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1.0Press Technology

Press Technology Offset Overview / The Unity Print Production Handbook 2012

7

Offset Overview

The conventional offset press market could

not have had it much tougher in the past

few years.

Research company PIRA International reported that

global printing revenues, worth up to $785bn in current

values, slumped by five percent in the year 2008 – 09

and recovered only marginally by one percent up to

2010. Last year and this are hardly going to be

much better.

Whilst the worst may have passed we still face

considerable headwinds. In the Far East, China’s Tiger

economy is showing signs of weakening,

and the Japanese economy is still suffering the

aftermaths of the tsunami and the rising value

of the Yen. Yoshiharu Komori, the chairman, president

and CEO of Japanese press manufacturer Komori

summed it up in a recent pre-drupa address when he

said: “The world has become noticeably cloudier.”

Closer to home, the Eurozone crisis still looms large,

depressing demand for marketing spend and

print products. At the same time as a slump in

demand, the Western economies are also facing a rapid

period of technological and trend changes as electronic

substitution switches markets away from print.

The internet has eroded printing volumes by up to a third

over the last 10 years. Printing runs are shrinking as

marketers cut costs or switch to alternative means of

electronic communication.

The collapse of German press manufacturing giant

Manroland, one of the ‘Big Five’ names in press

manufacturing, didn’t come as a total surprise. Many

manufacturers had been struggling to turn profits for

many years. Whilst Manroland’s sheetfed and web

divisions have been saved from administration and now

operate as separate companies, albeit with the same

intellectual property rights, the long term future is far

from certain.

Manroland sheetfed UK Managing Director Adam

Robotham says it has been a difficult period for the

company but it has all the factors in place to continue

trading. Now under the ownership of UK engineering

conglomerate Langley Group means the press

manufacturer has a sound future. By his own admission,

not many people have heard of the Langley Group and it

prefers to operate below the radar in terms of profile and

www.unity-publishing.co.uk

The Unity Print Production Handbook 2012 / Press Technology Offset Overview

8

publicity.“I can’t say it is business as usual in the normal

sense,” says Mr Robotham.

“Whenever a company has been through a financial

shock then you have to rebuild customers’ trust and the

company name. However unusual it is for a British

engineering company to come in and rescue a German

manufacturer, it has happened this time round and we

are on a firm footing to continue operating as we were

before.” Nearly all economic trends are cyclical, adhering

to the rules of ‘what goes down must come up again’,

but behavioural changes are much harder to reverse.

As Mr Komori wryly observes:

“The printing industry, exposed to severe waves of

environmental change such as the switch from paper to

electronic media, stands at a great turning point.”

The arrival of new technologies, such as Landa’s

Nanographic Printing, launched at the recent drupa

printing show in Germany, is keeping everyone on their

toes. Although the technology is still not commercially

available, and probably won’t be until at least mid-2013,

what it represents is the breakthrough everyone has been

waiting for, namely digital output at offset speeds and

qualities. The repercussions for both the digital and offset

sectors could be profound.

Every conventional litho press manufacturer is looking to

adapt to the digital era. Hybridisation has become the

keyword of every print room as conventional press

technology strives to match the versatility, short-run

capability and quick change-overs provided by digital

technology. Where once digital technology strove to

match the performance of conventional press speeds and

output, the reverse is now true. Many offset presses for

instance can now achieve full plate-changes in just over

three minutes and are 30 percent more productive than

models manufactured just a few years ago. It seems

every manufacturer is striving to automate and digitise

its conventional press lines like never before. Those that

don’t will suffer a swift and sudden fall from grace.

People need print

But not all is doom and gloom. People still need print and

always will. Whilst some sectors of print are in serious

decline, there are bright spots. So far, digital print has not

been able to match the demands of the mass produced

folding cartons market or direct mail printing. Only an

estimated 2 percent of all printing is produced digitally

and the transition to digital production is taking longer

than some analysts may have predicted.

Plate manufacturer Agfa says that after an initial dip in

plate sales in the early days of the recession things have

pretty much returned to normal in the Western

European economies. Although not a completely

accurate barometer of the industry due to technology

changes and trends, it is an encouraging sign that print

need not panic.

In Western European markets, shorter runs are holding up

sales. Plate manufacturers have made significant strides

in bakeless plate technology, making them more robust

and able to handle longer runs. But advances in

platesetting and press automation means it is as

economical to make a plate change on a press as it is to

install a baking oven to produce hardened plates that are

more suited to longer runs. Agfa Head of Product

Marketing, Pre-Press, Ralph Hilsdon says: “Digital printing

technology has been around for a long time yet still only

accounts for a small proportion of all print produced.


Press Technology Offset Overview / The Unity Print Production Handbook 2012

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What people need to remember is that many printers

have a ten-year old B2 or B3 press running in the

corner of the factory that is just as good today as

when they bought it. The investment has been

written off, so it is a much simpler choice to keep on

running it then spending another £1.5m on a new

digital press line. It will be some time before that

situation changes.”

