In the world of print production, creating a high-quality sample is often a carefully crafted process, requiring meticulous setup and fine-tuning. However, sustaining that level of quality for large-scale production runs is another challenge entirely. The inefficiencies of conventional methods can lead to wasted materials, increased downtime, and reduced profitability.
At Apex, we’re committed to changing that narrative. With our patented GTT (Genetic Transfer Technology) anilox engraving, printers can achieve consistent, high-quality results across extended runs. Let’s explore how GTT transforms loss-making orders into profit-making opportunities.
The Challenge: Maintaining Quality Across Long Runs
Producing a flawless sample is one thing; replicating that quality over thousands of feet of production is quite another. Many conventional anilox rolls struggle to maintain consistency, leading to issues such as dot gain, ink flooding, and frequent adjustments. These disruptions eat away at both time and profitability, leaving production teams searching for better solutions.
The Solution: GTT XS vs. Conventional Anilox Rolls
To demonstrate the power of GTT, we conducted a head-to-head comparison between GTT XS (1.9 BCM) and a conventional anilox roll (H60 1100 LPI x 2.2 BCM) over a 196,000-foot production run, split into two batch runs. We analyzed the results at three critical stages of the run:
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Start-Up
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32,000 Feet
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98,000 Feet
Key Findings
Comparable Start-Up Quality
Both GTT XS and the conventional anilox roll produced high-quality prints during initial setup. However, while the conventional roll’s performance began to degrade, GTT maintained its precision throughout the run.
Sustained Consistency Over Time
- Conventional Anilox Roll: At 32,000 and 98,000 feet, significant dot gain and dot swelling appeared in highlight areas. The result? Dirty prints, hard edges, and declining image quality that demanded constant adjustments.
- GTT XS: Maintained a stable dot structure and ink transfer, delivering smooth, predictable prints even after extended production lengths.
Profitability Boost
- Conventional Roll: Frequent adjustments to correct dot gain led to downtime, material waste, and increased costs, turning what could have been a profitable order into a loss.
- GTT XS: Minimized waste and downtime, allowing the production team to focus on efficiency and quality. The result was a seamless operation that preserved profitability.
Why Consistency Drives Profitability
In print production, consistency is king. Maintaining controlled, high-quality output across the entire run ensures customer satisfaction, reduces waste, and eliminates unnecessary downtime. Without this reliability, even the most promising orders can quickly become cost-prohibitive.
The GTT XS Advantage
Consistent Print Quality: Smooth, clean prints with minimal dot gain.
Reduced Downtime: Fewer adjustments mean less disruption to production.
Enhanced Profitability: Stable quality ensures even the most challenging jobs remain profitable.
Conclusion: Maximize Your Production Potential with GTT
At Apex, we believe every production team deserves technology that works as hard as they do. Our GTT engraving technology enables printers to achieve the highest level of print consistency and efficiency, even on the most demanding runs.
By reducing variability, minimizing waste, and maintaining top-tier quality, GTT helps transform your production runs into profit-making ventures.
Ready to optimize your print processes? Contact Apex International today and discover how GTT can revolutionize your approach to long-run production.
