Case Study: Waldo Ltd. (UK)

Direct-to-substrate proofing:
„Something new, that no one else offers“

As an established supplier to the packaging industry, Waldo Ltd. is renowned for delivering high quality files and plates. To maintain this hard-won recognition, the company requires the best available state-of-the-art technology in order to ensure high-quality spot and brand color reproduction as well as accurate halftone proofing. As an additional service, Waldo Ltd. also provides realistic mock-ups of final products.

At the end of 2020, the reprographics and platemaking specialist invested in the new proofing system developed by CGS ORIS and Mutoh Europe: A unique end-to-end digital print solution allowing direct-to-substrate proofing for packaging.

“This is what the flexo packaging industry has been looking for a long while,” states Phil Walmsley, Managing Director at Waldo. “We have been looking into different ways to produce proofs that are more lifelike. Paper proofs are OK but don’t give a true representation of the final printed product.”

Mutoh printer web

“We wanted something that could actually create proofs on client’s original substrate. With a paper proof you have to make allowances for what it will look like on the final substrate”, he explains the challenges his company was facing.

“With this solution the proof and mock-ups look like the finished product product – particularly with a metallized film. Notoriously, metallized film will not back all the colors, chiefly the white. Now we can be sure it will match”, Phil summarizes the experience his team made during the first months using the new system.

This is what the flexo packaging industry has been looking for a long while

Phil Walmsely, Managing DirectorWaldo Ltd.

The new opportunities open up a lot new chances: “That will give us the edge against our competitors,” says Phil on the system that is already opening doors. “It is something different and new that no one else offers. We are working closely with Modern Packaging, who has relationships with all the major retailers in the UK, to develop this. They are looking to put it out to their customers.”

Waldo also offers the new solution to design houses: “Our experience show, that many are not really aware of the intricacies of flexo packaging. But now we can deliver that touch and feel in the proofs which adds another level of excitement around the design development.”

Waldo Ltd Darren Havercroft and Phil Walmsley edit web

As for return on investment Phil states: “We believe there is massive potential for this service. We can offer some significant savings in price. I was used to paying £120 a SKU for a mock-up. Now, we can make a considerable saving on that, especially, if we use offcuts that are sent to us to test. The finished print is also touch dry so we can easily get something out in the mail to meet deadlines. Being able to supply a more realistic and economically commercially viable proof is a win-win all round.”

Aside from immediately seeing how the solution answered Waldo’s needs, Phil said the longstanding relationship built up with CGS ORIS was also an important factor in the investment: “In 2014 I went to Packaging Innovations and saw the CGS ORIS software for the first time. I bought it there and then. I knew it could do what we were looking for. It did and we have worked with CGS ORIS ever since. I had a very similar feeling this time. It is great to work with CGS ORIS and Mutoh.”

Mutoh sample web

Steve Chappell, Managing Director, ORIS Packaging Innovations UK, adds: “It has been great to work so closely with Phil and the team at Waldo as they have adapted their proofing capabilities to enhance the service they offer. They are committed to continually developing their customer focused approach to support creativity and exploration of new possibilities cost effectively. Their customers know they are in safe hands when they want to try something different. We are proud to be able to help create a solution that helps everyone involved push boundaries in a considered way that achieves outstanding results.”

Founded in April 1984 by Jim Dows and Phil Walmsley, Waldo Ltd. services the flexible packaging industry. The Louth, Lincolnshire, firm has 28 employees and supplies leading UK companies and brands, many of whom require special colors to be reproduced.

CGS ORIS´ well-known packaging proofing and mock-up system FLEX PACK work with the Mutoh ValueJet 628 MP, 630mm wide digital piezo inkjet printer, specially optimized for the specific requirements of the packaging industry.

FLEX PACK, is a cost-effective solution for flexible packaging proofing and mock-up production. At the heart of the application is CGS ORIS’s patented four-dimensional iterative color management software which, combined with a specially designed custom interface, enables the ultimate in production flexibility for halftone and continuous tone proofing.

The Mutoh ValueJet 628 MP runs newly developed multi-resin XG series inks (C, M, Y, K, Lc, Lm, White). The non-toxic, pigmented inks deliver excellent adhesion on coated and uncoated substrates. The correct distortion of a shrink sleeve prototype can be checked thanks to their unique stretch and shrink capabilities. They also support accurate proofing on uncoated label stock and corrugated board.

