Thinking Big!

LTI is a small family-owned flexographic tag and label printer with a reputation for printing hard jobs

"Since we added the Martin equipment, we're able to accomplish in a day what would have otherwise taken us a day and a half to do," says Baker. "It's like adding extra hours of production capacity to every shift."

According to Baker, every stop of the press for a roll change results in waste of about 300 feet of material, representing an average cost of about $30 per roll change. In addition, Baker points out this $30 of cost is based on a newer press, which is easier to bring up on impression. An older press could cost LTI as much as $50 per roll change.

For a typical job using 100,000 feet of substrate, Baker estimates the Martin Automatic equipment saves the company at least $300 in materials and $100 in ink waste. He also notes that the anilox rollers stay cleaner and last longer running nonstop, and there is less wear on the presses from constant starting and stopping.

"Our press operators love the automatic roll changing," reports Baker. "It frees them up to pay closer attention to the press run, which results in a higher level of consistent quality. They can run the press faster with confidence, and that means more throughput on every shift."

Baker adds, "Our people like to see new equipment on the floor because they know that it makes us more competitive. They receive performance bonuses when we're doing well, and that helps keep everyone motivated to produce the highest quality product possible."

Jim Baker, Leroy's grandson and LTI's facilities manager, notes, "We wouldn't be able to take the [new] business we have without the splicer and rewinder. While other converters are struggling, the Martins have enabled us to grow our business."

According to Jim, the company works to constantly reinvent itself by moving into new technologies and industries. "By decreasing our waste levels and associated costs, the Martin Automatic splicers have helped us expand into new machinery in other areas," he says.

For example, LTI recently purchased a Kodak Flexcel Trendsetter digital platemaking system. With this new equipment, the company can print up to 200 line halftone screens giving its process color work a near photographic appearance, says Jim.

"We've built our business printing the hard jobs—challenging jobs that other printers were either unable to do or wouldn't do," he says. "We ended up buying a lot of equipment to produce all those demanding jobs, but in the long run, that has brought greater diversity to our portfolio of capabilities and products. And when the economy gets slow, it's really good to be diversified."

This diversity has certainly paid dividends this past year. "We have seen the economy curtail some of our promotional customers but increase in other areas of our mix," reports Jim. "We have seen an increase in our sales and profits this year."

What's in store

The current LTI facility is 15,000 square feet and there are plans to add to the plant in the future. In the meantime, Leroy Baker—with his wife, daughter, and grandson—runs his small printing operation as if it were many times its actual size. The family pays attention to detail, constantly tracks operating costs, and continues to invest in top-quality equipment and processes. They compete for and win new business based upon a simple business principle—produce the best quality product and sell it for less.

"We have gained a reputation as a premier flexographic print shop because of our commitment to using the latest technology, as well as the company's emphasis on quality and rapid response to evolving customer needs," says Jim. "As for our future, we will continue to be on the forefront of new technology. We only want the best, and that is what we will pass along to our customers." pP

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