Founded in 1967, Terenzi helps companies turn ideas into reality by offering services such as design, prototyping, optimisation, production and assembly. Operating three main lines of business, Terenzi specialises in metal and plastic applications, providing everything from medical devices to interior furnishings.

In recent years, Terenzi has noted a significant increase in demand for its vinyl records production offering, with more requests coming from its client base. One of the core challenges has been with the materials used to create records, namely polyvinyl chloride (PVC), which is one of the most environmentally damaging of all plastics.

In response, Terenzi partnered with music label and publisher Rude Records to develop an innovative solution in the form of Greenyl. Made from recycled plastics using sustainable production processes, Greenyl discs are created using an industrial press, before Terenzi prints the name of the artist, song, and album information, plus graphics, directly onto both sides of the record.

During the design and testing stages, Terenzi used a small printer with standard inks to add information to one Greenyl record at a time. However, as demand for the service increased, Terenzi took the decision to invest in a new printer to support expanded production.

“In the first year, we plan to produce around 500,000 Greenyl records, and, after that, we estimate volumes will increase even further,” Terenzi Chief Executive Luca Terenzi said. “To achieve this, we needed a solution that would deliver high print speeds and productivity to keep lead times as short as possible for clients. And it was essential to create an energy efficient and eco-friendly workflow in line with our sustainability goals.”

An environmentally friendly solution from Ricoh

When seeking an appropriate solution, Terenzi’s aim was to identify a printer that would not only deliver the same high quality on each print, but also one that would match the sustainable aims of its Greenyl venture.

After speaking with experts at partner Ricoh and running tests on several UV flatbed devices, Terenzi settled on the Ricoh Pro TF6251, which was installed in February 2023. Luca said one of the primary factors behind the decision was the performance of Ricoh’s eco-friendly UV inks when printed directly onto the face of the Greenyl records.

Terenzi paired the Ricoh Pro TF6251 printer with ColorGATE Productionserver software to maximise the machine’s performance.

“Ricoh provided excellent guidance during the initial consultation, including a detailed total cost of ownership analysis,” Luca said. “As we increase production volumes, maintaining cost efficiency will be extremely important. This gave us added confidence to move forward with the proposed solution.”

High-quality colours

The Ricoh Pro TF6251 allows Terenzi to print onto 16 Greenyl records simultaneously. Newly pressed discs are placed onto a custom-made jig installed on the flatbed table and when printing on one side is complete, discs are flipped to print the artist, song, and album information onto the reverse.

Colour was also an important factor in the new investment. Terenzi offers Greenyl records in multiple colours and as such required inks that could produce a range of colours in high quality. The company opted for Pro UV Ink GP120 formulations, with the ability to use CMYK colours, plus white and clear inks, to create more vibrant and unique graphics for different artists.

Ricoh’s UV inks also carry a Greenguard Gold certification, meaning they have low environmental impact and chemical emissions, while the use of long-life LED lamps in the Pro TF6251 to cure the inks helps to optimise energy efficiency and reduce power consumption.

“The colour capabilities of the Pro TF6251 are impressive, especially the option to use white and clear inks to create multi-layered graphics,” Luca said. “The precision and quality are excellent, allowing us to print very small text onto both sides of the record that remains completely legible.”

Supporting a growing business

Such has been the impact of the investment that Terenzi has been able to develop the innovative Greenyl concept from small scale testing to full industrial production.

“We initially questioned whether we could find a device to print directly onto records at high speed and scale, but the Pro TF6251 meets and exceeds our requirements,” Terenzi said. “The instant cure UV inks enable us to start printing immediately onto the reverse of the record once the first side is finished. And when the second side is completed, we can place the record straight into a sleeve ready for packing and dispatch.”

“The Pro TF6251 forms a key component in the Greenyl production process. We will highlight our use of Ricoh’s eco-friendly inks and sustainable production in our online content to promote the concept and attract new business.

“In the coming years, we aim to produce well over one million records annually, so this is just the beginning – and we hope Ricoh will continue to support us on the journey.”