Digital creativity: A tale of four Konica Minolta customers - The Noel D'Cunha Sunday Column

Amar Fax Services raises its profile with MGI JetVarnish 3D One kit
Covid-19 lockdowns were difficult phases for us, says Prabjoth Singh Allagh of Lucknow-based Amar Fax Services. “Running a business when the economy is at a halt is quite difficult. But we never lost hope.” 

 
Alagh (l) with Oberoi of Amar Fax Services

The 2005-established Amar Fax Services was started by two partners, Surjit Singh and Harpal Singh. The due began print business with a Xerox kit before replacing it with Konica Minolta (KM) bizhub Pro 1100. As the business grew, the firm invested in yet another KM bizhub C1060.
 
In early 2020 and just before the lockdown in March 2020, the company opened a new unit in Aliganj, investing in KM AccurioPress C6100 and two monochrome printers. Soon after, Covid-19 pandemic struck. It impacted the print business in Lucknow hugely.
 
Allagh, son of Harpal, and a part of the management, says, “During this period, we were constantly in touch with our designers, creating a new range of designs for the post-lockdown period. Once the lockdown was over and businesses reopened, we could introduce our designs to potential clients and bring our business back on the growth track.”

Besides the Alaghs, Bhuwan Singh Oberoi, a partner, is also part of the management.
 
The JetVarnish investment
If a crisis hits, profits fall, and the first reaction of any company is to stop investment. No, says Allagh. “We did have a plan of investing in KM products in near future but again we were waiting for the print embellishment market to mature before we took the plunge.”
 
In March 2022, Amar Fax Services installed the MGI JetVarnish 3D One. The machine was installed in seven days; and after the trail runs, the JetVarnish 3D One press armed the firm with the capabilities to apply selective UV varnish, spot varnish, and textured varnish followed by hot foil stamping on various types of labels or light cardboard.
 
Allagh uses the JetVarnish kit to print a wide array of products. “For instance, we create high-end visiting cards, money envelopes, brochures, profiles, boxes, paper bags, menus, wedding invitation cards, and so on.”

Allagh explains, “The varnish and the gilding over visiting cards, money envelopes and brochures give them added value and sensory dimensional textures.”
 
However, while executing print embellishments, accurate and fast registration becomes important. Here key components of MGI’s JetVarnish technology, including the intelligent and adaptive AIS SmartScanner registration system, come into play. “This eliminates more than 80% of operator setup time spent on registration processes while also reducing makeready waste,” says Allagh.
 
The new kit became a trigger for more business. “After installing MGI, we have delivered outstanding outcomes, resulting in strong client relationships. In fact, we are proud to share that our digital print volume has increased to 30,000 copies a month,” says Allagh.
 
The embellishment processes
Embellishments are finishing decorative applications added after the actual printing in the post-press phase of production. But it’s not as simple as it sounds. There’s a stage of pre-processing involved before the prints are pushed to the MGI JetVarnish, for which the company uses Adobe Illustrator and Corel Draw software.
 
Allagh explains, “Our printing process begins with creating designs, followed by a masking process, in-line spot UV coating, and embossed hot-foiling AIS varnish. Once prepared, the final piece is sent to the client for final approval. It gives us immense pleasure to see our customers’ satisfactory smiles.”
 
So what are the pros and cons of the JetVarnish 3D One. “There aren’t any cons. With the help of this machine, it is easy to spot coat digital prints, highlight defined areas, or add 3D effects – all of which enable businesses to offer attractive print products that are more vivid and tactile,” says Allagh.
 
However, embellishments on prints come at higher additional costs – capital cost and running cost. Does it bring you additional revenues? Without divulging the percentage of margin post-embellishment, Allagh says, “Yes, customers pay the premium for additional print.”
 
Konica Minolta is the only vendor distributing MGI’s JetVarnish kit on its behalf in India.
 
The JetVarnish 3D One supports various print media, such as, matte or glossy laminated surfaces, with or without aqueous coating, layered paper, plastic, PVC, and other coated materials.  It can produce 2,077 A3 sheets per hour. 

A new approach to business success – creating value
A year ago, Feather Graphics India bolstered its print operation with an MGI JetVarnish 3DS press. Today the company’s managing director Manish Luthra know what his customers want, and is armed to deliver it

 
Luthra: Feather Graphics produces 30,000 to 35,000 sheets of 13x19-inch size per month using the MGI kit

In July 2021, soon after the first Covid-19 pandemic-related lockdown was lifted, Ghaziabad-based Feather Graphics India invested in an MGI JetVarnish 3DS with iFoil press.
 
