Folding carton producer KennedySmith Press has taken a significant step into digital printing by installing its first digital press, the Xeikon CX500, to complement its existing B1 litho presses.
According to company director Michiel Molenaar, a detailed productivity review revealed that smaller-format jobs being printed multi-up on B1 litho equipment were inefficient — requiring more time for make-ready than for actual printing, ultimately reducing profitability.
“We saw this as the right moment to seriously consider digital,” said Molenaar. “Digital offers virtually zero make-ready, which is ideal for shorter runs, even if the substrate size is smaller.”
After evaluating various suppliers, KennedySmith selected Xeikon based on its broad substrate compatibility, colour accuracy, performance, and cost-efficiency.
Successful Integration and Growing Potential
Since the installation in late 2023, the Xeikon CX500 has proven its value.
“The quality has been excellent, and more importantly, it’s been well received by our customers,” Molenaar noted. “We’re still exploring the full potential of the machine and evaluating which jobs are best suited for digital, but it’s clear the technology complements our litho capabilities well.”
Re-training of litho press operators is ongoing, with support from Xeikon’s technical team praised for being prompt and helpful.
Enhanced Customer Experience
KennedySmith supplies packaging to a Swiss herbal products company with a global distribution network. The transition to digital has streamlined colour management.
“Previously, we’d receive conflicting colour corrections from clients in Australia and Canada. Now, with digital, we tell them: you’ll get exactly what you send us,” Molenaar explained.
Exploring Security and Personalisation
Digital technology is also opening new possibilities in security printing and personalisation, especially for pharmaceutical applications.
“We’re discussing adding best-before dates and unique numbering to cartons for security,” said Molenaar. “Digital gives us that flexibility.”
Production Capabilities and Outlook
Currently, the Xeikon handles short runs of around 2,500 cut sheets, but also manages longer jobs — up to 15,000 sheets after cutting from the continuous web. A coating unit and real sheeter have been integrated into the Xeikon press line.
The company operates the digital press on a single-day shift, while litho presses and finishing lines continue on double-day shifts.
“We anticipate extending the digital press to a longer working day soon, as we migrate more jobs to the platform. As a nimble, independent operation, we can quickly pivot to accommodate urgent orders,” Molenaar concluded.