What ReproPark will be in future

Будущее флексоформы

Over nine years of its existence the ReproPark company became a leader of Russian flexforms manufacturing market. "One of the reasons of such success is wise investment in modern technologies", says Vitaly Kovardakov, the executive director of the company.

Nowadays, according to its own esteem, the ReproPark produces 70% of all flexographic forms produced by reprostudios, and consumes 35% of all photopolymeric plates imported in Russia. "We've started as a small company producing 200 m2 flexographic formes per month. But these days we are the biggest producers of photopolymeric print forms in Russia and owners of the most advanced technologies in this branch," says Vitaly Kovardakov. "Nowadays we have five production sites. And production total value figures out about 6 000 m2 per month, that is 70 000 m2 print formes per year. During our development process we had left behind companies, which was at the outsprings. Later we had merged some of them, including their experience and personnel. Thanks for this merger, the best specialists of this branch form a core of the company."

Vitaly stressed on fact that 60-70% annual growth became possible because of constant renewal of technologies and equipment. He mentioned that company has never spared on high-quality requisite: equipment and soft. The management of the company is aimed at advanced technologies introduction, which can provide production with high quality and eliminate extra spend. That's why ESKO became one of the main ReproPark counterparts.

Along period of our collaboration there were purchased really great amount of equipment. Nowadays we have at least 9 CDI ESKO engravers of different size. Along with that we've constantly developed our soft, purchasing Automation Engine stream automation system and Package and ArtPro image editors. It's obvious that for correct use of these multifunctional programs good specialists are required," says Vitaly.

These days without taking in account economic difficulties in Russian Federation, our company continues investments into high-tech products. Recently we've purchased a new file ripping soft Еско Imagine Engine which replaced FlexRip.FlexRip proceeds a hard file in 30-40 minutes, whereas Imagine Engine can cope with it within 5 minutes.

Decision about investment in Imaging Engine was made in November 2014. Unfortunately payment had to be maid in a period of great appreciation of foreign exchange," Vitaly recalls. "Although its cost had been 45% higher, we didn't abandon this purchase on purpose. No doubt, anything bought for company's flourish sake will be fruitful. While other companies are forced to spare on everything to survive in circumstances of state financial crisis, ReproPark has both feet on the floor. We modernize and renew equipment stock, make huge investments in company development, even at this period of state economic crisis. We don't use credit or leasing -- our own finances only," says Vitaly.

Advanced technologies is base of leadership

Everything latest what appears in market -- if it was necessary for quality and productivity -- appears in our manufacturing site, assures Vitaly and explains that it is easier to order forms in reprocentres instead of keeping a form manufacture. It is obvious that producing period is the crucial factor here, but ReproPark equipment allows to deal with it and make the best relation between price and quality.

Choosing equipment we pay attention to some factors: efficiency, productivity, production quality and its exit value. Note that crucial point is quality. Thanks for quality we fulfill orders of companies which have their own preprint equipment. For example, in case of need for flat-top-dot technology or specific dot matrix.

ReproPark management believes that ESKO programmes are the best in the market. By means of ESKO soft we save our time, reduce need for hand labour and mistakes, raising quality and and reducing spents. Our concurrents have no such advantages. Our customers know it. Collaboration with our company gives the best result, says Vitaly.

Another key step on the development scala became lounge of Kongsberg cutter XN44 with steam automation program Esko Digital Flexo Suite. In Russia it is a unique installation yet. Over five months of exploitation of the plotter we achieved a significant economic result. Along with it we've reduced hand labour and operators' workload. The Layout Module for Automation Engine program allowed to automate fitting marking process for goffers and widen functionality of DFS. Therefore it is able to output fitting files directly on the astrolon sheet. This made this work much easier and correct. For example, in the processbof installing forms upon the astrolon the plotting papper or prepared by designers plastic sheet are traditionally used. This is hand work, which means possibility of incorrect installation. This may spoil circulation, return of tail-pan, etc. Now it's obvious how many problems it's possible to avoid with means of Kongsberg XN44 plotter, says Vitaly. There will appear another one -- Kongsberg XN22 -- in February. Two cutting plotters working simultanuously allow to devide some tasks in process of fulfillment: marking, cutting, assembling of composite forms. Our company and ESKO have a mutual idea of creating a plotter that could be able to pick up the mark from flexform.

What ReproPark will be in future

The ideal manufacturing as we see it, will be a fine clockwork machine. That's why we buy up-to-date equipment and automatisation means, explains Vitaly.

Crisis as a growth stimulus

Decline in economics always leads to market consolidation and manufacture enlargement. There is possibility to survive only for huge companies in the flexographic manufacture branch, and for those who can suggest the best relation between quality and price.

The ReproPark company continues to develop and make investments, because it's management believes that is important to calculate risk and expenses in a period of stagnation. The right strategy is to save money not by means of sparing on equipment or reduction of salary or personnel, but by means of process automatization and technology adoption.