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A consolidating, restructuringand overcapacity printindustry struggling withrising costs and flat pricing

in a sea of broadening alternative elec-tronic competition is increasinglyturning to technology to cut expensesand reduce production time cycles.

At least that is what most profitleader companies are doing. But evenmany of these industry leading com-panies are having difficulty in identi-fying the best technologies that willbenefit their companies and their cus-tomers. And once acquired, some ofthe advanced technologies are provingdifficult to profitably implement.

But the vast majority of printersmaintained their technological statusquo in 2004, in part, because with salesweak and profits under pressure, manyprint owners and managers decided towait out recovery—recovery that willnever come for the some 750 plantsthat were merged, consolidated or justplain went out of business in 2004.With improving but neverthelessanemic sales volume anticipated for2005, only slightly fewer plant closuresare anticipated. While profit leaders areexpected to continue to step up theirinvestments in technology, profit chal-lengers appear likely to wait for bettertimes while they struggle with theprice-profit equation.

For those able and willing to invest,there is an abundance of new tech-nology and improved equipment andsoftware to consider. drupa 2004 was, aswe reported in the July/August IPA Bul-letin, the JDF-enabled CIM drupa—ASeething and Bubbling Witch’s Brew ofTechnological Innovation; A CauldronFull of Hype, Smoke and Mirrors—aswell as technological opportunity forthose who could ferret it out.

Graph Expo last October was a repeatof drupa, albeit on a smaller scale withemphasis on products that can be pur-chased and installed now. Technologyunder development by the CIP4 organi-zation (International Cooperation forthe Integration of Processes in Prepress,Press and Postpress) is intended toenable computer integrated manufac-turing (CIM) across a broad spectrumof equipment and applications. TheJob Definition Format (JDF) supplier-pushed bandwagon at drupa andrelated technologies of computer-to-plate and ink fountain key presettingwas detailed in the July/August drupareview and in other IPA Bulletin articles.

From drupa to GraphExpo to Print ‘05The effective implementation of the righttechnology is proving to be the commondenominator in the success equation.BY WILLIAM C. LAMPARTER

An overcapacity print industry isturning to technology to cut expensesand reduce production time cycle.

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At Graph Expo 2004, JDF-enabled CIM took centerstage as it played to the American audience. As wasthe case in Düsseldorf, the most convincing informa-tive and all-encompassing JDF demonstrations andeducational efforts were provided by Heidelberg withits JDF-enabled Prinect system, the umbrella label forits suite of CIM workflow solutions. Since drupa andGraph Expo, Heidelberg’s efforts to expand its approach

beyond its own product lines havebecome increasingly evident. Heidelbergwas not alone in its efforts at Graph Expoas the CIP4 organization, every majorsupplier and many smaller ones as welldescribed their individual utilization ofJDF and its printer benefits.

Prior to Graph Expo 2004, a relatively few U.S.printers implemented largely isolated and segmentedportions of computer integrated manufacturing. Themost prevalent approach was, and still is, the settingof ink fountain keys using prepress data generated asa part of a CTP workflow. Although available for sev-eral years, fewer than 1,500 printers have taken thisfirst step toward CIM implementation. While someproprietary systems are used, most automated inkfountain key setting approaches utilize the print pro-duction format (PPF) protocols developed by theCIP3 organization, which was the predecessor to thecurrent consortium developing JDF. When GraphExpo’s doors opened last October, few printers hadattempted to embrace the evolving JDF for press orpostpress setups and control or for performancefeedback into an MIS system. The developing JDFwas clearly viewed by printers as a work-in-processnot ready for broad implementation.

At Graph Expo, printers watched JDF demonstra-tions and attended educational sessions with interestto see what the hype was all about and whether itwould benefit their operations. Since Graph Expo therehave been but a handful of pioneering printers movingto seriously adopt the technology. Several post GraphExpo surveys of printers, including one conducted byPrintCom Consulting Group, show the concept ispoorly understood, benefits are not clear; implemen-tation is viewed as difficult and costly; and technologyis not yet ready for prime time. Nevertheless, thesupply side of the industry is making plans for Print 05in September to be a JDF-enabled CIM extravaganza.The magnitude and potential impact of the tech-nology—if, or some say when, it succeeds—is such thatprinters are well advised to attend for a JDF education.

