In Fisciano (SA), Pioltello (MI) and Campi Bisenzio (FI), Mavigrafica, a flexo prepress service, has installed 25 Packz workstations and two complete Cloudflow systems by Hybrid Software, a Belgian company that produces integrated software solutions for the sector of the graphics industry. The advantages: automation of workflows, greater print quality and productivity for its customers, security for the internal management of orders, with a view of collaboration and continuous improvement thanks to the competent and timely support of Hybrid Software technicians
The history of Mavigrafica began in 1997 in Fisciano and its founder and current owner, Maurizio Vitale, immediately chose to specialize as a service dedicated to the flexo sector, already realizing its enormous growth potential. After a long trial period and local affirmations, expansion activity in Northern Italy began in 2013. Everything became real in 2017 with the purchase of a factory in Pioltello and the installation of new machinery to produce photopolymer plates. In 2022, never satisfied and always eager to grow, the company faces a new adventure, this time in Central Italy in Tuscany and precisely in Campi Bisenzio where the third headquarters are born. Today Mavigrafica can be defined as a global prepress service, aimed at offering the best of current software and hardware technology, also from the point of view of sustainability: in 2023, the first in Italy, it installed Flexcel NX Ultra by Miraclon, an ecological production system of plates with water washing.
Automate, streamline, enhance
In its growth path, which was also very rapid, Mavigrafica felt the need to automate its production processes as much as possible and identified Packz, Hybrid Software’s native PDF editing tool, as the right solution for its needs. In 2015 the first Packz was installed in Fisciano and the choice proved to be in line with Mavigrafica’s needs, in fact today there are 25 Packz systems operating in its offices. Naturally the three sites are connected to each other, the approach to the customer is the same, we find same flows and technologies to provide everyone with the same service and the highest quality. To do this there is continuous collaboration between the offices, a constant exchange of data that allows the same know-how to be used in relation to graphic work and more, to improve the quality of the service offered, which has always been a prerogative of the company.
But what is special about this tool? We ask Fabio Casavecchia, manager of the Pioltello office, who explains to us that “this software gets right to the point, because the performances are stable, it allows you to work even complex PDFs, including trapping and automation of color spaces and control of the resolution at PDF opening; furthermore, the compatibility with the most popular graphic software such as Artwork, Illustrator or InDesign is complete, in fact we are able to reduce the processing interval and increase productivity”.
“In essence, automation serves to speed up workflows, so the graphic designer can dedicate himself to just being a graphic designer. Without automation, routine work, which today is carried out by Hybrid Software solutions, made the process slow”, explains Maurizio Vitale.
For Maurizio, however, Packz editing programs were not enough, he had to go further. In fact, after a few years, two complete, fully customizable Cloudflow systems were installed in Mavigrafica, in addition to the Hybrid Software RIP to fully automate processes, streamline flows and further enhance the prepress skills of pre-press operators, leaving Hybrid Software the task of carrying out the most repetitive procedures, which unfortunately, if left to the operators, can be a source of error.
Cloudflow is a production workflow with a modular suite for file processing, asset management, soft proofing and automation. It is a web-based application platform specifically tailored for packaging industry graphics using native PDF, color separations, bleeds, dithering, correction and much more.
A workflow also useful as a management system
An aspect that differentiates Mavigrafica’s use of Cloudflow is the decision to also use it as a management system, because “a structured company works and produces better. With it we create orders, manage the control phases but also estimates and warehouse stocks. All our processes are therefore equipped with a sort of internal identity card with the characteristics of the specific artwork, so we do not waste time organizing incoming flows and the assignment of orders and this helps us manage the graphic and commercial part; and let’s not forget the importance of recording all the data relating to the processes, to keep production progress under control in real time and therefore be able to optimize it, also making easier and faster the operators’ work”, explains Fabio.
“We chose a single supplier for the graphics stations, workflow and management system because, considering the excellent collaborative relationship we have established from the beginning with Hybrid Software, it would have been counterproductive to install a system from another manufacturer. Besides I was sure to be supported by their technicians, so why change? The facts have objectively demonstrated that we made an excellent decision, our journey together with them has given great satisfaction”, adds Maurizio.
Dedicated modules to increase quality, precision and reliability
Mavigrafica is using all Cloudflow modules including Intelligent Flexo, an independent surface screening solution for high-quality flexographic printing, which improves the quality of flexographic production by identifying problem areas that need intervention before printing. Fabio underlines that “Intelligent Flexo allows us to build customized screens that improve the quality of the plates we produce. We can work according to complex customer requests using cutting-edge technology, which allows us to stand out”. Another module is iC3D, which confirms Hybrid Software’s commitment to provide fast, accurate and photorealistic 3D virtual prototypes for the packaging design industry. In fact, to increase the quality and visibility of the projects, Mavigrafica also has the possibility of creating, by printing directly on the end customer’s film, a real simulation of the wrapping, providing a mock-up as realistic as the final product positioned on the shelf.
A common path of growth
Hybrid Software and Mavigrafica have built this collaboration over time and to create a process with these characteristics “it was crucial the help of Luca Rossi, Regional Manager Italy and the Hybrid Software technicians, who proved available and flexible and helped us create a customized system, tailor-made for us. A software can be perfect, but if it is not accompanied by a support and collaboration service from the supplier its value is reduced. With Hybrid Software we have established a relationship of total trust, especially after the sale, with constant testing and refinement to improve continuously, because it is the people who make companies unique”, says Fabio.
Once collaborations have begun, they can only continue to develop, to the benefit of both parties. “With the support of Hybrid Software we are working on solutions to manage requests for particular screens which can solve productivity problems, but also increase quality according to the various needs of printers. We are also developing a portal for direct communication with our buyers, with the aim of overcoming downtime and making the production process totally transparent”, adds Fabio. “The goal is ambitious, but we are sure we will succeed, we never back down and we will concretize a process that leads us to be a single entity with the customer. Each of them has different needs and we will make the widest variety of products available” concludes Maurizio.