Unlike UV inks, CGS ORIS XG INKS retain the look and feel, as well as all other physical properties of the target substrates, intact. As such the proofs have the physical feel of the final product.

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Case Study: M GRUP (TURKEY)

Extended gamut printing with X GAMUT leads to incredible competitive advantages

M Grup is a fully integrated printing house with photography, graphic design and a prepress production department – all under one roof.

The company prides itself on following international trends and is always looking for the latest intelligent tools to provide its customers with world-class services.

A large challenge – beyond quality expectations – is, of course, cost reduction to increase margins while maintaining the highest quality at the best price: “If you can deliver high quality – you are good, but if you can offer your customers an incomparable price at the same time you achieve an incredible competitive advantage – for your company, but more importantly for your valued customers”, explains Mehmet Turan Tahtasakal, Sales Manager at M Grup.

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This is why, initially, the INK SAVER module gained the attention of the Turkish printing house. “With INK SAVER, we clearly reduced our ink consumption and overall production costs. But there was an additional benefit, which was even more important for us: The reduced make-ready times on all of our printing devices with the use of CGS ORIS color management.”

To realize further benefits and to optimize their processes, even more, M Grup integrated X GAMUT into their workflow. “With X GAMUT we finally use the full gamut of our Heidelberg CD74-8 and reproduce Pantone colors with a fixed ink set of CMYK+OGV. For example, we produce a local coffee and chocolate café recipe book in fantastic quality.“  

Optimized for each of their printing devices

Beyond that, profiling was a big challenge for the company. “We had a large problem with incoming customer creative files which were not always properly defined and correctly profiled to their required results”, Gökhan AkkamıŞ, Prepress Manager at M Grup.

Today, M Grup easily generates extended gamut profiles with X GAMUT which are adjusted and optimized for each of their printing devices – from flexo, digital to offset presses – with all different printing conditions and target-settings. “It doesn´t matter, if we do halftone printing, hybrid dots, or have various TACs or different media, with X GAMUT we can achieve accurate printing results on all of our production work.”

„We are thrilled with the features and functions of CGS ORIS software tools. They guarantee that our services are consistently repeatable and measurable.“

Gökhan AkkamıŞ, Prepress ManagerM GRUP

One additional benefit: “For many years we created our proofs with COLOR TUNER on Epson printers. We save a tremendous amount of time and money because we do not need to conduct expensive color trials on our production machines. Now, we can use exactly the same multi-color profiles, which were generated with X GAMUT for proofing and be confident that this is the color quality we expect to achieve on our production presses.”

M Grup and CGS ORIS have already had a long-standing successful partnership: “We were first introduced to CGS ORIS when we integrated our proofing system during our first Fogra certification process – in summer 2012. We are thrilled with the features and functions of CGS ORIS software tools. They guarantee that our services are consistently repeatable and measurable. Today, we are self-confident and know exactly what we can achieve and provide to our customers.”

M Grup was founded in 1998 in Kayseri, Turkey. Ömer Tahtasakal, Ahmet Aksoylu, Kazım Ketenci, Selim Kalanyuva, and Mustafa Özkan founded the company and many of them still work at M Grup, today with their team of 40 employees. The company has a Heidelberg CD74-8 F Format, a Heidelberg SM52-4 offset machines and a 16” Comco 7 color flexo machine.

In the near future, they plan to invest in a larger size flexo press. Their main focus is to serve the highest quality to customers worldwide. The company is currently manufacturing commercial offset printing and narrow web flexible packaging (flexo) printing and uses the highest quality equipment and supplies, from world-renowned companies like Heidelberg, Xerox, Epson, Sun Chemical and CGS ORIS.


Case Study: CXF TOOLS

Global communication of brand colors - consistent and effective

Our customer does business in more than 150 countries and has a large collection of over 200 brands. Several global players are included. They are one of the top consumer products companies in the world – according to their economic performance as well as their consumer relationship. Of course, color management is enormously important for them, because the look and feel of the brands, especially brand colors, always need to be perfect.

Needless to say, the company works with many different types of suppliers like packaging separators and printing companies all over the world. This caused a lot of color communication challenges in the past related to the exchange of data and printing results.

