VistaPrint Boosts Apparel Production Capacity with Kornit Apollo
The digital printing system adds approximately 25,000 units of weekly production capacity, delivers production around three times faster and improves operational efficiency.
Kornit Digital (NASDAQ: KRNT), a global provider of on-demand digital fashion and textile production technologies, has highlighted how VistaPrint is using its Kornit Apollo system to expand high-volume apparel production, speed up manufacturing and improve operational efficiency.
VistaPrint serves customers across Europe, the United States, Canada and Australia. The company has grown from a print platform into a one-stop shop for small businesses. Its services include business cards, marketing materials, apparel, promotional products, packaging and signage. It also offers design tools and expert support.
“Our customers have always been front and center in everything we do,” said Nick Dalby, Director of Category Experience for PPAG at VistaPrint. “We’ve evolved from purely a print platform into a one-stop shop for small businesses, supporting them from design through to print. Within Cimpress, we’re continually growing our manufacturing and supply chain network to deliver the best possible combination of cost, speed, quality and product choice.”
Advancing a Longstanding Digital Production Partnership
VistaPrint and Kornit have worked together since 2007. Over the years, VistaPrint has upgraded its digital production fleet with successive generations of Kornit technology, including Atlas and Atlas MAX.
As the company looked to improve efficiency and reduce delivery times, it identified Apollo as its next step. The system builds on the improvements VistaPrint achieved with Atlas MAX in production cycle time, print quality and wash fastness. It also offers higher output, lower costs per unit and improved ergonomics.
“We’re constantly looking for efficiency improvements that reduce cost while improving delivery times for our customers,” said Alicia, Engineering Lead, Manufacturing Technology, VistaPrint. “Apollo offered the output, print quality and wash-fastness we were looking for, together with reduced cost per print and ergonomic improvements. We knew it was the right next step.”
Kornit supported the installation through online training before deployment and an on-site technician during the first six months of production. VistaPrint reached full utilisation across three shifts approximately three months after production began.
Increasing Output and Speeding Up Production
Kornit Apollo has added approximately 25,000 units of production capacity per week at VistaPrint. It also supports production turnaround times of around one day. The system operates at approximately three times the speed of VistaPrint’s previous production process, helping the company fulfil orders faster.
Automation has also simplified garment handling and created a more consistent workflow for operators. In addition, it has helped VistaPrint make better use of equipment and labour across its production floor.
“Apollo has allowed us to produce around 25,000 additional units every week and get products to our customers faster,” said Jimm Purdy, Senior Operations Manager, VistaPrint. “It has significantly improved throughput and allows us to produce orders almost in real time as they come through.”
Looking ahead, VistaPrint aims to expand its Apollo fleet as its apparel business grows. The company plans to increase production capacity while maintaining the speed, consistency and quality its customers expect.