An avalanche of improved products and newtechnology with more recognizable short-term ben-efits was evident at drupa and on the exhibitionfloor at Graph Expo. To provide exhibition attendeeswith assistance in assessing the more than 6,000individual products and services presented by morethan 550 companies at Graph Expo, the GraphicArts Show Company sponsors a product and tech-nology recognition program known as Must See‘ems. The program identifies the new or significantlyimproved products that are likely to make a majorproduction difference for a majority of printers.Products with a more limited appeal but which areimportant for niche markets or that have yet toachieve full commercial implementation are singledout as Worth-a-Looks.

Must See ‘ems products and services are selectedby a panel of 15 leading industry consultants and trademagazine editors. Collectively, selections represent theevolving and compelling technologies that can assista printer to compete profitably. Selections from pre-vious years are reviewed and the best that are stillcompelling are highlighted as Encore Selections. TheMust See ‘ems brochure detailing the features of eachselected product can be obtained without charge bycalling Steven Prejsner at the Graphic Arts Show Com-pany 703-264-7200.

Important broad areas of technological develop-ment were identified by the Selection Committeethrough an independent analysis of industry tech-nical trends and a detailed review of the selectedMust See ‘ems product and services. In addition tothe JDF-enabled CIM emerging technologies, theGraph Expo and Converting Expo 2004 Must See‘ems technology selections were: the revitalization ofthe sheetfed lithographic presses, digital printing vari-able imaging improvements, workflow improve-ments, and computer-to-plate developments.

Sheetfed Press Development SurpriseWith most of the pre-drupa public relations focusedon JDF and improved prepress software, the extentof the revitalization of sheetfed printing equipmentwith an increasing number of inline coating and fin-ishing options was the technological surprise ofdrupa. Most of the “drupa generation of sheetfeds”showed up at Graph Expo playing to an enthusiasticgroup of printers who, in many cases, came to buyfor immediate implementation in hopes of catchingthe evolving business upturn with the most cost and

T E C H N O L O G Y

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time effective production approaches. The availabilityof a broad spectrum of noticeably improved and newsheetfed press designs was the basis of the selectionof the sheetfed press as a Must See ‘ems technology.Refurbishment of the industry’s sheetfed legacy pressequipment installed base, often on a one new for twoold basis, is a critical factor in reducing costs and pro-duction cycle turnaround time that is required tocompete with the alternative electronic media.

The newest small format sheetfed presses featureautomated plate loading and a growing range ofautomation features that are trickling down from theirlarger cousins. Mid-size presses are getting longerwith perfecting and coating capabilities. The almostextinct large format presses have been reborn inmammoth sheet sizes up to 60 inches by 81 inches.The return of the super large sheetfed offset press inlarger-than-ever sizes highlighted a competitive rivalrybetween MAN Roland and KBA. MAN touted its newRoland 900 XXL series, available in 47 inches by 64inches or 51 inches by 73 inches. KBA expanded itspress width another 7.75 inches—up to a 59.5 inchby 80.75 inch monster press to claim the title of theworld’s largest sheetfed press—the Rapida 205.

The return of the super wide sheetfeds in highlyautomated versions will, as they enter production,place new demands on prepress operations andrequire wider computer-to-plate equipment.

All of the major sheetfed press manufacturers par-

ticipating in drupa and Graph Expo highlighted per-fecting capability noting the growth of the long per-fectors in 5/5 and 6/6 configurations as well as on themore standard five and six color unit presses.

Heidelberg introduced at drupa and followed up atGraph Expo with a reinvigorated sheetfed press line.Highlighted in the innovative offerings from theworld’s largest sheetfed press manufacturer was:

kA new series of sleek appearing printing pressesintroduced in 2004 as the 41.3-inch, 18,000 sph Speed-master XL105 press designed with the long run labeland packaging printer in mind but which has also gen-erated interest from high quality commercial printers.Cited as the beginning of a new generation of presses,key features and significant improvements included anew feeder and delivery, contact-free sheet air transfersystem, an integrated inking/dampening system, andan innovative console controlled coating unit.

kA completely redesigned Heidelberg 40-inchSpeedmaster 102 made its world debut at drupa as a10-color perfector with double-sided inline coating.

kSporting a new feeder and improved sheet travelbetween printing units as well as a host of automa-tion components was an improved half-size Speed-master 74 sheetfed press.

kIllustrating the trend to increase on-press functions,Heidelberg demonstrated the inline production of CDcovers, presentation folders and self-adhesive stickerson an SM 52 with a diecutter installed as the fifth unit.