Accurate Color Exchange

On the one hand, several packaging separators edit and prepare data, put them in a color library and on the other hand, printing companies extract the data and produce with different printing machines and inks in individual environments. This workflow creates a complex environment and errors may occur which lead to a variation of printing results.

But, of course, the printing outcomes of the product labels, packaging or advertising material need to look accurate and consistent as defined by the designer – in every country and over time. This is vitally important for the company itself and its individual brands.

That means, the data, e.g. color aims, need to be communicated correctly between all involved parties. And the cooperation with the suppliers and the edited data files have to fit into the internal workflow. This includes, that the company has to be able to proof the results easily by themselves. For example, to check, if spot colors are correct and quality standards are reached.

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Working with CxF data was nothing new for our customer. This global player already knew the advantages of CxF and had an existing color library, where suppliers could leverage that data to work with.

Unfortunately, the library was not well-organized or ready to use. It contained a lot of duplicate color data or data that was incomplete to the current CxF-4 standard. This was the first challenge in the process.

Additionally, the customer required a central location to administer and communicate CxF data, which any of its suppliers would be able to easily access and utilize. CXF TOOLBOX & CLOUD offered all of the desired functionality.

Standard Operating Procedure

Therefore, the common journey began with the organization of the company´s color library. The first task was to clean and organize the existing CxF library. In the next step, a standard operating procedure (SOP) was established and communicated to all suppliers to ensure the SOP worked well and
delivered the required results.

An onboarding process was started to synchronize the suppliers color data, equipment and teach all involved parties on how to use the tool, either personally or by webinars. The initial rollout phase took roughly one year. By the second year, our customer was already using CGS ORIS CXF software across their global network of suppliers.

Excellent Service & Support

The functional core benefits of CXF TOOLBOX & CLOUD were obvious to them, but the main reason they selected CGS ORIS as a strategic partner was the added value, extended by excellent service and support. They expressed: “CGS ORIS listened to our needs and built a solution for us” and “it is incredibly easy to gain secure access to our brand colors, these are our crown jewels”, which creates confidence in the supplier, and makes it easy to reach the aim to be one team with one color scheme“.

It was essential for them to “own” their color library and have the flexibility to easily create their own CxF color definitions, instead of using alternative solutions with limited customization capabilities. CXF TOOLBOX & CLOUD on the contrary are holistic solutions, which enable end-users to communicate and even export spot colors directly, e.g. for ink formulation.

Quality Assurance at any time

CGS ORIS tools offer the ability to characterize printing substrate during the creation of CxF data, they are not pre-determined. CGS ORIS makes it possible to verify supplier measurements, which is essential for quality assurance, and to certify color accuracy.

To sum up, this international brand owner benefited greatly by having full customization capabilities and the ability to brand CXF TOOLBOX & CLOUD as their own.

"CGS ORIS believes strongly in the benefits of CxF standards. This project was unique and exciting, offering both companies an opportunity to work together to develop a solution that elevated their ability to create and communicate brand colors like never seen before. CGS ORIS did not just sell a software product to the customer, we were there to clearly understand the individual company needs and requirements to develop a customized solution and services that delivered on those needs. Listening to and understanding our customer’s needs and requirements has always been a key to CGS ORIS’ success”, Andreas Kämmerer, Chief Operating Officer of CGS comments

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Case Study: Stiefel Digitalprint & Eurocart GmbH

Quality Improvement with INK SAVER

By reducing ink, quality improvement is not possible, right? At first glance, most people will agree with this correlation. It’s unanimously believed that if you reduce the amount of ink the quality of the print will suffer. However, the opposite is true if you use the right tools as demonstrated here by the international STIEFEL Group.

Situated in Lenting, close to Ingolstadt, the company has 14 printing machines, 2 high-frequency welding towers, 4 guillotines and 3 laminators in their 5500m2 production hall.

Every day thousands of square meters of printed materials from giant fabric prints for flags, wall coverings, canopies and tablecloths, complex display banners and building wraps to foil printing for expo booths and vehicle wraps are produced. Direct printing to board and fleece wallpaper with imposing designs complete the STIEFEL portfolio.