Manish Luthra, director of Feather Graphics India, said, “Since the pandemic hit the country and everything went home, we diligently worked on our digital printing solutions. Through digital print solutions, we could meet the immediate demands in terms of quantity or requirement. We were able to successfully satisfy our customer base.”
 
Established in 2014, Feather Graphics India specialises in manufacturing of membrane keypads, flexible membrane keypads and polycarbonate stickers. The company is an offshoot of Shakti Keypads, which was established by Luthra’s father, Shyam Luthra, a weight lifter and a marathon runner – who forayed into the print business as a trader about 40 years ago. He used to produce stickers and metal labels for electrical and engineering companies. Shakti Keypads is today managed by Luthra’s brother as a separate entity.
 
Feather Graphics began its operation using the screen printing process and a couple of years later, in 2016 even won international awards at the Screen Graphic Imaging Association (SGIA) award. It included gold for screen printing of a membrane switch and a bronze for decals.

While the company’s screen printing production is around 25,000 to 30,000 stickers, in August 2021, the company brought in digital printing and is equipped with a Konica Minolta 3080 and a mono PU dom. While the company’s screen printing production is around 25,000 to 30,000 stickers, it produces close to 35,000 sheets daily.

Besides, the company possess manufacturing facilities that help it in running manufacturing procedures for membrane keypads and stickers with all-in-all machines, tools and technologies. 
 
Luthra is assisted by his wife, Rakhi, in managing the business.
 
The JetVarnish investment
Motivated by the growth of their clients in the medical, scientific and mechanical instruments segments, as well as clients in the sports equipment and accessories field, the company sought to incorporate embellishment services and focus on offering distinctive work for higher margins, and high-quality results.
  
Graphic overlays for membrane keypads give an aesthetic sense to the control panel and provide a greater user experience. It also helps users connect to their devices and protect the internal components from being exposed. Likewise, when it comes to sports equipment and accessories or decals, the radiant foils add explosive visuals that can draw attention on crowded store display shelves.
 
Luthra says, “We have witnessed the immediate effects of the machine since the day it was installed. Since the beginning, we have been very clear about our targets and the customers' demand that was supposed to be met. After the successful installation of the machine for over a month, we were able to meet the commercial demand.”
 
On average, Feather Graphics produces 30,000 to 35,000 sheets of 13x19-inch size per month using the MGI kit. “Currently, we are not working as a commercial printer, but we have a certain set of clients, and we align ourselves with their requirements.”
 
Since Feather Graphics’ products are different from the traditional paper substrates, how does the company balance the use of screen and digital technologies? Luthra explains, “We need to make masks and print either through the screen or via KM digital printing machine. The next step is to laminate. Then using MGI JetVarnish we put digital spot UV varnish and/or hot foil stamping in the same pass. To avoid lamination, we have developed our own coatings in certain applications where the end customer does not want lamination.”
 
Luthra adds that even the settings were done quite easily. “As per the machine's capabilities, UV varnish provides us with an immediate solution. We can print in any mode, whether screen mode, digital mode or UV printing. If anyone is looking for enhancement or upgradation, then there is no better option than this machine.”
 
Feather Graphics has also found the MGI JetVarnish ideal for shorter runs and can offer variable content on each piece. “This machine has very good foil enhancement which helps the product to stand out among its competitors. Plus it can provide results within a very short time,” says Luthra.
 
The benefits
If we talk about the revenue, Luthra says, there definitely has been an increase in numbers. “In the present scenario of the print market, we can say that we are able to generate around 10%-20% additional revenue. Providing immediate effects and serving our customers with on-time delivery, we have been able to achieve good business and generate revenue out of it.  Providing on-time delivery and a variety of print solutions have been our major USP, and in future, we will aim to generate better revenue.”
 
Feather Graphics’ USP now includes the enhancement of the final products through the MGI machine. “Along with that, we have some patent technologies that we have been practising for the last five to six years,” says Luthra.
 
He cites a challenging project his company had to execute in which the MGI kit came in handy. “It was a project where we were asked to supply keypads with backlighting to the Europe Defense. We faced some challenges but, in the end, we were too able to successfully meet the parameters and finished off that project, thanks to the MGI JetVarnish kit,” says Luthra without divulging the secret of how it was executed. “That’s our USP now,” Luthra says.
 
Luthra says he is very excited because brand owners and designers are always looking for something unique. “Need for digital embellishment is growing, and one can make unique applications which cannot be even dreamed of via traditional technologies. They get blown away when we show them embellishment samples with spot UV and creative foil placement. We know that this is going to be something big.”
 