Smart printers are also reinventing themselves to

become ‘cross-media’ service providers. Whilst they

still provide ‘print on paper’, they are also adept at

providing marketing, database, web and email

services as value added provision. Most likely

they are running conventional press lines

alongside digital printers. They have become

true hybrid print providers, adept at running a

myriad of services and providing high-level

consultation services across a number of

different disciplines.

Adaptability and change

No other industry in history has gone through the number

of changes and adaptations that print over the past 20

years. Rather than showing signs of slowing, the pace is

actually accelerating as press speeds increase, change-

over times shrink and automation becomes the norm.

Almost every major manufacturer has invested heavily

in its ‘on-demand’ element on conventional

press manufacture.

It means the modern press is automated and controlled

like never before. At the front-end, workflows have to

cope with multiple job streams and output engines, while

colour matching is carefully calibrated and profiled. The

press itself features automatic plate changing and wash-

up features, perfecting units, and sophisticated

registration and checking systems. On the back-end, cut-

sheeters and stackers automatically process sheets for

finishing. A press minder walking back into the industry


after a ten-year absence would be baffled and amazed

at the advancements in press-room technology.

While press manufacturers strive to keep up with the

technological change, print companies too are under

pressure to invest in the latest press kit. Failure to

do so could see them left behind in a fiercely

competitive market.

KBA UK Managing Director Christian Knapp says it is vital

for companies to consider all the options before investing

in new equipment. “Mature operations in a stable

marketplace may seek like-for-like investments with the

obvious marginal improvements that developing

technologies bring. But it has increasingly been the case

in recent years that markets are changing along with

economic circumstances.

“As a result businesses are being forced to reconsider

their strategy and in these instances it is necessary to

research the market in more depth and examine the

production options that are coming on stream.

This is where the relationship with an established world

class manufacturer can be of benefit since they have the

hindsight into market developments and bring its

developments to the table.”

To cope with the change and these commercial pressures,

more and more manufacturers are selling service as part of

their process – not just to keep the presses running but in

equipping printers with the tools to enable them to run

their presses profitably, search out new markets, sell to

customers and turn their investments into good money.

And good money can still be made in conventional offset

press lines. The skill is finding the niche areas, picking the

market, exploiting the potential and utilising the press

technology to its best. Printing has never been easy, and

constant changes make it harder than ever. But picking the

right press for the correct market, with a press partner who

can provide on-going long-term support, provides the

ingredients to make it a success.

Tony Brown

www.bizzymedia.co.uk

“ “

The Unity Print Production Handbook 2012 / Press Technology Offset Overview

10

... it is vital for companies toconsider all the options beforeinvesting in new equipment.KBA UK Managing Director Christian Knapp


Press Technology B1 Presses / The Unity Print Production Handbook 2012

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---

B1 presses

Modern B1 presses bear no

resemblance to the models of just a

few years ago. Automation, speed

enhancements and digitisation have transformed

their productivity and throughput to levels that

were unimaginable just a few years ago.

Manufacturers are striving to constantly update,

refine and improve performance in order to

provide a competitive advantage to their

customers. Printers on the other hand are

constantly balancing the pressure to reinvest in the

latest technology whilst facing reduced margins,

shrinking markets and competitive pressures that

stretch their business models to

the limits.

The major B1 press manufacturers have been stretching

their research and development budgets hard to

constantly introduce new features and technology

updates. A number of trends influence

their thinking including the drive towards lean

production, green printing, web-to-print workflows

and inevitably, a focus on short-run production even

on B1 press lines.

Perfecting presses perhaps offer the greatest

opportunity to enhance productivity for the modern

press room.

Once manufacturers resolved the issue of ink set-

off, the development of perfecting technology

presented a perfect solution whereby a small

drop in straight-through speed creates huge

advantages in productivity and ‘one pass’ printing.

Heidelberg has been the dominant player in long

perfecting presses since it first introduced the

concept to the market.

Claiming an 80 percent market share from many

years of development, it sees perfecting as the way

to push the barriers of sheetfed productivity to new

highs. Heidelberg’s B1 and B2 Product Manager

Matt Rockley says: “Right sizing is an issue which

all printers need to address, looking at whether

the format they are running is the best for

their business.

Greater press speed is important but in terms of

increasing net output it must be seen in tandem

with developments to reduce make-ready times.

1.1Press Technology


The Unity Print Production Handbook 2012 / Press Technology B1 Presses

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As the long run web offset market has declined, B1

long perfector presses with customised finishing

have secured the lion’s share of this market.”

The latest press launch, the Speedmaster SX102,

represents what it categorises as its peak-performance

press, reaching speeds up to 18,000sph in perfecting

mode. Aimed at the higher end of the print service

provider spectrum, it enables one-pass productivity that

boosts competitiveness and productivity.