Stiefel Personen web

This Upper Bavarian company also provides post-processing, delivery and assembly of the final product on site. Managing Director Bernhard Stiefel’s first priority is providing his customers with the best quality possible. Software from CGS gives him exactly that.

Just over a year ago, STIEFEL installed PRESS MATCHER with the INK SAVER module. “What’s most important in this solution is very clear to us, and that’s the quality improvement that we can achieve with it”, Bernhard Stiefel comments. “Printed results show considerably improved sharpness, they are noticeably more brilliant and edges are clearly defined” he said with satisfaction.

At first, he didn’t expect such incredible results. “We had already tried other ink-saving solutions, but none even came close to what we desired and this is why we were not convinced it was even possible. I was very positively surprised, because the results printed with ORIS Ink Saver even overachieved what CGS ORIS´ business partner, DRX Pack, had reported the software would deliver”, summarized Stiefel.

What’s most important in this solution is very clear to us, and that’s the quality improvement that we can achieve with it.

Bernhard Stiefel, Managing DirectorStiefel Digitalprint & Eurocart GmbH

As well as the increase in quality, ink-saving was also outstanding. On average, the company is saving around 20 % in ink. For example on the Canon Colorado that‘s 22% in saved ink costs. On certain printing machines the ink saving was even greater.

Stiefel Halle web

Ink savings can depend on factors such as image design, printing substrate and the machine itself. STIEFEL has a wide range of equipment from DURST, HP, VUTek, Canon and SwissQPrint. “We save most on the foil machines where we see up to 35%”, according to Stiefel.

Over and above the quality and cost-saving benefits the Managing Director praised the ease of integration of the software with his existing workflow.

As well as quality improvement and less ink usage, the INK SAVER module brings other unexpected benefits along with it. Because there is less ink on the substrate, drying time is reduced so that the production process can be speed up and the printer freed up for additional customer projects.

The origins of STIEFEL lie in the printing of maps. Bernhard Stiefel’s father, Heinrich, founded the company in 1982 with the idea of outfitting every school classroom with geography maps; in those days mostly by offset printing. “In the 90’s we started to use digital printing more and more, particularly as the many changes in European country borders meant constant map updates and that would not be economical on offset”, explains Bernhard Stiefel, who has led the company with his father since 1990.

So finally, in 2003, STIEFEL Digitalprint GmbH was formed alongside the existing STIEFEL Eurocart GmbH. Maps in various forms are still produced today through the major part of the business is advertising and display material of every kind and size. The Group has around 100 employees, mostly in Lenting in beautiful Oberbayern.

(Photo Credit: CGS)

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Case Study: Harder-Online GmbH (Zeithain)

Process optimization with X GAMUT

Online ordering today allows for multiple design iterations with personalized typeface selections and a host of special colors. Even product packaging can be turned into an individual “Limited Edition” with just a few clicks.

Personalized muesli packs, shower gels with pictures, or drink cans with logo and special themes for the perfect look at the next company function, can all be produced this way.

Stefan Harder makes many of these items possible. Under the names “Labelprint24” and “Partylables24” his company offers his customers complete packaging solutions.

BildHarder web

The customer hardly realizes how complex the process is to produce these many individual wishes. But already, since the founding of his company in 2010, the CEO and Owner of Harder-Online GmbH has continually worked on perfecting the ideal job workflow, with the mantra of intelligent job and process automation.

A decisive piece of the jigsaw in Stefan Harder’s cleverly thought out system is now provided by the color management software X GAMUT.

If a customer, for example, designs his particular muesli can on all the job files and data are automatically uploaded from there, overnight, into Harder-Online’s system, checked for printability (also automatically) and prepared for printing.

And then comes the decisive questions of any online printer: On which press should we now print for the best possible result? Which color space are we looking for? How can we reproduce spot colors accurately with our ink sets?


X GAMUT delivers all answers. The software decides which available press will produce the best result, converts the print data and sends it to the selected press so that the job can be produced.

Even the printing substrate, short delivery times and job costs are taken into consideration. In the case of mymuesli the whole process, from data input to the finished product, takes just 12 hours.

We have found CGS ORIS the ideal solution for our intent. The experience has shown us that we made the right choice!