Many industry leadingcompanies are havingdifficulty in identifying thebest technologies that willbenefit their companies andtheir customers. And onceacquired, some of theadvanced technologies areproving difficult to profitablyimplement.

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T E C H N O L O G Y

Also illustrating increasing process automation,Komori Chambon has introduced a rotary diecutter-creaser-stripper that can be installed inline on weboffset, gravure or flexo presses for carton production.

Another example of doing more on press is MANRoland’s new cold foil laminating system, the In-line-Foiler Prindor, designed for use on sheetfed offsetpresses such as the Roland 700. The system requirestwo printing units. In the first printing unit, the areasof the substrate where the foil is to be applied areprinted with special glue by a conventional plate. Foilis laminated to these areas in the second printingunit. The area where foil is required remains on thesheet while the excess is pulled into a rewind unit.The approach may offer printers the opportunity toadd foil uniqueness to their products where offlinefoil stamping is both time and cost prohibitive.

Must See ‘ems InnovationTwo press developments, one from KBA, the otherfrom MAN Roland were selected by the Must See‘ems Committee as particularly innovative amongthe new press designs.

The KBA Genius 52 is a unique new design litho-graphic 14-inch by 20-inch central impressioncylinder press shown at drupa and introduced to theU.S. market at October’s Graph Expo. The four or fiveprinting units on the Genius 52 are arranged as V-shaped assemblies around a central impressioncylinder. Each sheet is printed in one gripper bite withno sheet transfer, a technique that eliminates regis-tration issues. The inking units are keyless—a featurethat requires prepress to get it exactly correct becauseno fiddling and diddling to modify color on the pressis possible. Anilox rollers, ink form rollers, plate cylin-ders and blanket cylinders all have the same diam-eter to eliminate ghosting. The Genius 52 is designedfor one man operation with touch screen control andthe absence of dampeners and ink keys.

The direct drive of a press plate cylinder thatdecouples the plate cylinder from the press’ maindrive, a feature of many heatset web offset presses, hasbeen migrated by MAN Roland to sheetfed equipment.The concept was shown at both drupa and GraphExpo 2004 on a static Roland 700 printing unit. Theconcept makes possible parallel plate changing, i.e.,the changing of all plates on a press simultaneouslyinstead of one at a time—a feature that can substan-tially reduce makeready times. The decoupling alsopermits wash-up efficiencies. The mechanical isola-

tion of the plate cylinder permits 360-degree circum-ferential register making it possible to adapt printingplates that are not an exact fit because when they weremade they were intended for a different press.

Direct drive enables flying plate changes, making itpossible to take printing units in and out of produc-tion so that the plate change, usually a black plate, canbe made without stopping the press. This permits eco-nomical versioning, for example, changing textdescriptions or prices or making a language change intext without stopping and restarting the press. Whilethe black plate for the original runs on the fifth printingunit, the black for a new version can be loaded on asixth printing unit and then the change made almostinstantaneously with a minimum of waste. The con-cept is now in a testing phase and can be expected toreach U.S. markets, probably at Print ’05.

These innovations are just a sampling of the fea-tures now available in a reinvigorated line of equip-ment that virtually demands printers to re-evaluatethe capabilities of their pressrooms focusing both onimproved productivity and the ability to create newproducts inline.

