Garlich Printing--Lights! Camera! CTP!

As a leader in computer-to-plate technologies, Garlich Printing was selected as the site of Creo's recent video shoot. Having wholeheartedly embraced CTP, Garlich is "airing" its expertise of the technology.

BY CHERYL A. ADAMS

Most employees are bound to get the "heebie-jeebies" when informed they are having their picture taken—be it for a magazine article, a company press release or even a self-promo brochure. Posing for a professional, corporate photograph is enough to make any worker nervous.

But having a still picture taken isn't nearly as nerve-racking as having a film crew show up at your door. That's when you really start sweating bullets. Right?

Not if you're Garlich Printing.

This family owned firm was selected as the site of Creo's recent video shoot because of Garlich's many achievements, particularly its mastery of computer-to-plate.

As a high-end commercial printer, St. Louis-based Garlich (pronounced garlic) Printing has "wholeheartedly embraced CTP," says Vice President Brad Garlich, who heads sales and customer service. "Our niche is that we continue to positively and significantly impact the quality process of color management and replication."

At the core of its PostScript-based prepress environment is a Xinet FullPress OPI and file-serving system. Eleven G4 Mac workstations running three shifts drive Garlich's three eight-up Creo output engines—a Trendsetter 3244F, a Trendsetter Spectrum and a Proofsetter Spectrum.

Although Garlich Printing produces no film, Vice President Don Hockenbury, head of production, explains that it can accept furnished film and incorporate it into its PostScript environment via a Purup-Eskofot EskoScan 2024 copydot scanner. With a DS digital drum scanner, Imation Digital Laser Matchprint and DuPont Thermal Dylux proofing systems, the company closes the digital "loop," he reports.

Embracing CTP
Garlich installed its first two Creo digital platesetters in March 1999, and its third this past February.

"There is no single point of failure in our prepress workflow," Hockenbury contends. "Two of our three Creo digital output devices can generate plates, two can generate Imation Laser Matchprint proofs, and all three can generate double-sided DuPont Thermal Dylux proofs."

"Since embracing CTP technology, we raised our default line ruling standards from a 150-line screen on coated paper and a 133-line screen on uncoated paper to a 200-line screen on coated and a 150-line screen on uncoated grades," he continues. "Creo's SquareSpot Imaging Technology allows us to more finely control color on press."

Furthermore, proofing time has been reduced by 50 percent, plating time has been reduced by at least 50 percent and press makeready time has been reduced significantly, Hockenbury notes. "Yet our quality level has improved, all registration issues have been eliminated and a new, broader range of quality control measures have been introduced."

Virtual Proofing
Before a file is imaged on the plate, the virtual proofing systems allow operators to catch problems that previously they would have found only by generating film. Thus, Garlich says the company is able to produce higher quality for the same, or fewer, dollars.

"Not only do we see significant benefits of CTP in our daily production," he contends, "our customers perceive us as technology leaders in the industry—and our sales staff is excited to share the benefits of CTP with their existing and potential customers."

Company sales reps are also excited to share the news about their new Heidelberg Speedmaster 52-5+L, which was installed early last month and will allow Garlich Printing to compete in the print-on-demand market. The five-color press, with in-line aqueous coating, offers several automation and quality features, including automated plate mounting, automated blanket and cylinder washup, production speeds up to 15,000 sph, remote inking and register control system, as well as circumferential and lateral movement and cocking of cylinders from the console.

The Tools and the Talent
The new Heidelberg SM 52 joins five other presses: a six-color, 40˝ Heidelberg Speedmaster CD with aqueous coater; a six-color, 41˝ MAN Miller TP104 perfecting press; a four-color, 38˝ MAN Miller TP38A perfecting press; and a five-color, 25˝ Heidelberg MO with aqueous coater.

Garlich Printing's bindery is fully automated with two Stahl folders, two Polar cutting systems with robotic off-loading, Stahl saddle stitching, and diecutting, drilling, electronic counting/tabbing and padding equipment.

