Customer: Modern Press
State: New York
Website: https://www.modernpress.com
Industry: Commercial Printing
Solutions: 700i Pro Digital Booklet System, DC-646 Slitter/Cutter/Creaser, DB-290 Perfect Binder, and HC-680i Hydraulic Cutter
This success story highlights how Modern Press improved their efficiency and productivity after upgrading to the Duplo 700i Pro Digital Booklet System.
In today’s rapidly evolving digital age, print businesses are facing many challenges and embracing automation is crucial to remain competitive. Patrick M. Ryan, third generation owner of Modern Press in Albany, NY, recognized the importance of leveraging technologies to streamline processes. The shop successfully transitioned from offset to fully digital, incorporating and upgrading various pieces of equipment along the way. Their latest upgrade involved replacing their aging bookletmaker with the 700i Pro Digital Booklet System.
Adapting to Change
Modern Press has a rich history. It was founded in 1946 by Ryan’s grandfather, Patrick J., right out of the US Army Air Corps after WWII. In 1969, Ryan’s father, Michael J., purchased Albany’s first two-color offset press, establishing the shop as a reliable source for commercial print work. Today, it runs more on demand. Digital presses have replaced the 4-color offset presses, and Modern Press now uses online ordering and web-to-print portals. Duplo finishing equipment, like the DC-646 Slitter/Cutter/Creaser, make shorter print runs faster to complete.
In fact, Modern Press processes over 6,000 orders annually, with many shipped out the same day they are received. One of their most common jobs is program booklets for associations, non-profits, and schools. However, this work was being done on a decades-old bookletmaker. It was causing delays and inefficiencies in their workflow. To keep up, Ryan knew it was time for an upgrade.
Ryan explained, “Our seasoned staff has been retiring over the last half dozen years, and the days of hiring graduates from print vocational schools are long gone.” The shortage of trained labor is a reality commercial printers can no longer afford to ignore. “My new crew has been thriving with our modern equipment but our collator and bookletmaker were a challenge to keep running. It was also older than they were. I needed to invest in something that would be easier to use and more efficient.”
A Solution to Skilled Labor Shortage
The investment came in the form of the 700i Pro Digital Booklet System. The system integrates the DBM-700 Bookletmaker with the DSF-6000 Sheet Feeder, which feeds pre-collated output from his multiple digital presses. The 700i Pro is a productive solution that streamlines stitching, folding, and trimming – and now square spine finishing – up to 4,800 booklets per hour. Automated job setups and changeovers are key features that make operation simpler. The ability to perform these tasks from a PC station without any manual adjustments reduces the need for experienced operators. It minimizes the risk of human error, and results in more accurate work.
“I didn’t realize how much faster our 700i Pro would make the shop.”
“I didn’t realize how much faster our 700i Pro would make the shop,” he comments. “We start with printing the covers and if it needs a score, we put it on the DC-646. We no longer have to wait for the entire book to be printed. Moving that quick also helps us double check everything before printing the entire job. You can look at a PDF file all day and not notice something until it’s printed.”
He adds, “The artwork for the programs usually comes in at the last minute. They are often trying to finalize the speakers or secure one more advertisement. Our customers need to have things done the same or next day. Our ability to get the job done on time is why we have had substantial growth.”
A More Efficient Operation
Until recently, Modern Press processed thicker book jobs on the DB-290 Perfect Binder and trimmed them with the HC-680i Hydraulic Cutter. They’ve now shifted this work to the booklet system, which can produce thicker saddle-stitched booklets with a perfect bound look in-line. The 50-sheet capability and the DBM-700S Square Spine module— the fastest in the market—enable the system to create flatter books that are easier to pack.
“For years, I was rolling books over to the perfect binder because they were too thick for our old bookletmaker. Now we can produce a much thicker booklet on the 700i Pro.”
“My customers weren’t asking for a square back spine but now that we’re doing it, they can’t live without it. It has a very nice look and feel,” Ryan says. “For years, I was rolling books over to the perfect binder because they were too thick for our old bookletmaker. Now we can produce a much thicker booklet on the 700i Pro and it saves us time.”
The investment in automated equipment has transformed Modern Press, especially amid ongoing labor shortages in the industry. With the demand for last-minute changes and tight deadlines, being able to produce quality booklets efficiently reduces costs and allows them to be more competitive. Not only has the 700i Pro improved productivity, but it has also enhanced the quality of the final product.
“I like to have equipment younger than my employees and I chose Duplo for a few reasons. Their slitter/cutter/creaser, perfect binder, and cutter are cornerstones of the shop. And the service is second to none.” He adds, “Tim Davis, our service technician, understands the urgency of the work we do. He has an unparalleled ability to diagnose and fix our equipment quickly.”
The equipment was installed and is serviced by Mackey Electric.