Luthra plays down the toner versus MGI JetVarnish embellishment debate. “Every technology has its unique applications, but the output of MGI JetVarnish stands out from rest as one can touch and feel the embellishment. There is no such feel-factor in toner-based embellishment,” says Luthra.
 
There’s only one problem Luthra has sometimes faced: the machine's warm-up time at startup. “Else, we have no complaints about the machine and its services. The build quality and the printing solutions provided by the machine are beyond our expectations and help us get better results as well. The after-sales service from the brand is also great, and they have been able to provide us good in-time service, and we expect the same to be continued in the future as well,” concludes Luthra.
 
The MGI JetVarnish offers production speeds of up to 3,000 sheets per hour based on 30-micron coating thickness. It also can varnish up to 232 microns for 3D raised effects and tactile finishes.

Sharp Digital pivot brings MGI JetVarnish in-house
For some, recovery from Covid-19 pandemic started and ended with business. While there were obstacles, Sharp Digital, a digital print specialist in New Delhi, managed to survive and invest in an MGI JetVarnish kit

 
Singh (l) of Sharp Digital: We produce 50,000 to 60,000 sheets of embellished prints per month

“We specialise in printing books and brochures. Short-run prints of books were in demand, and digital was the technology that could provide it on-demand,” says Ekjot Singh, director of Sharp. “But we also had to deal with the challenges of doing business during the pandemic. Outsourcing decorating finishing was one.”
 
During the pandemic, Singh realised the need for a fully automated printing machine that would enable his firm to run its business with the least amount of human involvement. “Hence, in October last year, we decided to install the MGI JetVarnish press,” says Singh.
 
Sharp Digital was established by Singh’s father, Gurvinder, director and has been in the business for a long time. Besides the Singh father-son duo, Amarjit Chadha Kaur is also involved in running the business.
 
Besides the JetVarnish 3D One machine, Sharp is equipped with multiple colour engines &two mono Konica Minolta (KM) Mono machines and a couple of post-press equipment to cater to the commercial print market requirements. 
 
The JetVarnish investment
The image enhancement trend is catching up. That’s because people want more than just colour prints. 
 
Singh says, “The machine allows us to add embellishment to anything we want. Hence, we can use it to print different types of like catalogues, visiting cards, gift hamper, wedding cards, and brochures.” He adds, “Now, with print transitioning from offset to digital, we are experiencing good growth and expecting a good response in future.”
 
At present, Sharp produces 50,000 to 60,000 sheets of embellished prints per month.
 
While there are options like traditional analogue processes – offset and screen printing, digital print’s embellishment methods with no makeready and no plate or dies, allows for economical short runs and even variable data applications.
 
Singh says, “Without the additional cost of dies and blocks, they can get excellent results compared to traditional screen print process, which is unsuitable for putting UV over digitally printed sheets.” He adds, “It is expensive when working with short runs as the minimum quantity required to make screen printing viable is one thousand sheets. There is wastage involved when getting the position right for UV printing.”
 
The JetVarnish benefit
One of the best parts of the MGI JetVarnish press is its accuracy, says Singh. “As a businessperson in the printing industry, I understand the negative aspects of a printing error. These errors are not only non-sustainable but increase the overall cost. I realised that every print produced is the same after using this machine. It is essential for coloured prints, especially. This machine has enabled us to create wonderful, bright, and colourful designs.”
 
That’s not all, says Singh. “After using MGI Jetvarnish press, we accrued many benefits. Our colour print volume has increased. Now we can provide the total solution. Using MGI JetVarnish, we can also produce book covers and finishing.”
 
How Sharp does embellishment
The setting is fast. First, the design is created, and then the fifth digital colour mask is used to print the designs. In addition, to make designs more realistic with a 3D effect, the company uses the machine’s UV coatings and capacity feature. 
 
“Once the designs are approved, we produce them in bulk till the order is completed.”
 
Another way of digital print embellishment is: having a unit built within the digital printing machine - CMYK and a fifth unit, more common on dry toner presses.
 
However, Singh believes that the 2D and 3D effect embossing provides a sensory feel that is not possible with special colour toner. “We can provide the real metal effect. With toner devices, embellishment is flat, close to metallic effect, not metallic effect.”
 
There’s the advantage of capacity too. “The JetVarnish gives us the capacity to produce 5,000-8,000 sheets per day of digital spot UV, textured UV. We are also seeing a growth in variable data foiling production.”
 
Singh concludes, “With the JetVarnish, we have made great progress and envision strong financial results in the coming months. We produce quality products, which brings us additional revenue, and customers pay the premium for additional print.”