Stefan Harder, CEO harder-online GmbHHarder-Online GmbH

Stefan Harder and CGS ORIS have worked together for over five years. It all began with PRESS MATCHER, used to calibrate his complete fleet of presses - so-called “cross-fleet color management”, to bring all presses to a consistent print result and a common standard. In addition to his two workhorses, Screen Truepress Jet L350 UV printers, Harder has, among others, an HP Indigo WS6800 and an HP Indigo 12000 in operation.

“Stefan Harder was already an advocate of the ‚X-Gamut‘ idea. We worked earlier together on how special colors could be separated in more than four colors” explains Bernd Rückert, CGS ORIS Product Marketing Manager.

“We are very happy that we made a contribution to press optimization at harder-online with X GAMUT. It’s very nice to see how perfectly and easily the product can be integrated into an existing workflow and there be key function in the order process”, he continues.

„Our customers expect individual packages in top quality. CGS ORIS was ready to provide a software solution outside the norm, too.“

Stefan Harder, CEO harder-online GmbHHarder-Online GmbH

Harder-Online GmbH is one of the leading European digital packaging producers. At the digital printing facility in Zeithain, Sachsen, the Company makes labels, multi-layer labels, folding boxes, made-to-measure cartons and laminated tubes for all industry branches, commerce, trade and administration.

X GAMUT is the latest product from CGS ORIS. In 2019, the software was recognized as the Best Color Management Solution by the EDP Association. The fully automatic tool makes it possible to reproduce special colors on multi-color conventional and digital presses using an extended, fixed, ink set.

Moreover, the perfect match of software features and intelligent workflow tools in X GAMUT enable printers to produce a richer, saturated, color image for a more brilliant photo-reproduction for, e.g., photobooks (RGB).

In addition to the basic application areas, the converted color data can be, as here at Harder-Online GmbH, the basis for automatic decision making in the production process, enabling X GAMUT to contribute significantly to workflow optimization and error reduction.

(Photo credits: Harder-Online GmbH)

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Case Study: ZRP Printing Group (China)

Printing Spot Colors With X GAMUT Instead of Spot Inks

The ZRP Printing Group Co., Ltd. is one of the top 20 printers in China and the biggest manroland user worldwide. The company was founded in 1978 and has four production bases in China today. The largest has an area of 100,000 m2.

The group has approx. 3000 employees and is responsible for 120 brand customers. Many of them are part of the FMCG branch. ZRP has had its focus on the offset market, but is now expanding its digital and flexo printing business. They are specialized in customized industry solutions and produce high-quality consumer packaging products with outstanding finishings on several materials as well as promotional tools and smart e-commerce solutions. ZRP is a member of the Global Packaging Alliance (GPA).

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Spot and brand colors are very important for the global player and the multi-national corporations ZRP is working with. The unique spot colors attract attention and can help to build up a strong brand recall value. In addition, intelligent custom solutions and promotional material are increasingly in demand as well as special effects in food packaging and other individualized campaigns. In one of the projects conducted for a famous cookie brand, customers were able to customize the product online and to track the delivery route.

In 2004 CGS ORIS joined forces with ZRP to increase the capacities for providing individualized solutions tailored to their customers‘ requirements. First of all, ZRP has used COLOR TUNER. After substantial investments in digital printing, they decided to work with the new CGS product X GAMUT.
During their large project with a multi-national consumer goods corporation, the great power of X GAMUT was impressively demonstrated. Using the new multi-channel functionality, ZRP was able to import, measure and re-separate the 13 spot colors used in air freshener packaging samples and to convert these spot colors easily and reliably into a fixed ink set comprising CMYK, orange, green and violet – while completely maintaining visual brand identity.

The benefits they gained from all this were enormous: Large time savings owing to shorter ink changing, job change-over, press wash-up and press downtimes as well as more flexibility resulting from the ability to print jobs including different spot colors on the same press and in the same run.

As a result, ZRP was able to reduce production and delivery times and to increase overall productivity. This allowed them to offer their services to more customers and at more competitive prices. Finally, costs could be cut considerably because of reduced (spot) ink consumption, less ink to be kept on stock and less ink waste. All this allowed our customer to maximize their profits.

