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Case Study

Challenge:

Coveris Burnley was invited by a key client, Asda, to join a pilot project using ColorCert: X-Rite Edition as part of its efforts to intelligently manage their print base through a true closed loop color management process. Coveris was pleased to participate in the project, both as part of its deep relationship with Asda and for the opportunity to assess and improve its own operational performance.

Solution:

Coveris Burnley implemented ColorCert on its new W+H flagship press to achieve more reliable and consistent color measurement throughout production. The product is measured press-side during setup, pass off and, throughout the print run. Results are entered into ColorCert and uploaded to a cloud based portal to which Asda has real-time access.

Results:

Based on experiences with the ColorCert implementation, Coveris Burnley revisited its color workflows and methodologies to further improve its already high quality color measurement. Based on the successes achieved and to better manage the client expectations, the business has adopted key learnings from the project and purchased ColorCert, X-Rite eXact, Color iQC and NetProfiler which are being rolled out across Coveris UKFC print sites.

Coveris UKFC Partners with Asda to Implement ColorCert: X-Rite EditionCoveris Burnley | Packaging | Europe/United Kingdom

“Moving accountability for color measurement and real-time updating of ColorCert press-side has had a positive impact on the empowerment of our operators as well as improving our overall print and color performance.”

Coveris Burnley, formerly Learoyd Packaging Ltd, was established in 1976 as a flexographic printing specialist providing solutions for a wealth of blue-chip clients including Marks and Spencer, Warburtons, Seabrook Crisps and Muller Wiseman Dairy. Acquired in 2014 by leading global packaging specialist Coveris, the business now operates out of 16 sites within the UK, providing market leading plastic, paper and cardboard solutions to all major retailers and brand owners. Headquartered in the U.S., Coveris employs over 10,000 staff with operations in more than 20 countries and revenues exceeding $2.5bn.

Coveris Burnley has more than 190 employees and 172,000 square feet of manufacturing space. The company is renowned for premium quality flexible packaging, its focus on investment in people skills and technology, and is recognized for its superior performance throughout the UK and Europe.

A Challenge from Asda

In early 2014, Coveris Burnley was approached by Asda, a Wal-Mart company, with an invitation to participate in a pilot program designed to improve overall color quality and consistency throughout the Asda supply chain.

“We have a great relationship with Asda,” said Coveris, “and we were pleased to be included in a select group asked to participate in this programme. We already also had a great relationship with X-Rite and use several X-Rite Pantone products in the course of our operations. We are always keen to be at the forefront in the market, and implementing ColorCert: X-Rite Edition with Asda is not the first project we have done with a retailer.”

Coveris Burnley also uses X-Rite’s InkFormulation Software and PANTONE digital libraries.

“We implemented ColorCert on a flagship W+H press brought into the business with a clear view and strategy to develop and market fixed color palette printing (FCP),” Coveris explains. “The objective was to rationalize our colors and design using only a CMYK palette wherever possible using the latest press and plate technologies to optimize the achievable color gamut and registration control.”

This dovetailed nicely with another Asda initiative, adds Coveris, “We had talked with the Asda Print Team prior to the ColorCert project about converting work from conventional process and spot color to FCP. Not too long after the implementation of ColorCert, a significant proportion of the work we now produce for Asda has been converted to fixed color palette printing. ColorCert is a key part of the toolset we have in place focused on achieving exceptional process color control.”

Process Benefits

This increased focus on process color has led to improved consistency andrepeatability in production. Data captured in ColorCert has been used to help us re-define and manage our internal processes and SOP’s to support consistent quality output. In the studio we have also seen a positive response from our clients, particularly with regards to the approach and use of technology to support the control and measurement of print. To the delight of designers, there is also the removal of often unsightly grips and traps as well as an improvement in vignettes.

eXactly Right

Coveris Burnley has also acquired five X-Rite eXact next-generationspectrophotometers and uses NetProfiler to ensure inter-instrument agreement and proper calibration. “These replaced some older X-Rite spectrophotometers. We like to keep our technology up to date, and the eXact spectrophotometers ensure that we are getting the most consistent and productive measurements throughout the process.”

Case Study

A Structured Approach

Working with the Asda Print team to implement ColorCert, Coveris Burnleyneeded a structured approach to the project. “As indicated, our initialimplementation was focused on one press,” Coveris explain, “and we set up asite champion and implementation team, initially measuring all Asda samplesoffline. I have to admit that at the outset, everyone was quite ambitious abouthow we could measure and capture performance data using CMYK andgrey balance. We thought it would be straightforward, since we were alreadydelivering high quality, but it is fair to say that we learned a lot about ourproduction process in the initial stages of the program.”

Coveris and the project team found initial results to be a bit of an eye-opener,and used the data to revisit all of its color processes and SOPs. “It has beengreat for us. We have learned a great deal, and our ColorCertscores have improved dramatically. We are now able to achieve great scoreson a consistent basis and use the data captured to analyze and demonstrateeffectively print performance.”

Next Steps

In addition to rolling out the ColorCert process to other plants, Coveris is focused on moving measurement press-side and automating where possible. “In the pilot we were initially measuring offline, but by moving measurement press-side, it makes our operators completely accountable. They measure product, upload scores, and there is real-time sign-off in the cloud for Asda to see real-time score capture. Press operators are starting to see the benefits. They are engaged and feel empowered. It also engenders natural competition. If you can measure it, you can control it. We have standards for everything and we measure everything. ColorCert and the portfolio of X-Rite products we use daily have helped in making this possible.”

To get more information about PantoneLIVE and ColorCert:Contact us at: xrite.com/contact-us

Case Study

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