BECO Dairy Automation Inc. is a manufacturer of modern dairy equipment. BECO came to GM Nameplate (GMN) looking for several overlays for their Immix G2 machine, a dairy milking control module. The overlays had specific aesthetic requirements and also needed to be able to handle the harsh environment of milking farms.
There were six overlays made with each set: three labels, two control switches, and one large label with display windows to read measurements on the Immix machine.
The overlays were required to withstand one million actuations, frequent contact with chemicals, and being sprayed by powerful hoses on a daily basis. BECO also wanted the overlays to have a metallic look that was complimented by a red gradient.
GMN initially used its new digital THIEME printer for this project. The THIEME printer can run multiple colors and print the entire overlay in one run instead of having to switch colors with each run-through, which eliminates setup costs associated with other conventional printing processes. This printing process is best for low to medium volume products with multiple colors and gradients, such as the red gradient BECO wanted on their overlay.
Traditional digital inks aren’t very durable, but with this machine, GMN has the capability of digitally printing UV curable inks which can be used for overlays that will face a lot of actuations. With a suitable ink selection based on the substrate material, we are also able to perform additional post-printing processes, such as embossing, to enhance the product appearance and add additional value over an older digital press.
However, the biggest challenge was achieving the desired metallic look that could survive countless actuations. Most metallic inks aren’t durable enough to withstand the hundreds of thousands of actuations that the BECO overlays would endure. Therefore, GMN decided to use a silver ink that was slightly more opaque, but had a guaranteed long actuation life.
Once the overlay was designed and ready to print, BECO ordered a higher quantity of overlays than initially anticipated. In order to meet the timeline, GMN moved the printing process to an offset lithography printer, which is a more cost effective process for larger volumes while still maintaining the level of quality.
With years of experience in printing and manufacturing, GMN knows which production technique is most appropriate for each project. Through GMN’s diverse array of capabilities and equipment, we are able to use the most economical option that will get the job done to meet budget and time constraints.