First, in 2016, there was the installation of an HP Indigo 6800 digital label press, as well as an HP Indigo Latex press for large format jobs. After 10 years of printing self-adhesive labels and shrink sleeves on Mark Andy and Edale flexo machines, Mayapack’s move to digital was spurred by its high levels of short-term work and its desire to diversify its portfolio of products.
Equipped with new technology, the company started in-mold label production and set up a creative department to offer design services not only for labels but also for large-format products such as marketing materials and office decoration.
Today, Mayapack operates two factories: one for flexo – which accounts for 60% of the business – and one for digital, which covers the rest. On the conventional side, alongside Mark Andy and Edale flexo presses, the company uses shrink sleeve equipment from Karlville and finishing machines from Prati. About 80% of flexo work is in the production of PS labels, with some molded labels and shrink sleeves taking up the rest of the production.
The digital factory is home to the original HP Indigo 6800, as well as an HP Indigo 20000 installed in 2019. Here, molded labels make up 80% of what Mayapack produces, with shrink sleeves making up the second largest sector.
Brotech’s converting equipment complements digital presses. “Digital was not just adding a complementary process for Mayapack, but creating whole new areas of business,” Reyes points out. “Since installing the first HP Indigo press in 2016, Mayapack has quadrupled in size. This has been an exponential change for our business.
Mayapack’s extraordinary growth could not have been achieved, admits Reyes, without the installation of a Label Traxx MIS. He says, “While the first revolution within our business was the addition of digital, the second was our installation of the Label Traxx MIS in 2019.”
Mayapack was using a locally developed workflow system, but wanted something that was specifically tailored to their needs as a label converter. “Our growth had been so rapid that it was difficult to stay on top of all the information surrounding each job,” Reyes recalls.
“The Label Traxx software allows us to see all the information from every facet of our production in real time and to know the exact cost of production for each job. It gives us control over all data from all areas of the business and helps us make informed decisions.
“The great thing about Label Traxx is that it’s designed for label converters. I feel like it was developed specifically for our business,” says Reyes.
When Mayapack started using the Label Traxx MIS, opportunities for improvement quickly became apparent. “The way we priced our jobs made it difficult to know exactly how profitable each job was,” Reyes recalls. “Immediately after installing the system, we could see that some of our jobs were less profitable than others, and some were quite inefficient in terms of not using our production equipment to its full capacity.”
The Job Costing and Business Metrixx modules have been particularly helpful in this area, according to Reyes, with a focus on improving overall production efficiency.
He explains: “The Job Costing module allows you to analyze the costs of a job at each stage of its production, so that you can see how the estimate is up to what you produce. This means we can talk to a customer and say, “We can give you a discount on this order” or “For this one, we need to raise the price.” This brings transparency: the client can understand exactly how we assess the work.
“You can quote a price for a job, but its profitability will depend on how well you execute the job. What it should cost you to produce – and what it will ultimately cost you – is not always the same With Label Traxx, you can monitor these parameters in real time.
The impact on Mayapack’s business has been profound. Since the installation of the Label Traxx MIS, the converter has taken 70% more orders in its presses. Order generation speed for its digital presses has increased by 90%.
“With digital printing, you can bundle different jobs quite efficiently and print them at the same time. So we are much more efficient,” says Reyes. “We can also calculate much more accurately the downtime associated with each production order. We’ve reduced that downtime to just 3% of what it was before the system was installed. And we have reduced our delivery times by 50%, thanks to better administration. The estimate of the works is immediate, with real and updated data. »
Despite this already impressive impact, Reyes believes further improvements are possible. “We are not yet at 100% of our capacity to use our existing Label Traxx modules,” he points out. “There are still benefits to be had that we haven’t developed yet, such as inventory management. Once we have reached this point, we will move on to the next steps. The system will be increasingly integrated into all facets of our business and strategy in the years to come.
Reyes points to Siteline, a Label Traxx subscription module that allows brand owners to track their jobs online in real time, view their order history and confirm new orders with the click of a button, as ringing with his vision. of the future of label production.
“I believe the future is print-on-demand based on digital platforms. We want to make our customers’ lives as easy as possible, so they don’t have to wait for us to return their phone call, for example. They can simply enter the platform, view their previous orders and check their status. Label Traxx thinks about it too, and already their system allows your customers to interact directly with your GIS. You can also see it with their partnership with HP Indigo, and that’s another reason we went with Label Traxx. The system is integrated into the digital press workflow, with an HP Indigo in-system application that allows you to price jobs and organize workflow specifically with an HP Indigo press.
This data-driven digital future that Reyes envisions is reflected in Mayapack’s corporate culture. It has built a young, tech-savvy workforce, often promoted from within. “It can be difficult to attract young people into the label industry,” he says. “There is sometimes a certain stigma attached to manufacturing, and there is a perception that our industry is all about tools and machines. But the reality is that our business is very digitized, very automated; so yes, we we cultivate a digital start-up atmosphere and this culture is present in our staff and also in the decoration of our offices.
For Reyes, part of the appeal of the Label Traxx system is that it is specifically designed for flexo converters, but also for digital label production. “The evolution of the system from flexo to digital matches ours. Label Traxx adapts very well to both technologies.
“Mayapack wouldn’t be doing what we’re doing now without the combination of these technologies: HP Indigo digital presses and Label Traxx MIS,” concludes Reyes.
Steve Katz is the former editor of Label & Narrow Web and is now a regular contributor. He is dedicated to helping companies in the label industry share their news and tell their stories. Follow him on Twitter @LabelSteve.