This project and the calculations which were made during the tests showed that ZRP was able to save 376 hours of total press time, 20 percent of ink costs and RMB 370,000 of printing costs (approx. EUR 45,000) during the first half of 2017, which means that productivity could be increased by almost 50 percent – just with one single print project.

(Photo credits: ZRP/CGS ORIS)

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Case Study: Hanbuch Packaging (Pfungstadt)

50 % Ink Saving - 100 % Results

The desire of any business owner is to find the key to reducing his operating expenses by half.

14:00 Production meeting at Hanbuch Packaging. Amongst complex advertising displays for pharmacies, life-size advert cubes for car dealerships and 3D-looking posters for cinemas, Andreas’ team is discussing upcoming projects. In the background you can hear the hum of the machines from the printing hall.

The business is booming. Incoming orders are diverse. In spite of, or because of that, efficient organization of the production process is more important than ever. The best utilization of the printing presses is top priority. Production for the next few days is carefully planned out on the electronic whiteboard: What will be produced in-house, what needs to be sent out to sub-contractors for offset printing? Everything is covered by this company in Pfungstadt, from original concept to finished packaging or final display in the store.

Hanbuch Faller

(Andreas Hanbuch & Felix Faller)

Clever planning is one thing. The other is continued development. Which is great when you have men like Felix Faller. The former offset printer is only a few months with the company but has already implemented one major change.

“I looked at order processing and workflows and it was immediately clear to me that we could significantly improve production with software from CGS ORIS”, explains Faller. “I was very familiar with products from CGS ORIS at my previous company“.

After two production test runs, the CEO was convinced and, since the middle of January, PRESS MATCHER has been in full production. Its ink saver function has been of greatest benefit. “We are saving 50 – 60% ink on each print run” says Faller.

Automatic processes are increasingly important. Suitable hardware and the corresponding software must be taken into account. To be successful in the market you have to take every opportunity to digitize.

Andreas Hanbuch, CEO Hanbuch PackagingHanbuch Packaging, Pfungstadt

There is a large job being printed on the Durst Rho P10 200. It is a series of special stand-up displays for an advertising campaign of a well-known soft drink producer for beverage stores.

“You can see it clearly on this job” says Faller, showing the monitor. “You can check the ink consumption with, and without, INK SAVER” as he switches between both tables showing the calculated ink usage. 260 sheets on the Durst require just 8 liters of ink compared to 26 liters without ink saving.

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It is not at the expense of quality. On the contrary, fine details in the images can be seen more clearly because they are not clogged by too much ink laydown. That is especially noticeable in darker areas and shadows. What is also important for the packs printed on the DURST is that lower ink density increases wear resistance and reduces ink breaks across folds.

Less ink coverage brings with it some unexpected benefits. “While it is not normally possible to speed up the UV printer despite the faster drying time, the intensity of the UV lamps can be reduced leading to longer lamp life and lower energy costs”, adds Faller.

With 50 – 60% ink saving per print job, Hanbuch Packaging is well over the average of 20 percent ink reduction of other users. Each job is individually evaluated and maximum ink savings calculated, not just for ink and press but also for the design and end-use of the product.

The software helps us to reduce our internal costs and brings additional benefits for our customers.

Andreas Hanbuch, CEO Hanbuch PackagingHanbuch Packaging, Pfungstadt

Felix Faller, responsible as Production Manager for the pre-press and printing departments, is obviously happy with the performance of the software: “It is not just the cost savings. With PRESS MATCHER we get great color stability across all machines. At the beginning I was really surprised at how we could achieve the same result on all of them. On top of that, we can reproduce special colors and match standards with ease. In the past that took an enormous amount of time and effort going around and around again. Since we got the software, we no longer have that problem, it fits perfectly.”

Andreas Hanbuch is the third generation owner of the family firm and next year the 30 employees will celebrate their 70th anniversary. The company started predominantly as an offset printer, but now digital printing takes center stage.

Their offerings range from innovative point-of-purchase displays, exhibition graphics and cinema posters to diverse packaging such as high-quality gift boxes and mailers. And it’s not just about printing. Hanbuch Packaging can create, design and deliver the complete finished product to the final destination. An essential part of their equipment are full and semi-automatic plotters, die-cutting machines and laminators. More complex and involved jobs are carried out by hand.


(Photo credits: Hanbuch Packaging, CGS ORIS)

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