Trading for over 25 years, Showlite has earned a reputation for being one of the most trustworthy and professional event and exhibition contractors in the industry. The company has a head office in Andover, a manufacturing base just outside Pontypool, and satellite offices in Birmingham and London.
Showlite places a strong emphasis on design and creativity, employing a team of experienced designers, artworkers and Print/finishers. The company supplies bespoke solutions as well as its own established modular designs. Drawing on these skills and resources allows the company to cater for all budgets and the most demanding briefs.
New Manufacturing Base
In early 2020, Showlite moved its manufacturing base from Newport to Pontypool, just up the road. The brand new 11-bay building offered vastly improved facilities and the timing of the move, just as the Covid lockdown began, created a unique opportunity. The team at Showlite had time to analyse and adjust the layout of the new building to accommodate current manufacturing requirements and plan investment in new methods of production to streamline the business.
Up until the 2020 move, Showlite had outsourced all its print requirements, but bringing digital printing in-house was high on the agenda. When a decision was made to create a new printing department, operations manager, Eddy Jayne and head of design, Craig Bryant were tasked with going out to the marketplace to explore the best fit for Showlite. The decision to invest in a new digital facility meant that an entire department would literally be built around the proposed new machinery. After careful consideration, a large format, high speed Jetrix LXi7 LED flatbed digital printer was ordered. The next step was to look at a finishing solution for the materials printed on the Jetrix.
Shortlsiting Digital Cutter Suppliers
Craig used his experience of CAD/CAM and knowledge of the print world, as well as online research and industry publications to draw up a shortlist of digital cutter providers. When Craig compared his findings with Eddy, one name stood out…. DYSS, the digital cutter range offered by AG/CAD.
Craig explains “In a previous job I had experience using a cutter supplied by AG/CAD, and so already had confidence in the products and back-up offered by the company.”
A demonstration was carried out at AG/CAD on the DYSS X5 and DYSS X7 digital cutters. Both ranges of machine use a similar zero-backlash drive system for accurate finishing, but the X7 adds a routing capability. Although Showlite currently only processes 3mm Foam PVC which can be knife cut on either the X5 or X7, the decision was made to future proof the cutting facility by specifying a router.
“I could see so many possibilities, not only for a more efficient and precise workflow but also new products and revenue streams.” Says Craig.
The DYSS X7-1630T with its two tangentially controlled tool slots and high-precision, high-frequency router was the standout investment option. A 1600 x 3050mm bed allowed for 10 x 5’ sheet finishing and married up well with the Jetrix printer. The modular exhibition stands supplied by Showlite consist of an Aluminium frame, plug & play electrics and tailored 3mm Foam PVC panels. The panels can be supplied with creative, graphic-rich print all now produced on the new digital printer and cutter. The combination of the Jetrix LXi7 and the DYSS X7 allow for a high level of production, with all order requirements being fulfilled within a single shift.
Training
Craig explains about the DYSS X7 installation. “AG/CAD supplied training tailored to our business and in two days we were able to complete our workflow from print to pack. The machine itself is equally as impressive and far beyond what I expected.”
DYSS Versatility
At Showlite, the DYSS X7 is equipped with tangential knife tools (TKT) to cut the Foam PVC material. Tungsten carbide blades are used for longevity and accuracy. The production team utilise the versatility of the two-tool head, with a standard heavy-duty blade in one tool slot, and a second tool with a specialised blade. The first tool is used for general high-speed cutting, while the second tool is specifically designed to create a perfectly vertical straight edge which is required where multiple printed panels of Foamex are butted together to create a larger, seamless panel.
An added benefit of the investment in the new building, facilities, and digital equipment at Showlite is that it has attracted new staff keen to enhance their careers in a committed, forward-thinking and expanding business. Experience gained from new employees in the department has led the company to explore alternative materials for exhibition stands, furniture and sustainable products.
Sustainable Materials
Paper-based honeycomb board is an excellent sustainable material that can be offered as an alternative to conventional Foam PVC. A strong, structural material with an excellent print surface, honeycomb can be finished using the DYSS X7. The reciprocating knife tool (RKT) makes easy work of cutting even the toughest fibreboard materials. The addition of the XVT V-cutting tool means that thicker honeycomb and other materials that are difficult or impossible to crease can be mitre folded. As with all DYSS machines, additional tooling can easily be added later as new materials/markets are identified.
Cost Savings
The investment in the digital facility at Showlite has contributed to efficiency throughout the business. Craig explains. “We have experienced significant time and cost savings throughout the operation, and now have full in-house quality management.” The DYSS X7-1630T installation at Showlite has reduced lead times, improved efficiency and provides the potential to expand the product range on offer to the company’s exclusive customer base. The market-leading build quality and expandable versatility of the DYSS X7, mean that Showlite will reap the benefits from the investment in DYSS for decades to come.
