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Print Leeds ramp things up with a DYSS

Print Leeds ramp things up with a DYSS

During the last four years, Print Leeds has undertaken a factory refurbishment and extension and also acquired a Heidelberg Speedmaster CX102 UV seven-colour printer and, more recently, a DYSS X7-1630C digital cutter from AG/CAD. In addition, it will shortly be moving from its 20,000sq/ft factory to a 32,000sq/ft facility and plans to install another Heidelberg Speedmaster XL106 seven-colour printer before Christmas.

The company has specialist divisions, which produce wet-glue labels, UV litho printed plastics, plus digitally printed POS material and beverage and food packaging. As one of the most technically advanced print companies in the UK, Print Leeds always keeps abreast of the latest technologies and the 3m x 1.6m DYSS-1630C digital cutter was purchased to replace a smaller, slower cutter.

Commenting on its arrival, Rod Fisher, Print Leeds’ Managing Director, said: “We bought our previous cutter to reduce our reliance on dies and subsequent costs. However, as our POS and packaging work has grown, we realised that we needed a much larger machine, as well as one with a router cutting capability to cater for the more demanding materials we use. After considering all of the options, it was clear that the DYSS stood out above all others in respect of its build quality, capabilities and price point. It can do everything we need – for my money it’s the best machine on the market.”

The DYSS X7-1630C can cut polypropylene, PVC, foam-board, Perspex, vinyl and much more and the powerful DYSS X7 Superhead can provide high speed routing as well as creasing, kiss-cutting and a multitude of other extremely precise cutting operations with its oscillating knife tool.

Print Leeds already runs a 3.2m wide Truepress W3200UV HS flatbed digital printer and, when its factory move is complete, the DYSS be positioned alongside it.

Rod Fisher continued: “Having the printer and cutter side by side will enable us to streamline our workflow and further reduce lead times. The fact that the DYSS can cut three-metre printed boards and sheets has already enabled us to make significant savings and we can also cut a number of smaller jobs from a single sheet, which has reduced set-up times and improved our productivity by over 20 percent.

“Furthermore, the DYSS can cut jobs at least 30 percent faster than our previous machine. The Truepress was recently upgraded to a high-speed model and, without the equally fast DYSS, we would have had a major bottleneck. In fact, we would have been out of the POS market without the DYSS.”

Print Leeds’ DYSS operator, Mark Craven added: “We cut a lot of 2.4m high pull-up stands for exhibitions and these were previously cut by hand because they were too large for the old cutting machine. This caused inconsistencies that would sometimes mean scrapping and then re-making jobs. Even when the job was hand cut with precision, each pull-up would take five minutes to cut. Now, the DYSS processes these displays in less than a minute with no errors, scrappage or re-working.”

“Additionally, the DYSS has a roll feed facility, so higher quantities of pull-up stands, wallpaper and large posters can be run continuously from full printed rolls up to sixty metres long. With the previous machine, we had to guillotine each poster down from a roll to fit the machine bed. Following this, we would have to hand load, set-up and finally cut each individual job, one by one– a very labour intensive and time consuming operation.”

Previously, Print Leeds subcontracted a percentage of its litho work which required cutting, but now the DYSS has reduced this by at least 20 percent, thus saving the company over £20,000 a year.

Mark Craven revealed: “We also used to get acrylic cut externally and some jobs, such as fascia signage, placards and some PoS work took around two to three days to process. Now, we can cut these materials in-house and further reduce our lead times.”

The powerful routing head on the DYSS X7-1630C has provided Print Leeds with the ability to cut just about any material it wishes, but the speed, consistency and precision of the knife tools are equally important.

He went on: “We currently use the DYSS to produce two to three varnish blankets each week for our Heidelberg printer. Using the kiss-cut tools, we can set a cut depth at precisely 0.8mm and maintain this even if there are any surface variations or discrepancies in the material. The same tool also handles vinyl kiss-cutting. I’ve worked with all leading vinyl plotters and the DYSS is as good as any specialised plotter for vinyl work.”

Rod Fisher concluded: “The DYSS has been a great buy for our business. It has done everything we expected and so much more besides. It has given us the potential to open up new markets and take on work that wasn’t previously possible. We’re delighted with the performance, the service and the technical support provided by AG/CAD – we really couldn’t ask for anything more. And, at the rate our business is growing, there is little doubt we’ll be acquiring a second DYSS machine soon!”

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