By investing wisely in technology, aggressively pursuing sales and always looking to its customers for direction, Vice President Greg Garlich, who heads finance and accounting, says the firm has experienced 116-percent growth over the past 10 years. In 1999, the company generated 6.3-percent growth with annual revenues of $19.9 million.

Furthermore, Garlich predicts future growth for Garlich Printing in such areas as acquisitions, complete fulfillment services, flexographic printing capabilities and by adding sales teams in key locations across the United States.

"Wherever our future takes us, we know we will be led by our customers. Our goal for growth, measured in dollars, is to double our sales in the next decade," he says, noting that such growth will take place "in a conservative and controlled manner." Conservative with respect to upholding the highest of standards, but aggressive in its pursuit of technological success.

"Garlich Printing has always maintained a balance between R&D, keeping abreast of technology and investing wisely in solutions that benefit our customers," adds Brad Garlich. "Part of our research resulted in us being selected as a beta site for several products: DuPont's Thermal Dylux material, Western Lithotech's LT-1 digital plates and Creo's RIP and proofing software."

Shop Floor Management
On yet another technological trek, Garlich Printing is currently in the process of installing Profit Control Systems' Client Series computer information and data management system company-wide. Greg says this Windows-based, open architecture PC platform allows the company to take advantage of its employees' existing computer skills.

"Although we have developed our own internal scheduling and communication software applications, it is important for us to remain on the industry leading edge in shop floor management and real-time data access—even to the extent that we are placing laptop computers in our pressroom for data collection of job particulars and scheduling information," Greg Garlich reports.

"PCS will allow us to monitor and manage all aspects of production information, from administration, purchasing and sales through press and bindery activities," Hockenbury adds. "This system will tailor with several of the advancing, Web-based print buyer portal and file transfer systems.

"In addition," he continues, "by providing all of our sales and customer support personnel with the PCS system, there will be a significant improvement in response time for our customers, as well as all of our employees."

Founded in 1928 by Leo T. Garlich—joined in 1953 by his son Bob—this third-generation, commercial printing operation is growing, not only technologically, but physically. Garlich Printing will be expanding its facility later this year, by adding 7,000 square feet to its existing plant, which will be used to expand the bindery and pressroom. Greg Garlich also reports that the company has purchased another 9,000 square feet adjacent to its facility for future expansion.

For a forward-thinking firm like Garlich Printing, the concept of "company expansion" goes beyond the physical, technological and financial realms, to the level of employees.

"By establishing such innovative practices as not issuing titles to our employees—and by letting them know that there are no boundaries within the company—each employee can take their career at Garlich Printing to whatever level they choose," Brad Garlich claims. As an example of employee-friendly practices, he cites the company's daily card tournament, wherein a variety of different sales, production and management staff gather to play and "blow off steam."

"Our corporate environment is simple, employee spirit is high, management is always open to suggestions and comments, and customers are our top priority," Greg Garlich contends, noting that such achievements do not go unnoticed. In fact, those achievements will soon be "aired" via Creo's video to dozens (maybe hundreds) of people.

Sound like a happy ending? For Garlich's commercial printing operation, the Creo video is only the beginning.

The Step-by-step Transition to CTP

To prepare for the installation of CTP equipment, Garlich Printing spent several years designing and implementing new processes so they could perfect production techniques before becoming dependent upon the Creo equipment. Following are the steps Garlich took along the way:

1. First, they migrated from a four-up imagesetter to an eight-up imagesetter, familiarizing the operators with full-format output.

2. Next, they developed systems that eliminated 80 percent of the prepress technical problems (mostly related to trapping and PostScript anomalies).

3. Subsequently, the firm refined its copydot workflow, perfecting its ability to convert furnished film into a digital file.

4. Next, Garlich trained its experienced prepress staff for CTP quality control and imposition.

5. The final step was to find a full-format digital halftone proofing solution; they chose Imation's Laser Matchprint.