Crucially it represents a 30 percent productivity gain

over the Heidelberg SM102 and is capable of

producing more than 45 million sheets per year.

There are advances in cylinder jacket technology, the

grippers, bearings, and the overall handling of the

paper through the press. Along with new side

frames and strong cylinder rigidity, the press is

equipped with Auto Pro plate loading and preset

feeders and delivery.

Productivity enhancements

As with all manufacturers, reducing make-ready

times has been one of the number-one priorities.

Most press lines can now achieve full plate change

and wash-ups in less than three-minutes as they

squeeze all they can from their press automation.

Japanese manufacturer Komori has developed a

concept called ‘Offset on Demand’ to handle short-runs

and tight delivery schedules by cutting print

preparation times, paper losses and print production

times. The key is a module that covers the offset

prepress and post press processes and includes the

latest digital printing technologies. Offset on Demand

targets the printing of extremely short runs with

short turnaround times primarily by reducing

makereadies, cutting paper waste and shortening

the printing process itself to the maximum

extent possible.


Press Technology B1 Presses / The Unity Print Production Handbook 2012

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The system is being demonstrated at drupa on a

Lithrone G40P (40 inch perfecting press), one of its

most popular selling models. High-speed start-ups

obtain the correct colour balance within 20 sheets

using an integrated control system, but the H-UV

system passes printed work to the post-press

department for finishing as soon as printing

is complete.

An asynchronous automatic plate changing system

also changes plates within 75 seconds regardless of

the number of colours used. A Komori colour

management system matches the output of a

printed sheet to a digital proof to ensure constant

colour matching throughout the print run.

Manroland’s popular ROLAND700 series of B1

presses features DirectDrive enabling the press to

become a true multi-tasker, capable of changing

plates automatically and simultaneously for up to

12 printing units in only one minute, regardless of

the press configuration. As this process takes place

in conjunction with the three to four minutes

needed for the automatic washing of the

cleaning and impression cylinders, the company

claims the plate change takes effect in no time at

all, something it describes as eroTimePlateChange.

Manroland takes the concept one step further

with the ROLAND 700 HiPrint, incorporating a fully

automated plate changing system, with automatic

plate setting controls and pre-set press parameters

that provide quick change-overs for different

coatings, air settings, gripper bars, wash-ups and

inks changes.

The HiPrint HS (High-Speed) version can also run at

speeds of up to 18,000sph, making it ideal for

packaging and industrial scale publishing and

commercial printers.


The Unity Print Production Handbook 2012 / Press Technology B1 Presses

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Integrated digital solutions

KBA has developed a new system that takes

hybridisation to a new level. Partnering with Atlantic

Zeiser, together they have developed an integrated

digital module to its Rapida 105 line called the DELTA

105i. As a high-speed digital printer, it integrates with

KBAs offset-sheetfed line to enable printers to realise

a wider range of special applications and open up new

business sectors. Realising that the combination of digital

and offset can significantly enhance productivity, the

Atlantic Zeiser system prints at up to 240 m/min and a

resolution of up to 600dpi, providing variable data

printing onto different materials without the extended set-

up times. The system provides solutions for the

individual coding and serialisation of products, the

traceability of pharmaceutical goods and forgery

protection for a range of products.

It is a perfect example of the marriage of digital

and offset to create a highly productive hybrid print

environment. The European debut of this hybrid

product will soon be available for the first time

following its considerable success in Asia.

Service and support

No manufacturer is an island. The days when press

providers can sell a customer a press and then leave

them to their own devices has long gone. Now,

printers are looking for an integrated level of support,

backup and maintenance to ensure their presses can

run 24/7 without interruption. In addition, they

will sell or provide services or support on top that

includes training, business development, and selling

strategies that will last the lifetime of the press. It is

all part of the mix that printers consider before

signing on the dotted line as commercial pressures

weigh down on them like never before.

B1 will always be the workhorse of any mainstream

commercial printing company, but choosing the right

format of press and the partner who can help develop

your business plan is the best bet for long

term success.

Tony Brown



Press Technology B2/B3 Presses / The Unity Print Production Handbook 2012

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B2 / B3 presses

Of all the press sectors, B2 and B3 sized

printers find themselves most squeezed

from the pressures of dwindling print

volumes and the increasing competition from

digital presses, which are competing more

effectively for short-run jobs.

Digital print providers such as Canon, Xerox, Fujifilm,

Kodak, Ricoh, and HP have deliberately targeted their

product development at capturing market volumes

from small print jobbing shops with applications that

cater for the short-run, personalised print collaterals.

HP’s latest digital printer launch, the HP Indigo

10000, specifically targets the B2 sector

for instance. As does the Jet Press 720 from Fujifilm.

Canon’s recent report, Digital Directions: Redefinition

of the Digital Printer, forecast that litho and digital

print volumes will reach parity by 2020 with more

and more short-run work migrating to digital format.

