In today’s rapidly evolving digital age, print businesses are facing many challenges and embracing automation is crucial to remain competitive. Patrick M. Ryan, third generation owner of Modern Press in Albany, NY, recognized the importance of leveraging technologies to streamline processes. The shop recently completed the transition from an offset to a fully digital operation – a move that saw them swapping various pieces of equipment. Their latest upgrade involved replacing their aging bookletmaker with the 700i Pro Digital Booklet System from Duplo. 

A Solution to Skilled Labor Shortage

Modern Press has a rich history, founded in 1946 by Ryan’s grandfather, Patrick J., right out of the US Army Air Corps during WWII. In 1969 Ryan’s father, Michael J., bought Albany’s first two color offset press. Today, it runs more on demand. The 4 color offset presses have been replaced by digital presses. Online ordering and web-to-print portals are being used and Duplo finishing equipment, such as the DC-646 Slitter/Cutter/Creaser, have made shorter print runs faster to complete.

Modern Press processes over 6,000 orders a year with many flying out the door the same day they are ordered. One of their most common jobs is program booklets for associations, non-profits, and schools. However, this work was still being done on a decades-old bookletmaker. It was causing delays and inefficiencies in their workflow and to keep up, Ryan decided it was time for an upgrade.

“Our seasoned staff has been retiring over the last half dozen years and the days of hiring graduates from print vocations schools are long gone,” says Ryan about the shortage of trained labor, a reality commercial printers can no longer afford to ignore. “My new crew has been thriving with our modern equipment but our collator and bookletmaker were a challenge to keep running. It was also older than they were. I needed to invest in something that would be easier to use and more efficient.”

The investment came in the form of the 700i Pro Digital Booklet System, which integrates the DBM-700 Bookletmaker with the DSF-6000 Sheet Feeder. Automated job setups and changeovers are key features that make operation simpler. The ability to perform these tasks from a PC station without any manual adjustments reduces the need for experienced operators, minimizes the risk of human error, and results in more accurate work.

“I didn’t realize how much faster our 700i Pro would make the shop,” he comments. “We start with printing the covers and if it needs a score, we put it on the DC-646. We no longer have to wait for the entire book to be printed.”

A More Efficient Operation

Until recently, thicker book jobs were processed on their DB-290 Perfect Binder and HC-680i Hydraulic Cutter. The work has now been shifted to the booklet system for its ability to produce thicker saddle-stitched booklets with a perfect bound look in-line. The finish is made possible by the new 50-sheet capability and the DBM-700S Square Back module, the fastest in the market, which allows books to lay flatter and be packed with ease.

“My customers weren’t asking for a square back spine but now that we’re doing it, they can’t live without it. It has a very nice look and feel,” Ryan says. “Now we can produce a much thicker booklet on the 700i Pro and it saves us time.”

Overall, the investment in more automated equipment has transformed Modern Press at a time when the industry continues to deal with labor shortages. With the demand for tight deadlines from customers, having the capability to produce high-quality booklets efficiently reduces labor costs and allows them to be more competitive. 

“I like to have equipment younger than my employees and I chose Duplo for a few reasons. Their slitter/cutter/creaser, perfect binder, and cutter are cornerstones of the shop. And the service is second to none.”  

The equipment was installed and serviced by Mackey Electric.