VistaPrint has evolved from a print platform into a one-stop shop helping small businesses bring their brands and marketing to life. Kornit Digital highlights how VistaPrint has used Kornit Apollo to increase high-volume apparel production capacity, accelerate production and drive greater operational efficiency.
‘Our customers have always been front and centre in everything we do,’ said Nick Dalby, 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.’
Focused on increasing efficiency and accelerating customer delivery, VistaPrint identified Kornit’s Apollo technology as the next step. Building on improvements achieved with Atlas MAX in cycle time, print quality and wash fastness, Apollo offered significantly higher throughput, reduced costs per unit and ergonomic improvements.
Kornit supported the implementation with online training ahead of installation 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.
Apollo has enabled VistaPrint to add approximately 25,000 units of production capacity per week while supporting production turnaround times of approximately one day. The system produces at around three times the speed of VistaPrint’s previous production process, allowing orders to move through production significantly faster.
Automation has also simplified garment handling, creating a more consistent workflow for operators while helping VistaPrint optimise 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 is hoping to expand its Apollo fleet as its apparel business grows, building greater production capacity while maintaining the speed, consistency and quality its customers expect.
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