Bioracer accelerates the design process with DDP Suite
Bioracer specialises in designing and manufacturing cycling clothing and accessories. The combination of advanced technologies and high-quality materials ensures that cyclists of all levels are provided with comfortable and performance-oriented outfits. The company works closely with professional cycling teams, such as Ineos, to ensure their products meet the requirements of most riders.
Quite a mountain to climb
This innovative company was faced with two problems. Since the sustainability of their products is high on their priority list, they are keen to extend this to their production. However, with the method they were using half a metre of paper and quite a bit of ink was wasted per order. This was something they could no longer tolerate.
An additional problem was that their DTP operator was in high demand. For each order, the DTP operator spent a huge amount of time preparing a print file. A huge job that could actually be much easier and faster. With high wage inflation, time spent in the process has become incredibly expensive, so the more efficient the process, the better.
Catena Company helped us to actually create those derivatives by size and by item based on the standard design.
Today, Bioracer rides on agility
Our expert went on site to see how Catena Company could improve the way it was operating at the time. After a thorough analysis, a new approach was set up, in consultation with Bioracer. Out came a mix of new and existing components. The design file created in Adobe Illustrator is still prepared by the graphic designer. When the design file is created, it first passes by the DTP operator. He gives a final “go” to the CRM system. After this signal, Catena Company’s Dynamic Data Publishing Suite starts running at full speed and completely takes over the preparation of print files by template.
Catena Company helped us a lot in the preliminary process, before going to production. On average we still needed between 40 and 45 minutes to get a design ready for production. With the automation achieved by their expertise and their experts, that’s all automatic now and easily half an hour quicker. Which, of course, makes quite a difference. Especially when you know we make 12,000 designs a year."
A solution was also provided for the sustainability problem. Where previously one print file was needed per design and per size, Catena Company now provides one print file created per template. This solution even goes so far as to add several designs in one document. This results in fewer print jobs, which in turn results in time savings. In addition, up to 30 cm of paper is lost per print job. Combining several print jobs into one saves a lot of paper.
But that is not the only thing. With Cluster printing, all other margins are removed in advance, allowing the design to be better positioned on paper. As a result, less ink is consumed and each job occupies less space on the paper.
Facing the future at a good pace
Catena Company’s solutions not only enabled Bioracer to maintain their sustainable image, but they now operate time- and cost-efficiently. The same operation can now be completed 90% faster. Really amazing.
Finally, by revising the working method, technical errors are noticed more quickly because the DTP operator is involved early in the process. This immediately results in fewer reprints, so less extra time and extra material.
We used to work fast, but now we work even faster because of Catena Company’s automation core.
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