But what it also stresses it that the most profitable

print shops are those that run hybrid print rooms, or a

combination of digital and litho presses, under the

same roof.

That has put additional pressures on manufacturers to

come up with integrated workflow systems, capable of

running both digital and offset side-by-side. But there

is no doubt that the small jobbing printer, relying on

the B2 and B3 format press for the mainstay of their

work, are under pressure like never before.

The litho press manufacturers are not sitting back.

There are a plethora of providers in this area; the

likes of Sakurai, Hamada, Ryobi and Presstek all

provide press lines to serve the B2 and B3 sectors.

Without needing the large manufacturing tools to

produce larger format presses, they can manufacture

small-footprint presses that can compete on price

and performance with the more established players

such as Heidelberg, Komori, Mitsubishi, Manroland

and KBA. Most have UK distributors for new build

presses and there is also a ready market for

reconditioned second-hand presses that can still

perform well but can be purchased at a

premium price.

If small offset manufacturers can’t match the

personalisation and versioning capabilities of digital

presses, they can still compete by redesigning their

1.2Press Technology


The Unity Print Production Handbook 2012 / Press Technology B2/B3 Presses

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press lines to be as fast, robust and as automated as

possible. They are embracing digitisation from a

different angle, with fresh approaches to working

with Web-to-print ordering and workflow controls or

providing hybrid print systems, with offset and inkjet

combined in the same press unit, to compete more

effectively with pure digital press lines.

Neil Handforth, sales and marketing director for

Apex Digital Graphics, says the B2 and B3 sector has

been hit by the double whammy of the recession

and the encroachment of digital presses into the

conventional offset market. As the exclusive Ryobi

distributor for the UK market, he says the B3 sector

has been particularly hard hit, especially on two-

colour presses, as short run jobbing print is

substituted for digital production.

The trend is now more towards five colour presses with

in-line coaters that can print on heavyweight stocks in a

variety of substrates, in areas that digital can’t touch

with the same levels of productivity. And of course it

helps if the presses come with all the bells and whistles

too. “We’ve seen a growing trend towards more and

more automation. All the press lines now come with

semi-automatic plate changing, automatic blanket

cleaning, impression cylinder cleaning and

ink-roller cleaning as standard features,”

says Handforth.

Ryobi’s most popular presses are the B3 size 520GX

Series and the B2 750 Series. Equipped with smart

makeready functions and automatic plate and

blanket cleaning, preset inking and test printing for

superfast changeovers, the presses also come with

size variants to suit user demands. The Ryobi 750G

series comes in two types for instance; the S type

with a maximum printing area of 765 x 545mm

and the XL type with a maximum print area of 765

x 580mm.

There may also be a glimmer of hope around the

corner. “This year has started very positively and we

have had the highest level of enquiries and

quotation requests for B2 and B3 format presses for

the past three years,” says Handforth. Light at the

end of a very long tunnel maybe?

Not that the established press manufacturers should

have it all their own way. There are new kids on the

block, from the Far East, offering goods that are

highly price competitive and ready to bite into an

already lean market. Chinese manufacturer Hans

Gronhi is introducing two new B2 presses in

Europe for the first time through UK distributor

Printers’ Superstore.

With claims it has already sold 50 of its B3 presses in

the UK market, Printers’ Superstore joint Managing

Director Graham Moorby says: “The formula will be

the same as for the B3 presses – all the technology

you expect from a modern machine with high

standards of engineering and output, but for

considerably lower investment and lifetime costs.”

The new GH79 range comes in 74cm, 75cm, 78cm and

79cm versions, just in case the customer can’t make up


“ “The Trend is towards 5 colourpresses with enhancementsthat digital can’t touch.Neil Handforth, Apex Digital Graphics

their mind what size they want. At drupa it is also

showing two of its tried and tested 52cm (B3) presses,

the GH525, in five-colours. One will demonstrate its

inline UV inking, whilst the other is set up for inline

numbering and perforating, demonstrating its

capabilities for adding value to packaging products.

Steve Cavey, Heidelberg product manager for special

applications says buying an ‘off the shelf’

press is no longer the way to do business.

Today, each customer comes with a bespoke request for

presses that are highly specific to their end needs. “The

selling process has changed. It is not about shifting

boxes any more but giving customers’ highly technical

advice about what is and what is not possible and the

commercial benefits to each solution.“Configurations

are increasingly complex and the range of options

more comprehensive. The choices can include

printing aspects such as the number of units, to

perfect or run straight, with conventional or UV inks,

with or without alcohol, to network to prepress or

MIS and so on. But it also extends into added

value options such as whether to add coating,

numbering, perforating, die-cutting, cold glue

foiling or holography all of which can be

added online.”

