THERE’S NO LONGER ANY DEBATE ABOUT WHETHER DIGITAL WILL DEFINE THE FUTURE OF PRINTING. BUT FOR CONVERTERS TODAY, THE MORE PRESSING QUESTION IS: DOES IT PAY OFF RIGHT NOW?
WITH THE RIGHT PRODUCTION PROFILE, THE ANSWER IS YES.
BY JOCHEN SPROLL, SENIOR BUSINESS DEVELOPMENT MANAGER, KOENIG & BAUER DURST
Digital printing, especially with the VariJET 106 from Koenig & Bauer Durst, has moved well beyond being a futuristic luxury.
Folding carton converters no longer invest in technology based solely on speed or print quality. The bottom-line matters, and any new press must deliver tangible returns.
Real Results, Not Hype
That’s why our approach has always been grounded in real business cases and real data. We start by analysing your actual production: how many sheets do you run annually? How many jobs? What are the run lengths? How long do make-readies take, and how much waste do they create?
Then we factor in your target market – whether it’s pharmaceuticals, food, beauty, or luxury packaging – and calculate the exact point where the VariJET 106 becomes the most cost-effective choice. No guesswork, just clear numbers.
The Mid-volume Advantage
Our experience across numerous converters reveals one consistent trend: the sweet spot for digital lies in jobs between 4,000 and 10,000 sheets. These mid-volume runs are too short to be offset-efficient, yet they represent a significant portion of real-world demand.
A VariJET 106 running 8 to 12 million sheets annually typically pays for itself in just two to three years, depending on job mix and customer requirements. Why? Because traditional offset presses don’t reach their headline speeds on these types of runs. Frequent make-readies, plate changes, and colour tweaks all chip away at productivity and profit.
Even with a top speed of 5,500 sheets per hour, Koenig & Bauer Durst’s VariJET 106 offers comparable throughput when viewed holistically. Digital setup is nearly instantaneous, colour calibration is faster, and waste is reduced.
In most real-world production cases, the higher ink price is outweighed by savings in makeready waste, plate costs, and labour time. Our calculations show that in 95% of relevant jobs, digital efficiency gains more than compensate for ink costs.
The Mid-volume Advantage
Our experience across numerous converters reveals one consistent trend: the sweet spot for digital lies in jobs between 4,000 and 10,000 sheets. These mid-volume runs are too short to be offset-efficient, yet they represent a significant portion of real-world demand.
A VariJET 106 running 8 to 12 million sheets annually typically pays for itself in just two to three years, depending on job mix and customer requirements. Why? Because traditional offset presses don’t reach their headline speeds on these types of runs. Frequent make-readies, plate changes, and colour tweaks all chip away at productivity and profit.
Even with a top speed of 5,500 sheets per hour, Koenig & Bauer Durst’s VariJET 106 offers comparable throughput when viewed holistically. Digital setup is nearly instantaneous, colour calibration is faster, and waste is reduced.
In most real-world production cases, the higher ink price is outweighed by savings in makeready waste, plate costs, and labour time. Our calculations show that in 95% of relevant jobs, digital efficiency gains more than compensate for ink costs.
The VariJET 106’s B1 format is proven to be ideal, and with robust uptime performance, converters can confidently plan real production, not experiments.
Unlocking Added Value
Add in the flexibility of versioning, serialisation, and personalisation, and you unlock added value – though admittedly, customer willingness to pay for these features remains limited today. Still, the process efficiencies alone often make a compelling business case.
We built the VariJET 106 with format and reliability in mind. Folding carton converters need a format that fits their workflow and one that’s productive enough just complement existing machines. The VariJET 106’s B1 format is proven to be ideal, and with robust uptime performance, converters can confidently plan real production, not experiments.
For converters targeting demanding segments like pharma, cosmetics, or premium foods, the combination of digital quality with double-coating capability and exceptional registration allows them to hit the highest market requirements.
Software Integration is Crucial too
However, digital printing is not just about improving efficiency and thus making money. It’s about transforming your entire workflow. If your processes – from artwork to prepress to converting – remain analog, you’ll never realize the full benefit.
That’s why successful digital adopters also invest in software integration, automated workflows, and lean change management. We help you digitize the full value chain, to unlock not just a more agile print process, but a more responsive and scalable business model.
The VariJET 106 is designed for converters who are ready to grow profitably and embrace new opportunities. If your job mix aligns and you’re looking to increase efficiency and flexibility, it can be a true game-changer. And the best way to explore its potential is through your production data.
