Technical Capabilities

Technical Capabilities

Machine Park
We expand our machinery according to Client needs.

Our machinery constitutes offers complete equipment necessary for production of cardboard packaging from solid and corrugated cardboard, soft and hard glued binding, stitched brochures and advertising products while applying elements rendering the materials more appealing. We use solutions enhancing the quality of our products and process efficiency. We have two complete cardboard packaging and printed materials production lines. The cardboard line is based on printing machinery from Heidelberg – the latest developments in multi-colour offset printing. Their efficiency reaches 18 000 sheets/h while maintaining high-quality print during the entire volume printing. Stamping machines for packaging cutting and folder-gluers from Bobst allow us to manufacture any packaging range. Our stamping machines also enable separation of the output during the production process directly on the machine while completely separating it from the so-called process waste. It allows us to maintain the quality and accuracy of the packaging detection process. The lines for production of books, brochures and instructions comprise printing machines from Heidelberg offering a possibility of duplex mode printing, provided with an electronic sheet control and gluers and stitchers. The glue binder from Muller Martini is adapted to use both traditional hotmelt as well as PUR technology. The latter one allows to glue volumes using coated raw materials such as high-quality coated paper at the binding rate of 1000 blocks/h. The Muller Martini stitching machine (booklet binding stitched with staples) allows wire-stitching of any kind of brochures using both straight as well as ring binding while achieving the performance of 9000 pcs/h. A standardised printing process offers a guarantee of colour repeatability. The print is always consistent with the colour model accepted by the Client (the so-called proof). Machinery setting is the responsibility of the CTP division which generates colour profiles which are subsequently distributed to printers through an internal fibre-optic network. This automatic control system is more advantageous in comparison with the traditional first proof verification methods, shortens the machinery setting time and accelerates the printing time while guaranteeing colour consistency.

Colour Management
ICC profiles applied at KEA guarantee print colour consistency with the results expected by Customers.

Customers expect predictable print colours, comparable with the graphical design provided in a digital form. To this end, we have implemented the ICC and we encourage our Clients to apply them already at the design stage. This allows the graphical designer, DTP/CTP operator and the printer to fully control the final outcome of work. The ICC profiles contain information concerning the manner of reproduction of a coloured space on printers as well as receipt of data concerning the applied base. That is why at KEA 4, ICC profiles of the most frequently used printing bases were created. The use of the same media such as among other things printing inks and ISO standardized optical densities ensure predictability and consistency of the colour printing process. It is also a guarantee of obtaining print fully matching the proof as previously accepted by the Client. A standardised printing process guarantees colour consistency. The print is always of the same quality as the proof accepted by the Client. Printer setting is managed by the CTP division through colour profile generation.  

Packaging Safety Features
Safeguarding the products against forgery becomes imperative.

The share of fake products in global trade is estimated at 7-8 %. The most exposed sectors include pharmacy, cosmetics and food industries. The risk of legal manufacturers’ losing customer confidence in original products is as dangerous as suffering financial losses. We offer a number of solutions with respect to packaging safety features. We choose the most effective product safety features while applying techniques emphasizing the original nature of the brand. The proposed protection methods may be, on a visual level, parts of the graphical design or have concealed elements which can be identified using extra tools or specialist decoders. Each of the techniques offers a different safety level and therefore should be individually selected to match product safety requirements.

Graphical Studio
Clients provide KEA with a graphical design. We make sure it is adequately realised.

Specialists from our graphical studio verify and adapt printing materials in a professional way. At this stage, our priority is to ensure flawless preparation of the provided files. Individual graphical elements of the submitted designs are subject to individual processing to adjust them to the form, shape and type of base material they are to be printed on. Next, they are put together into a complete design of publication pages. The so prepared material is exposed in the CTP system enabling the commencement of a proper printing process.

Technical Prepress Specification