Digital Printing Variable Imaging GainsIn 2004 digital printing variable imaging (VI) gainedprocess market share, primarily at the expense ofoffset lithography. While different industry analystsforecast different rates of growth for digital printing,virtually all agree that offset lithography, particularlysheetfed, is declining while digital VI is growing. ThePrintCom Consulting Group estimates that about 14percent of all printing in 2004, calculated as a percentof producing printer sales dollars less substrate valueis produced digitally. Although most of this digital pro-duction is of static content material, variable imagingfor versioned and personalized material is growingrapidly. PrintCom forecasts that in the 2010 to 2015timeframe more than 25 percent of all printed prod-ucts will be produced digitally. The move to variableimaging content, personalization and one-to-onemarketing creates a new series of requirements andskills in the prepress area.

The utilization of variable imaging digital printingis growing because in some cases entirely new appli-cations and markets for print are being created. Elec-tronic collating—printing a job in page sequence sothat each individual run through the press results ina complete collated ready-for-finishing product—offers a major economic advantage in the short run

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market. Lithographic printers that also have digitalprinting equipment have recognized the opportunityto offer their customers almost immediate partialdeliveries of a job while producing the long run por-tion of the work by offset.

Digital printing was selected as a Must See ‘emstechnology category because of its continuinggrowth, substitution for offset, and process improve-ments that characterize its immediate and long-term opportunities.

Step Right Up for a New WorkflowStep right up and get this new, improved, open archi-tecture, better than anyone else’s. Proprietary work-flow was a cry heard up and down the aisles of drupaand Graph Expo. Almost every supplier has their indi-vidual approach to workflow. A close examination ofthe workflows being offered shows that it is not theflow that gets the work done, but rather it is the indi-vidual devices and modules in the workflow chainthat make the difference.

As printers try to improve their performance, it iscritically important to periodically review workflowstructure, its impact on costs and customer relation-ships so as to continuously change and offer the bestpossible solutions for both customers and internalefficiency. Workflow is intertwined with computerintegrated manufacturing but also stands alone forthose not interested in CIM or JDF.

Workflow is an all-encompassing technology moduleand was selected as a Must See ‘ems technology cate-gory for that reason.

Computer-to-Plate Continues to EvolveComputer-to-metal plate is an almost mature butlagging in implementation technology that is con-tinuing to evolve. CTP is characterized as “almostmature” because digital plates continue to evolveand change, having an impact on device selectionand, to a lesser degree, on workflow. Characterizedas a lagging technology because at the end of 2004only about 25 percent of U.S. printers have adoptedCTP, in part because of its cost and workflowrequirements. It was ignored by a portion of theindustry because metal plate CTP was not eco-nomically configured for the printer with two-upand four-up press equipment.

Developments revealed at both drupa and GraphExpo may be changing the CTP landscape. It wasthe re-entry of ink jet platemaking technology into

the small press market, the growing emphasis on two-up and four-up devices, the option of using UV pre-sensitized plates, the commercialization of processlessand chemical free plates, and the continuous devel-opment of flexographic CTP that led to its selection asa Must See ‘ems technology. The Selection Committeefelt that it was important for printers of all sizes thathave not adopted CTP to update themselves on thetechnical status and economics of this first step tocomputer integrated manufacturing.

Aside from its platemaking capabilities, CTP cou-pled with using platemaking prepress data to calculateink fountain presets is the basis for moving into CIM.Although even CTP users often overlook this make-ready cost and time reducing capability, the tech-nology is proven to be effective in these areas as wellas providing for a reduction in waste and spoilage—while at the same time improving quality. This com-pendium of CTP related benefits is a key factor in itsselection as a Must See ‘ems technology category.

An Avalanche of TechnologyWhile capable management, effective sales, innova-tive thinking, a knowledgeable workforce, and a hostof related variables are all critical factors in the successof a printing company, the effective implementationof the right technology is proving to be the commondenominator in the success equation.

With technology proliferating and suppliers makingseemingly conflicting representations, it is becomingincreasingly difficult for the average printer that doesnot have a technology manager on staff to select theright technology that will best serve the needs of anindividual marketplace and provide the internal effi-ciencies that are critical for survival in today’s com-petitive climate. The only answer is to participate inindustry education efforts such as the IPA Seminarand Webinars and to attend the industry’s tradeshows such as September’s Print ’05 with a tech-nology analysis plan to help sort it all out.

It is becoming increasingly difficult to select

the right technology. The only answer is to

participate in programs such as the IPA

Seminar and IPA Webinars and trade shows.

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