesta folder/gluer is giving Dyno Press an edge, allowing it to convert larger and more complex cartons and POP displays.

Just six years after its founding, Dyno Press went from literally producing checks to printing university books and publications, before finally emerging as a specialty packaging converter in 1978. That's when the company purchased its first new press, a Consolidated platen die-cutter, and earned a reputation as a finishing house for packaging printers. The company converted everything from folding cartons and point-of-purchase (POP) displays to tags and labels. (Dyno Press itself no longer does any printing.)

"In the beginning we took in everything we could get our hands on," says president Tom Mumford. "We still operate that way today. No job is too big or too small. Our customers have helped us grow and will always be with us, no matter how big we get or how small their jobs become."

Dyno Press has gained its reputation as a one-stop contract converter, offering print finishing and industrial parts fabrication. Services include die-cutting, foil stamping, embossing, holographic and film laminating, automated folding and gluing, CAD (computer-aided) die design, laser diemaking, and hand assembling. Equipment is from several suppliers, including Bobst, Thomson, Steuer-Matik North America, and Kluge.

Products that can be converted by Dyno Press include straight-line boxes, double-wall boxes, four-corner boxes with and without lids, six-corner boxes, pocket folders, envelopes, CD boxes, tapered boxes, inner partition boxes, beverage containers, and almost everything that takes decorating and assembly.

Staying on Top of Technology
"Our market is changing rapidly," notes company VP Todd Amar. "We try to anticipate where it's going. We need to stay ahead in the area of technology in order to meet those challenges."

The company took a big step in doing just that last May with the purchase of a Vesta Model 1100 folder/gluer. Complementing it are two older Kluge and three Bobst die-cutting/foil stamping presses in addition to many other pieces of converting equipment operated by Dyno Press. The new folder/gluer allows the company to convert larger and more complex cartons and POP displays and has opened up even greater market opportunities for this one-time check finisher.

The unit, which can handle widths from 23 to 44 in., allowed the company to expand its converting services to customers in these and other markets that handled larger boxes and cartons.

When the company decided to invest in a new folder/gluer, Todd Amar spent six months investigating virtually every model in the marketplace. Then, a representative of Matik North America, the exclusive distributor for Bielomatik, Global, Steuer, Boix, and Vesta in North America, contacted the company.

"We were not the first customer for Vesta in the US, but they gave us the feeling that we were special to them," says Mumford. "This is something no other competitive manufacturer gave us. We knew that we would always be special to them. We have come to understand that this is the way Matik treats all of its customers."

While on vacation in Spain, where Vesta is headquartered, Mumford was invited to its plant to examine the folder/gluer up close. Ultimately, he saw the machine in action, not only at the manufacturing plant but also at a new installation in Barcelona. The Vesta had been installed at the plant in the morning and was running product by the afternoon of the same day. Mumford was sold, and so was the Vesta Model 1100 folder/gluer.

"The Vesta gave us everything we were looking for in a folding carton gluer," says Mumford. "Once I saw the demonstration, I knew we had found the machine we were looking for."

A Leap of Faith
But why invest in a press from a manufacturer with little presence in the US marketplace when there was equipment available in the states from a number of companies with more established reputations?

"We took a leap of faith," says Amar. "Vesta wanted a stronghold in the US, and they showed themselves to be willing to support the press a little more thoroughly than any of the other manufacturers. On top of that, the price was attractive, and the value we received as far as capabilities was quite significant in comparison to all the other machines."

The Vesta 1100 folder/gluer has a touchscreen panel that operates the speed control, counter, kicker, and all other functions of the machine. An electronic fiber optic monitoring system is programmable for each box, there-by stopping the machine before jamming occurs, Amar reports.

He adds that the folder/gluer uses the latest servo motor technology that ties into the main CPU of the machine. Once the length and gap between the boxes are input into the computer's memory--using the touchscreen panel--the machine will compensate automatically for any variations in speed.

The system uses an adjustable algorithm embedded in the program of the machine to accelerate the rear folding fingers as the blank passes by. The model purchased by Dyno Press has a precision grinder that removes the small bead of the laminating material, exposing the pocket folder or blank box. This feature, notes Amar, allows them to use conventional liquid glue or hot melt directly onto the blank and not the laminate.

"We asked them for 'counter-rotating' grinders, one for each side of the machine," says Amar. "Once we explained why we wanted it this way, they said, 'Great idea.' We got every bell and whistle we could. We also ordered the Vestafold four-corner folding module. This unit allows us to back-flip or rear fold four- and six-corner trays made of thicker E-flute or F-flute corrugated cartons, as well as board."

"The Vesta does everything they said it would and more," Amar reports. "We keep coming up with new challenges, and they keep meeting them. The Vesta performs so well that it produces product almost four times faster than we can pack. It is equipment that is manufactured a continent away, but the way they support and service us, they seem like they are right down the street."

Supplier Information
Vesta-Matik North America
, West Hartford, CT; 860/232-2323

Consolidated Intl. Corp., Chicago, IL; 773/376-5600

Bobst Group Inc., Roseland, NJ; 973/226-8000; bobstgroup.com

Thomson Group., Franklin, MA; ph: 508/528-2000

Brandtjen and Kluge Inc., St. Croix Falls, WI; 800/726-7320

Under the Loupe
Dyno Press has received national recognition for several of its accomplishments, including development of a unique process called "Foilesse." VP Todd Amar, who developed the process, refers to it as a "poor man's hologram." The end product has the look and appeal of a hologram at a greatly reduced expense.

In addition, notes Todd, the proprietary process does not require the special lighting that a hologram does, with a resulting effect that makes for excellent point-of-purchase appeal.

The process has even proved valuable in galaxies far, far away, having been used to produce Star Wars memorabilia when the first cassettes and CDs were released.

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