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Derwent Displays invests in a DYSS

Derwent Displays invests in a DYSS

Founded over quarter of a century ago, Derbyshire-based Derwent Displays, which specialises in design and prototyping, printing, finishing, in-house assembly, packaging and project delivery has invested more than £1.75m in the latest technology in order to continue its growth trajectory whilst also enhancing its customer service and experience.

The investment program has included the acquisition of a FujiFilm Onset X2 digital printer, and a DYSS X9-1630C Combo Head digital cutter from AG/CAD. The Onset X2 printer features a robotic arm unloading system and similarly, the DYSS X9-1630C incorporates sheet handling automation.

Commenting upon the acquisition of these machines, Derwent Displays’ Commercial Director, Paul White said: “The display industry is extremely competitive and the ability to offer speedy prototyping and sampling can be the difference between winning and losing business, so both machines were absolute must-haves.”

With an older existing digital cutter running flat out, Derwent needed additional capacity, as well as further capability in terms of handling a wider variety of substrates. Paul White continued: “We cut a lot of paper-based corrugated and display boards, plus plastic corrugated, but more frequently we are being faced with the prospect of cutting boards up to 10mm thick. Anything above 5-6mm was beyond the capability of our existing machine and is also too thick for die cutting with cutting formes. In addition, we are increasingly being asked to quote for jobs that include the cutting of Dibond, Foamalite and Polypropylene, all of which meant that we needed a machine able to handle this sort of work as well as our bread and butter jobs.”

Derwent, which employs 30 people, researched a number of different options, but it soon became clear that the versatility of the DYSS X9-1630C Combo Head machine, with its variety of different tools for heavy duty cutting, creasing, V-cutting and kiss-cutting, plus a powerful routing spindle for processing more diverse rigid material types and thicknesses with impressive speed, precision and edge finish, was the only choice that fulfilled all of the company’s criteria.

Equally important, was the synergy between the DYSS and KASEMAKE CAD software, which Derwent was already using to drive its existing cutting table and design studio.

With automation being a major element of its business strategy, Derwent specified the DYSS X9-1630C with an automatic board loader. Referring to this, White said: “We wanted to fully automate the loading process on the new machine, so AG CAD delivered the X9 with a fully integrated loading solution that accommodates a stack of boards up to 3.2m by 1.6m, the same size as the maximum cutting area. It can hold upwards of 70 sheets of EB flute or varying quantities of boards of different thicknesses. As soon as a sheet is loaded and the cutting process started, the auto-loader will pick up the next sheet so that it is ready to take the place of the finished one, which can then be stripped, stacked and packed.”

With 70 percent of the work flowing through Derwent comprising production runs ranging from 500 to 3000 sheets, the loader equipped DYSS X9 offers an automated production alternative to die cutting, without the cost of cutting formes. The remaining 30 percent of output is made up of prototypes and smaller runs.

Derwent Displays has historically ordered around 35 sometimes very complex tools every month, but by rapidly processing jobs in the 200 to 500 range, the DYSS has reduced this requirement by up to 15 tools per month and the cost o by up to £1500 per month. In addition, the lead times on jobs has also been reduced by an average of two days, thus significantly improving throughput.

Equally important is the elimination of the cutting forme cost from low quantity jobs, something that has previously deterred some customers from placing smaller orders.

With two cutting machines running side-by-side, Derwent Displays has one operator running both tables. White observed: “Previously, we had one operator running one cutting table, but having the DYSS X9-1630C next to the older machine is making us twice as productive, without increasing our labour costs.”

Credit for some of this productivity has to be awarded to the KASEMAKE CAD software, which Derwent uses to design its projects and create cut files. These programs are immediately accessible on the DYSS X9 and, as the operator only has to quickly prep and run jobs, machine downtime is eliminated.

White concluded: “We have only had the DYSS for a short time, but we are already realising the benefits. It has lowered costs, reduced lead times and increased productivity, while also helping us to generate additional business with existing customers and to attract new business in market segments that would have previously been outside our scope. We are delighted!”

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