Advancing Printing Technology as Specialists in Heavy-Stock Packaging

Since starting with matchbox package printing in 1968, Suzuki Printing and Paper Processing has established a strong reputation across the Tokai region as a dedicated specialist in heavy-stock packaging, displays, and POP production.

"We actively take on complex printing jobs, including rigid boxes with specialty finishing made by laminating high-quality paper onto heavy stock as well as unique processing using the coater cylinder that is difficult for printing companies specializing in thin paper. Our technical capabilities are highly appreciated by our clients," explains Senior Managing Director Suzuki.

State-of-the-Art Press Chosen for Its Inspection Accuracy, Backed by Government Subsidies

Lithrone G40 advance EX Edition: "In multi-imposition printing, color variation between the gripper and tail sides was usually inevitable, but with this machine it is minimal and quality is very stable."

Yusuke Suzuki, Senior Managing Director

The decision to introduce the Lithrone G40 advance EX Edition was driven by two main factors: the aging of the existing machine that had been in use for over 20 years and the need to strengthen the production system to meet the high quality standards required by clients.

"To achieve zero-defect production, introducing a high-performance inspection system was essential. Although we had installed a retrofit inspection system on our previous non-Komori press, the Komori press features an inspection system that is integrated from the design stage. This ensures excellent system coordination and enables high-precision quality control, which gave us the confidence to move forward with the investment," explains Suzuki.

In addition, the availability of an energy-saving subsidy also encouraged the investment. "Komori provided a dedicated support team for the subsidy application process, which allowed us to proceed with peace of mind," he adds.

Advanced Features Improve Quality and the Workplace Environment

The Lithrone G40 advance EX Edition is equipped with unique features such as Smart Inking Flow, DC Blower, and e-Mist, all of which contribute to higher productivity and sustainable printing.

DC Blower highly rated for its quiet operation

e-Mist eliminates static electricity during dry seasons

Suzuki commented, "With the DC Blower, the operating noise of the machine has become remarkably quiet. With this machine upgrade, we increased the number of units from five to six, yet the electricity cost has remained almost the same." He expressed high expectations for both improvements in the work environment and enhanced energy efficiency.

"With all the automation features, the Fully Automatic Plate Changer (Full-APC) is the most valuable feature. During plate replacement, I can move ahead with other tasks such as preparing the ink."

Takahiro Sasano, Chief Press Operator

Chief Press Operator Sasano commented on the Smart Inking Flow, noting that "With fewer rollers, color density stabilizes much faster," highlighting the improvement in color management.

"Since the DC Blower releases heat through a duct built into the cabinet, it suppresses both noise and heat. The e-Mist system removes static electricity during dry seasons like winter, so we expect it to improve the stability of paper feeding," he said, describing the actual improvements experienced on site.

Enhanced Productivity with High-Performance Feeding and Automated Color Adjustment

When choosing the machine, feeder performance was given special importance so it could handle a variety of paper types. "With heavy stock, if the paper has troublesome behavior, the feeding will be difficult, and it sometimes took over an hour just to dial in the paper. All paper used for production is supplied by the customer, so we do not have the option of selecting the paper ourselves. That is why the feeder performance is critically important. The Lithrone G40 advance EX Edition delivers highly accurate feeding regardless of paper quality, which was another reason for our decision to introduce it," says Suzuki. After the installation, he praised the press, saying "It can feed any type of paper quickly and consistently, which has significantly reduced working time."

"Because the air settings of the feeder are automatically adjusted, there is almost no need for manual intervention. The machine memorizes the characteristics of each paper stock, allowing us to flexibly handle a wide variety of substrates," Sasano explains.
Color stabilization time has been significantly reduced. "With the new workflow, PPF data is now transferred to the machine to automate the print settings, which has dramatically accelerated the color stabilization process at job start-up. As the Komori machine performs highly accurate automatic adjustments, only slight manual fine-tuning is required by the operator. This has resulted in a substantial improvement in operational efficiency," said Suzuki, praising the machine.

Enhancing Quality Control with Inspection Systems and Improving Work Efficiency through Automation

The introduction of the PQA-S V5 (Print Quality Assessment System) and the PDC-SX (Spectral Print Density Control) has significantly strengthened the company's quality control capabilities. The previous machine lacked an integrated inspection system. According to Sasano, "Manual inspection inevitably leads to oversights. By entrusting the task to the machine, the precision of our quality control has risen significantly. As a result, inquiries regarding quality have decreased dramatically, and operator stress has been greatly reduced. The time saved can now be allocated to other work, improving operational efficiency and boosting productivity," he says.

Another key benefit is ease of operation.
"The control screen now features a touch panel interface, which is especially user-friendly for younger sub-operators who are accustomed to touchscreens. In the past, the press operator had to walk to each unit to operate the buttons, but now all tasks can be completed from the operation stand, significantly reducing workload," explains Suzuki.

Automation and Labor Reduction Beyond Expectations: Future Prospects

As a final assessment of the installation, Suzuki commented: "The press is now running at full capacity. Compared with our previous machine, printing speed has increased by approximately 50 percent. Even at higher speeds, sheet alignment and print quality remain stable, so we are very satisfied."

Sasano also added that productivity has improved, saying: "We're now able to handle a greater volume of jobs."

Regarding the future, Suzuki commented, "With the introduction of the latest Komori press, we achieved automation benefits that allow us to make better use of our people, far beyond our expectations. To keep pace with the times, we would like Komori to continue proposing advanced solutions, including for peripheral equipment, that enhance automation and reduce labor. By proactively leveraging these proposals, we aim to further enhance productivity and support sustainable growth," he said.

The Lithrone G40 advance EX Edition with the team at Suzuki Printing & Paper Processing Co., Ltd.