The Heidelberg Speedmaster SM52 is the latest

offering for the small- and medium-sized commercial

print shop. It offers a high level of flexibility and

machine configurations can be customised to meet

the exact needs of the print shop. The spectrum

ranges from two to ten printing units, with or without

perfecting. Various coating systems, including UV

technology, Anicolor zoneless inking unit technology,

and inline die-cutting are just a few of the possible

configuration options.

It can be extended with a number of further options

including inking unit temperature control, or the

Color Assistant Pro software for ink-zone calibration

and optimisation of the colour pre-setting data.

Analogue offset press manufacturers are keen to play

up the advantages of litho ink quality compared to

digital output. KBA’s offering in this sector comes in the

form of the high-end Rapida 76, a technological

advancement to the 15,000sph Rapida 75E, that takes

many of the product enhancements directly from the

large- and medium- format presses into the

half-format class.

The Rapida 76 is capable of running at 18,000cph in

straight printing mode, and includes a number of

technology enhancements including fully automatic

plate changing, a sidelay-free infeed, direct drives

for the plate cylinders, fast and parallel washing, and

the online colour measurement and colour control

system ErgoTronic ColorControl on the new console,

and the inline colour measurement with the

QualiTronic ColorControl system.

Whilst Komori’s focus is heavily on new digital

solutions under the banner of ‘Komori onDemand’, it

has not overlooked smaller format presses entirely. It

is introducing the Ethrone 29P as a five-colour

convertible perfecting offset press with a relatively

modest straight printing speed of 13,000sph (11,000 in

“ “... all the technology you’d expect but for considerably less investment.Graham Moorby, Printers’ Superstore

Press Technology B2/B3 Presses / The Unity Print Production Handbook 2012

19www.unity-publishing.co.uk

The Unity Print Production Handbook 2012 / Press Technology B2/B3 Presses

20

perfecting mode). Again, the focus is on semi-automatic

plate changing and print density control. It may not be a

show stopper, but is significant that a company that

traditionally has put more R&D funds into larger format

presses is still investing in the lower end of the market.

For those printing houses that are fully committed

Komori users, then it may make commercial sense to

add another Komori B2/B3 model to the mix.

It is clear that the B2 / B3 sector remains under

pressure. But crucially when the press manufacturers

are not giving up on it, it means there is a future.

Digital print may be creating a new level of

competition, but go into any jobbing printer up

and down the land, and the B2/B3

press is still banging out the goods in the corner

of the factory and keeping the money rolling

in. Which at the end of the day is what it is

all about.

Tony Brown



Press Technology Large & Super Large Format / The Unity Print Production Handbook 2012

21

Large and super-largeformat presses

Whatever B1 presses or smaller variants

can do, then large and super-large

formats can handle just as well.

Whether it is automatic plate changes, perfecting

printing, wash-ups or colour controls, the press lines

can handle super large stocks at comparable speeds

to their smaller cousins.

The applications for large format presses are wide

and diverse. They have established a niche in

packaging, book and poster printing, for Point of Sale

products, brochures and calendars. With the increase

in the use of Web2Print processes to order print jobs

over the Internet, they are also finding an effective

use for printing ganged-up jobs in the most efficient

possible manner, providing the speed and versatility

that offset provides.

Large format presses have to handle sheets up to

3sq m in size, or the equivalent of moving more

than 28,000sq m of printed sheets every hour, in

exact tolerance, registration and density across the

page, even when in perfecting mode. Loading and

finishing systems need to be refined; when a single

sheet pile weighs up to 3 tonnes, then normal rules

of engineering no longer apply. Large and super-

large presses need a design specification all of

their own.

Thankfully, press manufacturers have been

dealing with these problems for more than 60

years. Market leaders such as KBA’s Rapida, the

Heidelberg’s XL 162 and XL 145, or the MAN Roland

900 and 900XXL provide the most advanced

computer controls, shaftless drives, double size

impression cylinders, automatic grippers and plate

change systems, making presses better and easier

to control and maintain.

As with all press lines, large and super-large format

presses come in a variety of configurations to suit

client demands, from straightforward four- or five-

colour versions to special-purpose presses with 12-

units and sophisticated inline coating systems. In all

cases, a high-level of automation is included to

match the medium and large format presses. But,

due to the laws of physics, a totally new approach

to engineering is required.

1.3 Press Technology


The Unity Print Production Handbook 2012 / Press Technology Large & Super Large Format

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Shaftless technology is the key to operating each

printing unit, enabling them to disconnect completely

from the print process when not needed.

Dedicated drive motors control all major aspects of

the press, including pile heights, registration, transfer

feeds, cylinder adjustments and many others.

Gripper systems automatically adjust to suit every

conceivable substrate thickness, whilst an array of

video cameras and calibration equipment ensures

registration is maintained precisely throughout the

run. Although measurement and control systems cost

more, the estimated payback time is within two years

in the reduction in wastage and set-up times.

