Wausau Container, which employs about 50, currently generates about $20m in annual revenues from its 65,000sq ft production facility.

In a press release announcing the install, Wausau Container president Chuck Plier said: "We were founded two decades ago and filled an unmet market need for smaller quantities of cartons that larger converters are not structured to address.

"As lot sizes for many products continue to decline and quality requirements escalate, we needed to find a press that could cost-effectively augment our flexographic production for higher quality carton work, especially those requiring line colors.

"The 75DI’s 31" x 23.5" sheet size covers the needs of about 80% of the folding carton market. It also enabled us to bring in-house a significant volume of print that we had been outsourcing on behalf of our customers."

Wausau Container said it has added the Presstek 75DI to its four flexo lines that are all equipped with inline die cutting and blanking for very efficient short run operations.

In an interview with PrintWeek, Presstek vice president of sales Joe Demharter suggested Presstek now finds itself very well positioned with the 75DI as the packaging industry transitions toward short, ‘non-conforming’ production runs.

"A lot of big packaging companies have been outsourcing non-conforming work to other companies with digital presses, part because their equipment, systems and infrastructure are geared to do long runs on big 56" presses or 40" presses."

Demharter added that while overall production for folding carton has held steady, much of that volume is being taken up by multiple shorter jobs rather than say, one long 400,000 run. "This non-conforming work continues to grow and as it grows, the carton makers are increasingly looking for digital type solutions," he said.

The Presstek 75DI is a 31" direct imaging press that is available in 4- to 10-color configuration and features a full range of options, including an inline aqueous coater. It can print up to 16,000sph and includes support for 300lpi and FM screening.

According to Presstek, it has the ability to go from digital file to printed sheet in six minutes.

"What helps us in this folding carton market is the flexibility or our product," Demharter said. "We provide a platform that can give you fast make-readies and quick turns, so you can still make money on these short run jobs. We can also run a variety of stock and we’re truly ink on paper - not ink-jet on paper and not toner on paper."

Demharter also noted the 75DI hybrid solution has a process and business model similar to offset presses. "You’re not operating on a click charge - you’re buying the plate, you’re buying the inks, so they’re very familiar with that," he said.

Late last year, the then financially struggling Presstek was formally acquired by American Industrial Partners (AIP) - the private equity firm that also owns narrow and mid-web flexo press maker Mark Andy - for $26m.

Demharter said AIP’s purchase has actually been a real positive to the company and its selling efforts. "The fact that we now have a very strong, financially stable owner is very important," he added.

"You’re buying a piece of equipment that cost a million and a half dollars and from a company that also provide the plates for the press and provides the service for that press. And now, because of the deal, customers can look at us as a much more stable company than prior to the acquisition."