Vitrapack is a flexibles packaging printer. At the recent Fogra CMS 2024 conference, Michael den Putte, Project Manager, shared insights into its process of standardisation. This article highlights how effective project management and collaboration with external experts can lead to efficient print room standardisation.
Vitrapack approached standardisation as a change-management initiative
Recognising the need for standardisation around the year 2000, Vitrapack’s owners, led by Jan Laeremans, made a strategic decision to partner with Co-ëfficiënt – a team of standardisation experts. This alliance proved crucial in helping Vitrapack navigate the complex process of standardisation, while avoiding costly mistakes. By leveraging Co-ëfficiënt’s expertise – alongside Vitrapack’s internal knowledge – Vitrapack significantly accelerated its standardisation timeline, reaping benefits years ahead of schedule.
In 2019, Vitrapack became part of the larger Korozo group. Building on its previous success, the company is spearheading standardisation efforts across the entire organisation. With Vitrapack’s annual revenue of €30 million, it has served as a pilot for the €300 million Korozo group. Its approach offers a scalable model for standardisation in the printing industry.
Comprehensive Assessment – The foundation of Vitrapack’s standardisation process has been a thorough evaluation of current practices, tolerances and methodologies. This initial assessment – conducted with the fresh perspective of Co-ëfficiënt’s external experts – forms the basis for a detailed standardisation blueprint. The blueprint outlines the proposed methodology, realistic timelines and high-level budget implications.
Securing Management Buy-in – Before proceeding with detailed planning, Vitrapack emphasised the importance of presenting the blueprint to C-level management. This step ensured leadership support based on clear financial projections and realistic timelines. Setting the right expectations regarding project duration (typically 18 months) and return on investment is crucial for long-term success.
Vitrapack significantly accelerated its standardisation timeline
Effective Project Management – Vitrapack approached standardisation as a change-management initiative. It recognises the need for strong project management throughout the process. Key aspects include maintaining consistent communication with all stakeholders and keeping the team motivated over the 1–2 year project timeline. Furthermore, regular progress reporting and early demonstration of results as well as thorough preparation in each project phase to ensure smooth execution were paramount.
Empirical Testing and Validation – One of the core principles in Vitrapack’s approach is the emphasis on practical experimentation over theoretical analyses. This ‘seeing is believing’ philosophy is particularly important when integrating diverse technologies on a printing press. Rather than relying solely on supplier specifications or consensus agreements, Vitrapack and Co-ëfficiënt prioritised real-world testing to validate performance.
Vitrapack’s standardisation process was broken down into three distinct phases. Firstly, a clear starting project was established, to serve as a starting point for future reference. Secondly, preparation included training staff on colour and process management. In addition, the definition of references, tolerances and measurement tools. Finally, determining standardisation parameters through extensive testing (accounting for 80% of project time).
Implementation involved improvement of process stability through variation testing and analysis. Once the standardisation was in place, real-world fingerprints could be created and prepress was trained in this way of working. In addition, Pantone workflow and formulation were optimised, as well as the implementation of Statistical Process Control for ongoing monitoring.
To maintain the newly standardised process, Vitrapack employs data-driven statistical process control. Tools such as Printspector, provide a comprehensive view of the printing process. This allows for easy monitoring of overall performance. At the same time, it enables detailed analysis of specific jobs or parameters that deviate from expected behaviour.
Demand for print approvals is drastically reduced, streamlining the production process
The approach transforms troubleshooting from a time-consuming, sample-limited process to an objective, data-rich analysis. It means that Vitrapack can fine tune its process with confidence, knowing that all available data is being considered.
With a standardised print room, colour correction shifts upstream to the prepress stage. It In the 1980s, the Laeremans family established a specialised prepress company – RASK. RASK performs all print preparation for Vitrapack. RASK also implemented a brand portal called Interask, which directly integrates brand owners and prepress agencies into the workflow.
Vitrapack’s policy now includes the creation of an internal proof – with the correct profile for every job – even when files are delivered with the appropriate profile. This ensures consistency and reduces the need for press approvals.
While undertaking a standardisation project requires significant investment in time and resources, Vitrapack’s experience demonstrates the substantial returns it can yield. These include improved Overall Equipment Effectiveness (OEE) and cost reduction. Additionally, customer service is enhanced through consistent, high-quality output, as well as real predictability and repeatability in printing processes. Brand-colour consistency can also be achieved across multiple print runs. This means that demand for print approvals is drastically reduced and, in turn, streamlines the production process. Furthermore, measurable guarantees of print quality are possible.
For printers looking to remain competitive in today’s market, standardisation offers a clear path to delivering superior results, while improving operational efficiency. It enables printers to meet the increasing demands of brand owners for consistency and quality, while simultaneously reducing time to market and eliminating costly approval processes.
As the printing industry continues to evolve, standardisation emerges as a key differentiator
Vitrapack’s journey to standardisation serves as a blueprint for success in the printing industry. By using Co-ëfficiënts’ methodology and expertise, results include data-driven decision-making and a commitment to continuous improvement. In this way, Vitrapack has positioned itself at the forefront of print quality and efficiency.
As the printing industry continues to evolve, standardisation emerges as a key differentiator. It not only improves internal processes and profitability, but also enhances the value proposition to customers. For printing businesses looking to secure their future in a competitive landscape, Vitrapack’s approach to standardisation offers valuable insights and a proven path to success.