Books and packaging

Books are an ideal application for large-format

press lines, with the ability to print up to 64 pages

in a single pass in four-back-four perfecting mode.

The KBA Rapida 130 – 162a series presses

accommodate the folios perfectly with an extra

5cm print length built into the eight- and ten-colour

perfector lines. Sheet layouts are arranged with

fewer print-free corridors than in the past whilst the

press operator controls the positioning of the suction

rings and guide elements, and provide precise

powder metering.

If publishers work with a relatively small range of

papers, then optional reel-sheeters can save

substantial amounts of money for any printer.

Packaging is also an ideal product for large format

production and Heildeberg reports that 41 percent of

all its Very Large Format press sales are to

packaging printers. Coating units can apply gloss and

matt effects, all-over and spot finishes, single and

multiple coating applications with dispersion and / or

UV varnishes. Coating forme and anilox roller changes

are all automated and sophisticated coating supply

and cleaning systems ensure no down-time between

coating changes.

In addition, the double-size impression cylinders and

transfer drums enable an enormous amount of

packaging substrates to be handled, including fluted

and corrugated board. Inline sheet inspection systems

are also able to keep a close quality control check on

printed output, ejecting defective sheets on the fly.

New developments

KBA has revamped its large format Rapida 145

with a host of new features to speed up make-

ready and production on the press which they

showed at the recent drupa exhibition in Germany.

With a format of 105x145cm, the press can now

run at a straight-through rated speed of 17,000sph.

With a ‘revolutionary’ three-drum perfecting

mechanism, it can also perfect four-back-four

sheets at 15,000sph, making it one of the fastest

large format perfecting presses on the market.


“ “KBA has revamped its largeformat Rapida 145 making itone of the fastest perfectingpresses on the market.

23

Automated features are packed into the press

including the in-feed pallet, which can change whilst

the press is running at maximum speed.

The DriveTronic SPC can complete simultaneous plate

changing, blanket wash and loading of new press

profiles in around three minutes. KBA claims make-

ready time savings of between 40 and 70 percent on

competing presses over 1,000 job changes. Heidelberg

is a relatively late entrant to the world of large format,

having started production only in 2009 with the

Speedmaster XL 162 and XL 145. With that however, it

brings with it the advantages of its mastery of

engineering with a completely new approach to the

design drawing board. Today it supplies the XL 162 and

XL 145 models in four-to eight-colours with coating

unit, dual coating, UV equipment, perfecting technology

and material logistics.

The press lines offer the perfect answer to global

market trends such as lean manufacturing as the

market calls for ever larger formats suitable for

processing ever-shorter runs. Heidelberg claims one of

its customers is printing 5 million sheets per month on

a six-colour Speedmaster XL 145 and another is

achieving make-ready times of 12 minutes per job on

40 jobs per day, equivalent to 13 jobs per shift. For

poster production, presses are running jobs as low as

200 sheets between plate changes.

Heidelberg’s economic assessment shows that, thanks

to the numerous automated components in the large

format perfecting press, the investment costs account

for around 40 percent of the machine’s hourly rate.


y The new Sunday Vpak from Goss, which made a successful debut at the recent drupa exhibition

Press Technology Large & Super Large Format / The Unity Print Production Handbook 2012

The Unity Print Production Handbook 2012 / Press Technology Large & Super Large Format

24

This is about 10 percent higher than other

press configurations.

The manufacturing costs per print sheet are far lower

than other presses, for which the time and material

savings cannot be reduced to the same extent.

MAN Roland’s 900XXL press comes in four formats,

ranging from 1,120 x 1,620mm to 1,300 x 1,850mm.

Compared to the 3B format, the 7B format (1,200 x

1,620mm) provides an increase from 16 to 40 DIN A4

pages and goes further, with a large 60 millimetre

step. The 7B plus format offers 20 percent more

multiple-up images than the 7B format and three

times more than the 3B format. Format 8, the largest

press line available, can accommodate 64 DIN A4

pages on a sheet and is still capable of 12,000 sheets

per hour. Apart from offering the choice of scalability

and formats, all provide the automation and set-ups

that are now standard on their smaller offset cousins.

That includes a full automated plate change, and

QuickChange features enabling swift changeovers

from dispersion to UV coating, coating form

materials and ink-fountain cleaning. It seems

clear that the major manufacturers have some clear

water in the market and have achieved remarkable

engineering feats with the productivity and

automated enhancements in large format presses.

Offering a real advantage in terms of the sheet

sizes and stock weights they can handle, large

format presses offer a niche market for applications

that other areas of the print market just can’t touch,

but at speeds that put them in the production

Premier League .

Like everything else in print, nothing stands still for

too long and a technological alternative could

snatch away any competitive advantage large

format presses enjoy in an instant. But for the

moment, large format manufacturers and press

users can enjoy the sunshine while it lasts.