Upadhyay raised its profile and is making good impressions
 
When the dust of the Covid-19 pandemic was settling, Upadhyay Colour Copier found it the best time to invest in MGI JetVarnish and Accurio Shine 101 machines. Six months down the line, it is reaping rich dividends

 
Upadhyay of Upadhyay Colour: After investing in JetVarnish, we have seen 20%-25% growth in our revenue

When Lucknow-based Upadhayay Colour Copier invested in MGI JetVarnish 3D One and Accurio Shine 101, it was an expansion of its small-format finishing and embellishment capabilities. At that time, the digital print specialist had leaned heavily on gaining a first-mover advantage in a city which has demand but had no print service providers with such kit to deliver.
 
Pawan Upadhyay, the owner of Upadhyay Colour Copier, claimed his firm then was the first to usher in the new technology to the UP print market. “Earlier embellishment services were provided by print companies in Delhi, Mumbai or Kolkata. It used to take a minimum of 10-12 days for the finished printed sheets to be delivered, after which the converting was done.”
 
By bringing the MGI JetVarnish, Upadhyay has given the print decoration in the city a fillip. “We provide service with 12 hours because of the new-age technology we have invested in.”
 
It may sound clichéd, but the Covid-19 pandemic affected industries across the globe and our print industry wasn’t untouched. “We too were affected, but it also allowed us to rethink and re-evaluate our strategies, and once the lockdowns were lifted, we started executing our ideas into sustainable practices,” says Upadhyay.
 
Upadhyay saw big demand from customers for embellishments and different types of printing as the market started recovering. The MGI JetVarnish 3D One was installed in April 2022. “Within three days, and the machine was up and running on the fifth day,” says Upadhyay. 
 
The firm started producing decorative print on wedding cards, greeting cards, invitation cards, visiting cards, books and brochures. “Apart from this, we have also done several government projects through the MGI JetVarnish machine,” confirms Upadhyay.
 
Started 20 years ago with a copier machine, Upadhayay Colour Copier has been upgrading its production process with new technology addition. As a printing service provider, its principal clienteles are freelancers. “Book publishers, offset printers, end corporate customers and designers are our clients,” Upadhyay says.
 
The 1,000-sqft facility of Upadhayay, besides the two new kit, houses three digital print engines, a plotter device of Epson, a Polar cutting machine, a thermal lamination machine and binding machines, among others. 
 
The JetVarnish advantage
For any print service provider, the pain area is wastage due to errors in printing which not only drains profits but also create a negative image for the print provider. 
 
With the use of artificial intelligence scanner technology, JetVarnish can control the waste that may have occurred due to improper registration, which is a common phenomenon in the conventional method. “By using JetVarnish 3D One, we are assured that quality is never compromised in terms of improper registration, which is very important in the image enhancement process.”
 
So how does Upadhyay go about the task of producing decorative prints? “Normally, we get print-ready files from the print buyers. However, if required, we have facility in-house to design and produce what our clients need.”
 
Upadhyay agrees that every stage of pre-processing the decorative work on the JetVarnish requires attention, but he says our manpower is well-trained to carry out the task. “Konica Minolta (KM) trained our operator at KM’s digital innovation centre in Gurgaon before our machine arrived. We were ready with trained manpower from day one, and the KM team is very helpful and provided inputs regularly.
 
Print decoration, the multiplier
Almost all effects, such as spot UV, embossing, texture UV, and foiling, can be produced on the MGI JetVarnish press. 
 
Upadhyay says that there are vendors to whom his firm provides service at a low cost. These vendors add their commission on the project, and as a result, not just us but even our vendors' profit.
 
The additional embellishments on prints come at a higher cost. “We have seen immense growth in our revenue, clocking somewhere around 20%-25%. Also, our colour volume has increased. We provide the best service to our customers, and in return, these customers ask for additional print services and pay us a good amount,” exults Upadhyay.
 
And Upadhyay cites an example of customer satisfaction. “We do not cater to a specific brand, but most of the time, it’s an assortment of brands and freelancers. The trickiest project that we executed was for Central Drug Research Institute (CRDI). We were asked to print covers. So with the help of the UV features of the Konica Minolta machine, we printed 500 sheets within four to five hours. This would not have been possible if we didn't have this technology and the Konica Minolta machine.”
 
Upadhyay says, “We can produce 8000 to 10,000 sheets daily and are adding new customers every day. Volumes, too, are increasing.” He also is a KM loyalist. He concludes, “The company provides technology and helps customers develop business by creating awareness among print buyers. We want to benefit from KM's special initiative for volume growth.”