Hughes Integrated (US) - Prepress and digital flexo solutions from Esko-Graphics solve their clients' toughest technical challenges.

Customer demands drive change

Hughes Integrated, a Michigan-based shop with over 50 years of platemaking experience, has evolved to become an expert in digital prepress and flexography. Customer demand for sophisticated packaging motivated the decision to go digital. Bill Amsbury, director of operations, explains: "Consumer product companies want to use a wide range of challenging packaging – shrink sleeves, plastic bottles, special effects, or day-glo ink." After the installation of Esko's prepress and CDI technology, the firm has earned the reputation as a technical problem solver for the most demanding packaging jobs.

Turn-key solution needed

Hughes Integrated had installed a competitive digital system as a beta test but this proved to be a frustrating mistake. Bill Amsbury was already using DeskPack and was hooked on the capabilities. A closer look at Esko's solutions convinced Amsbury to 'pull the plug' on the other system. „Workflow was a key factor in our purchasing decision. Esko offers a turn-key solution with incredible throughput and a flexible upgrade path,“ states Amsbury. Esko's complete workflow system was installed, including the CDI Spark 4835 flexo digital imager and FlexRip. "We ran old and new jobs and there was an instant improvement in the smoothness of the screen. The results simply blew me away,” says Amsbury.

No job too difficult

“We've been astounded by the results we achieved with the Esko system. We haven’t encountered a single project that we haven’t been able to do digitally,” states Bill Amsbury. Spot colors are a lot less complicated using the Esko ColorTone color correction tools. The ability to run partial plates with the CDI Spark 4835 flexo digital imager saves time and money. “We’ve been able to greatly reduce scrap when a client needs a small, stand alone plate or two," explains Amsbury.

FlexRip has turned 'impossible' jobs into customer success stories. For example, a printer showed artwork samples and the substrate for some new packaging—seriously doubting that the job was possible. When Amsbury used Esko's FlexRip to build special curves and ran the job, the result looked better than the original sample. “Our expertise won the project—a 3.5M part run—for our client," relates Amsbury. "This is just one example of why the Esko system is ‘predictably perfect’."

Flexo delivers positive results

Flexo has produced convincing results and impressive savings. “Many steps are done in-line instead of off-line, special colors are fully integrated, and lead times are shorter,” says Amsbury. When a job comes off the press, it is ready to go to the converter and steps such as die-cutting and foil stamping, done off line in offset, are integrated. Short runs are easily accommodated and has reduced inventory for Hughes Integrated's customers. "We’re seeing a 25%–30% reduction in per-piece cost over offset," adds Amsbury.

 Approximately 50% of Hughes Integrated's work is flexo platemaking with the balance being prepress services. “We can now match—or even surpass—what has been traditionally run on offset," states Bill Amsbury. "Once we show samples of what can be achieved with the digital plates, the customers are amazed that it is flexo.”

Hughes Integrated has successfully differentiated itself from the local competition, while adding value to their core competency in high-quality plates and process control. "We made the right decision. The autotrap features, an easy-to-use interface, the ability to build curves—everything is perfect,” concludes Bill Amsbury.

Unique Esko benefits for Hughes Integrated

Ease of use: short runs are easily handled.

High quality: the ability to match or surpass offset quality.

Increased profitability: 25%–30% reduction in per-piece cost over offset.

Time & cost savings: running partial plates with the CDI Spark 4835 saves time and money.