Tony Brown



Press Technology Packaging / The Unity Print Production Handbook 2012

25

Packaging

Packaging is one of the few areas

of print that is a genuine good

news story.

Research company Pira International says in 2010

packaging recovered all 2009 losses, and grew by

around 4 percent in 2011 to reach global sales

of $696bn.

The strongest growth came from emerging and

transitional economies, but the more mature

economies also played their part. The next few years

should be robust, with growth of 3 percent per year up

to 2016 to a market size exceeding $800bn. For a print

sector that has seen declines in most other traditional

markets, it seems a relatively safe haven for press

manufacturers and printers alike.So far, digital press

technology has not been able to generate the volumes

and print quality needed for the packaging sector.

Digital presses can carve a niche in mono work,

especially labels, but have yet to breakthrough to

challenge the established mainstream markets. For

more on the march of Digital into Packaging (see

Volume 2 of Print Production Handbook out in July).

With the emphasis on sheer speed and flat-line

printing, especially on heavier weight stocks, the

balance of power still resides with conventional offset

presses (both sheet-fed and web), flexo or gravure

lines. But as print lengths shorten and pack shelf-lives

decrease, more and more applications are coming

within reach of large format or very large format sheet-

fed presses. With straight-line speed and perfecting

speeds as fast as medium and small format presses,

they can produce highly efficient print volumes on a

wide range of substrates.

Agfa’s Head of Product Marketing for PrePress,

Ralph Hilsdon says run lengths in the packaging sector

have been reducing for a number of years under

market pressures for shorter pack-shelf lives and

retailers’ special offers. The increases in press

automation and platemaking have increased

manufacturer’s abilities to accommodate these

demands. “Even on long runs, it is sometimes more

efficient for them to make a number of plate changes

rather than produce specially hardened plates as

presses become more and more efficient, “ he says.

The demand for anti-counterfeiting measures, Braille

embossing and durable ink adhesion is also as

1.4Press Technology


important as ever. Special finishes and embossing also

enhances the look and feel of finished products and coil

foil embossing presses are specially equipped to add

these textures. Food packaging has demands all of its

own to meet stringent safety measures on ink toxicity

levels and adhesion.

With the market segmented into a number of different

areas – labels, folding cartons or flexible packaging– it is

a diverse and fragmented sector that needs specific

presses to suit precise job specifications. The number of

press manufacturers spans an entire gamut of

machines and formats – names such as Mark Andy,

Edale, Cerutti, MPS, Nilpeter, Omet, Gidue sit alongside

the more commonly known press manufacturers such

as Xeikon, KBA, Komori, Heidelberg and Goss.

All the press manufacturers offer specialist solutions

to specific packaging needs and are investing heavily

in new developments, updates and enhancements to

existing technologies on a pace akin to an arms race –

each is striving to gain the upper hand in the

packaging press battlefield.

Digital press technologies

In a few specialist areas, digital presses have made

some impression on the packaging sector, but in fairly

specific niche markets. Pira International consultant

Sean Smyth has forecast a strong future for digital

packaging particularly in the carton market, with

worldwide growth trend rates of over 30 percent

between 2011 and 2016.

“Digital technology can significantly help brand owners

and retailers improve their supply chains and make

packs more appealing to specific groups of consumers,

who will buy more and at premium prices,” he says.

Digital press manufacturer Xeikon has responded to

these trends by developing its established Xeikon

3000 Series press. Based on LED array dry toner

electrophotography, the press is capable of printing

on paperboard up to 350gsm with a web width

ranging from 200mm to 516mm, producing sheets of

variable lengths to minimise paper wastage. Working

in conjunction with a jumbo unwinder ensures high

levels of autonomy as the cutter unit converts the

web into the appropriate sheets defined by the

imposition system.

Fujifilm is another entrant into folding cartons with its

B2 digital inkjet press, using core components

pioneered within the Jet Press 720. Now adapted to the

packaging market, Fujifilm has developed new UV

inkjet ink to meet the requirements of folding carton

applications, called VIVIDEA.

It aims to reproduce ultra-high quality images on

thicker paper stocks, whilst being suited to the different

post-press operations this market demands.

Both these presses remain confined to fairly specific

markets however and remain specialist players in a

much wider hemisphere.

The Unity Print Production Handbook 2012 / Press Technology Packaging

26

“ “


... shorter runs and theincrease in special offers hasdramatically changed thepackaging landscape.Ralph Hilsdon Agfa

Press Technology Packaging / The Unity Print Production Handbook 2012

27

Specialty finishes and enhanced

print solutions

Packaging throws up a number of challenges mostly

relating to the range of substrates and specialty

finishes on board and cartons, especially on non-

absorbent materials. Demand for plastics and films

such as PVC, PC, PS, ABS and PET are increasing for

the jobbing, packaging and label sectors.

