Finishing automation works for PPG

Integrating HP Indigo technology is changing the way Pinnacle Print Group operates: owners Justin Hall and Pedro Carlus flank press operator Damian Caulfield.

Incremental steps to eliminate time consuming manual processes has changed the way Pinnacle Print Group operates as Pedro Carlus follows his plan to find the most appropriate technology.

The qualified offset printer, and co-owner with partner Justin Hall, of the Reservoir-based printing company, is deeply versed in the craft-based traditions of the industry. He knows how to get the best from his equipment and employees and is in no hurry to make big investments in technology.

For years he operated his commercial print company with minimal digital integration, running two Komori Lithrones, a Stahl folder, guillotine, a Sheridan binder and a line-up of cylinders, pushing through the work in traditional fashion. There is a Fuji Xerox C800 digital engine in the prepress space, but according to Pedro he had difficulty fitting its output into the workflow. Customers were known to point out that the digital results were not what they wanted

It all began to change when PPG became engaged with Currie Group while making the switch to Agfa printing plates and installing a Cron TP-4696. After a period of doom and gloom the company was keen to develop relationships with suppliers that were still passionate and engaged in the industry.

Pedro singles out the efforts of Stephen Monkhouse, now with Currie NZ, as a good example of someone who goes the extra yard to deliver customer satisfaction.

“His persistence and constant updates on Currie’s offerings as well as the enthusiasm and enjoyment he showed working for them, was vital in developing the strong relationship we now have with all the Currie staff we deal with from management to the  helpful and friendly service staff,” he said.

Soon afterwards PPG took on a HP Indigo 3550 Digital Press from Currie Group with Pedro maintaining that the output is closer to the offset results his customers wanted.

The trade-qualified members of Pinnacle’s two-shift workforce are a flexible team in what they do, multi-skilled and enthusiastic, switching between presses and folders, even jumping into the truck to make deliveries around Melbourne’s metropolitan area. Pedro realised he could free up even more time and resources by investing in appropriate finishing technology.

So began another chapter in the upgrade path that is changing the way the company operates. First came a Foliant Mercury 530 SF laminator, installed to add an extra dimension to the process, followed by a Horizon CRF362 creaser folder to take the increasing amount of digital output.

Finally, as Pedro went overseas to his first drupa trade show in Germany this year, Currie Group installed a Horizon StitchLiner5500 that was up and running on his return. The result is not only a more efficient and employee-friendly operating environment, but also a new recognition and confidence in his own investment philosophy.

“We are more relaxed now about making the decisions. It’s not too big an investment but it changes the way we work, for the better. If it’s too big you have to worry about fitting it in and then maybe you’re not ready for it. I think taking the small steps is the way,” he said.

It’s little wonder that the exhibit that fired his imagination at drupa was the High Con laser-powered digital finishing. While he can see a use for it in his operation it’s not on his immediate shopping list. Ever pragmatic he’s now considering automatic sheet counting to relieve employees of having to do the essential process by painstaking manual count.

“I reckon it’s the way to go. I was very impressed with the renewed confidence and excitement in our industry at PrintEx in Sydney last year, where I saw the HP Indigo. I’m looking forward to PacPrint next year in Melbourne where I can see more of what’s there,” he said.

It’s been an upward track for Pedro and his partner Justin ever since they took over from the founders – who included Ron Hall, Justin’s father­ in 2004. Both were already working in the business, Pedro as general manager, Justin heading sales. Over the years they’ve shared the responsibilities between them; Pedro continues to operate the factory while Justin looks after the sales. It’s a system that works very well and the whole workforce is cheerful and engaged.

Pinnacle Print Group is a text box example of why there is an optimum scale for a mid-size printing company. It’s not over burdened with debt, nor struggling to keep up with technology. Neither partner has any great desire to grow it much bigger.

Phillip Rennell, sales and marketing director, Currie Group, reinforces the benefit of right sizing a business. “What I like about Pinnacle Print Group is that they are prepared to keep up with new technology while never letting it disrupt their business or production. They are an example of how to grow at your own pace,” he said.

The goal now is to make PPG work even better and with their continuing investment in productive automation that’s well on track.