Smart Graphics Co., Ltd. a part of the Uematsu Group, has been operating at its current location since November 2019. The company specializes in manufacturing as a contract production company for major online shopping businesses in the printing industry. At its production facility in Toda City, Saitama Prefecture, multiple printing presses are in operation, including the latest Speedmaster SX 102 Version 92-8-P LED UV + CutStar Gen 4.
The company's high productivity is not just a result of its performance of the press but stems from its vision of a "Smart Factory" that aims to optimize the entire production process through automation and workforce reduction. The installation of the Speedmaster SX 102 Version 92, an 8-color perfecting offset press, is their answer to the relentless pursuit of reduced make ready time, minimized waste sheets, and enhanced production speed.
The Speedmaster SX 102 is a next-generation multi-color, perfector press, combining the proven perfecting technology of the Speedmaster series with innovations from the peak performance class. It offers a plate size of 650 mm x 940 mm, allowing up to 20% savings in plate costs compared to the 70 x 100 format. “Considering the characteristics of our production site, where we handle uniform paper types and job lots between 2,000–3,000, I initially thought the Speedmaster XL 106 would be ideal, but plate size was a challenge. Then, when I learned that HEIDELBERG could accommodate a B1 plate, we decided on the SX 102 Version 92,” recalls Keisuke Fukuda, Director and Head of the President's Office, on the background of the installation.
President Hiroshi Fukuda explains the three elements the company strives for: "In this type of business, cost is truly down to the wire. Make ready time, waste sheet reduction, and printing speed—all must be pushed to the extreme." The first element, reducing make ready time, is enabled by the Prinect Inpress Control 3, which measures color spectrophotometrically and adjusts registration during the production run, as well as by AutoPlate Pro, a fully automated plate-changing device that cuts plate-change time by up to 50%. "After a plate change, Prinect Inpress Control performs inline color matching, allowing us to start full production immediately, reducing touchpoints. Plate change takes about three minutes for all units, and waste sheet is significantly reduced," continues President Fukuda.
The waste before starting full production is around 30 sheets per job. Make ready time has been reduced to mere seconds, and the press operates continuously at 14,000 sheets per hour. Fukuda further notes, “For small-batch jobs, reducing make ready time, waste, and printing speed lowers costs per sheet. While variable printing is the only weakness, offset still competes with on-demand printing’s typical break-even point.”
Based on cost comparisons between roll and sheet paper, Smart Graphics opted for Japan’s first CutStar Generation 4 roll sheeter to optimize paper cost. The CutStar enables cost-effective and competitive production across various job sizes. "For average runs of around 300–400 sheets, the CutStar can handle a massive number of jobs," anticipates Fukuda. While prioritizing cost efficiency, there is no compromise on quality. Fukuda positions Smart Graphics as a factory producing high-quality industrial products within the Uematsu Group. Unlike Uematsu’s artistic high-quality products, Smart Graphics adheres to Japan Color standards, which Fukuda asserts guarantees higher quality.
Since installing the Speedmaster SX 102 Version 92 in 2024, Smart Graphics has expanded its printing and postpress production lines, achieving rapid growth. To avoid bottlenecks in production, investments extend beyond the presses, such as in ink piping systems and automated plate distribution devices. The palletizing system installed before the SX 102 handles product identification and pallet stacking by destination, aiming for minimal manual labor from printing to delivery. Fukuda envisions further automation, targeting the efficiency of movement from the press to the cutting machine as the next step.
Currently, Smart Graphics is working on scheduling automation. Fukuda states, "Our focus is significant as we hadn’t fully optimized our operations, including the Speedmaster SX 102 Version 92. To maximize the use of SX 102 and CutStar, we believe a focus on smaller run jobs is necessary. This will improve the efficiency of not just the SX 102 but the entire plant," indicating a strong drive toward upcoming challenges.