The KBA-MePrint Varius 80 offers a solution to some

of the challenging stocks packaging producers have

to contend with. It uses waterless technology on a

variable-format web-offset in order to print on

flexible non-absorbent substrates. Without having

to manage the complex water / ink mix used on

most conventional offset presses, it can tackle

some of the more challenging substrates at what

the manufacturer claims to be significantly lower

plate prices than flexographic sleeve blankets. The

keyless and waterless Varius 80 is capable of reaching

full colour production quality after only 100 metres

running, providing a waste saving of around 80

percent compared to other comparable presses. With a

maximum web-width of 800mmm and a

production speed of 400m per minute, the Varius

80 handles substrate thicknesses from 30 to 800

microns and accommodates a variable printing

width between 21” and 34”. An automated plate

and blanket-change cylinder function can change

format lengths to suit the end product specification

within minutes.

Manroland also has a range of foiling solutions to

produce ‘stand-out’ solutions, especially for Point of

Purchase products. According to its recent survey* of

print buyers, more than half believed that enhanced

print products increased the value of print by 10 to 30

percent and 53 percent said they expected higher value

consumer products to be associated with foiled or

coated packaging.

Its InlineFoiler Prindor is compatible with its ROLAND

700 B1 and ROLAND 500 B2 presses and can be used

with conventional or UV inks. It delivers exact print and

foil registration to existing print products on a broad

range of substrates in a single pass.

Gapless, shaftless and sleeveless

As run lengths reduce, mainstream press manufacturers

are increasingly seeing the opportunities the packaging

market provides.

With so many different choices, Goss Marketing and

Communications Manager Greg Norris says it is important

to consider investments carefully. “The everyday cost of

producing products is far more significant than the

capital investment cost of the equipment.

Therefore it is important to accurately assess and

account for the cost savings, added productivity and

improved margins that could be achieved by investing

in new equipment.


“ “When investing it is important to consider futureand emerging customerrequirements.Greg Norris, Goss


28

“It is important to consider future and emerging

customer requirements. The demands for higher quality

print, lower costs and faster turnaround times will

intensify across a wide range of packaging applications.

This will increase the appeal of web offset as an

alternative to sheet-fed offset, flexography and gravure

due to the advantages it can offer in all three areas.”

Goss is a relatively new entrant to the packaging sector,

having adapted its newspaper press expertise to tap

into a market that may provide more potential. drupa

2012 provides the opportunity to give ‘world first’

showings to its Sunday VPak 3000 and Sunday VPak

500 packaging presses.

As the name suggests, the press line is based on the

ground-breaking ‘Sunday press’ gapless press concept,

providing cassette-style web offset packaging presses

with quick-change blanket and plate cylinder sleeve

adaptors, making ‘infinitely’ variable repeat lengths

easier and more affordable.

With the VPak running at web widths from 41 inches

to 75 inches at 457m per second makes the Sunday

presses up to 200 percent more productive than

sheetfed presses, with press make-readies on a

comparable level. The VPak is also capable of tackling

a wide range of substrates, ranging from 0.5mm to

30mm in thickness, including a full range of films and

board stock. High-performance infeed, outfeed and

closed-loop tension controls assist operators in

accommodating a wide range of substrates.

There is no doubt a need for sheetfed options however

as run lengths decline. With more than 1,000 printing

units sold, one-in-three units of the Speedmaster CX

102 go to packaging applications. With specific

configuration options for the press perfectly tailored

to customer needs, the Speedmaster 102 has been

installed at leading packaging companies in the

luxury, cigarette and spirits markets. It meets the

needs of all packaging print lines in that it has

consistently high production speeds, of up to

16,500sph, combined with shorter make-ready times

than its predecessor models.

The wide range of configurations and equipment make it

possible to adapt the press to any specific requirements

to suit the relevant business model. From a straight-press

to a dual-coating configuration with ‘offset before

flexographic’ printing, it can be equipped with

numerous surface finishing options, such as UV

coatings and cold foil applications.

No mention of the packaging industry is complete

without mentioning narrow-web flexographic printing

presses, specifically geared to the labels and specialty

sector. A number of manufacturers compete in the

space, but it is well worth flying the flag for

British narrow-web press manufacturer Edale

in Hampshire.



30

Its gamma model is typical of some of the

innovative technology advances seen in this

field, with its use of servo motors and shaftless

technology providing a high-degree of automation for

swift changeovers, pre-registration, auto-registration

and print length control features. Job change times

and setup wastage are kept to a minimum, with

print-head colour changes performed in less than

90 seconds.

It proves that all manufacturers, in every sector of the

print market, are heeding the pull of shorter print

runs and faster make-readies in whichever sector

you operate.

The packaging market may be more robust than

other areas of the printing sector, but it doesn’t mean

press manufacturers and their customers are resting

on their laurels. The message is the same: only the

most robust and innovative will be in a position to

survive to take advantage that the markets

may provide.

Tony Brown



y The star in KBA’s large format range in terms of performance

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