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October 2011

Digital technologies help packaging prepare for a faster future PROFIT FROM DIGITAL PRESSES Real World Marketing Techniques Premium-quality colour labels and packaging Bringing digital quality to specialist printing What will be the theme for drupa 2012?

Bigger and Bigger for Heidelberg site in Qingpu Toppan Security Printing Received ISO 12647-2 Certification Litho & Digital –A Complementary Mix The Scotsman in us: save, save, save From the Oldest German Printing and Publishing House to an Efficient, Future-Oriented Media Company The case for 96-page web offset production manroland at IFRA Expo 2011: full control at the push of a button Versatility and Productivity are key features Making a Big Impression Trends in Large Format Printing Industry news from all over the world Classififed pages Some funny items collected over the last month

No 71 Geylang Lorong 23 #07-02, THK Building Singapore 388386 tel+65 6733 5342 fax +65 6733 3586 Publisher

Paul Callaghan paul@cpublish.com.sg

Managing Director

Elizabeth Liew eliew@cpublish.com.sg Editor

Ann Callahan calmor@ihug.co.nz Journalist

Christel Lee editorasia@cpublish.com.sg Advertising Sales

Matthew Callahan matt@cpublish.com.sg Accounts Manager

Radika PS accounts@cpublish.com.sg Accounts

Meynard Gloria accounts@cpublish.com.sg

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Digital technologies help packaging prepare for a faster future

By Gareth Ward

Modern marketing means brand extensions, on pack promotions, packaging to tie in with events – all designed to increase sales and enhance relationships with consumers. This provides opportunities to printers that can meet these demands When Heidelberg predicts that digitally printed packaging is set to grow at double digit rates for the immediate future, printers need to sit up. And Heidelberg is not alone. The prospects for printing packaging of all types on digital presses are exciting every press manufacturer. If digital printing on paper is understood and developing at a steady pace, digital printing of packaging has scarcely scratched the surface. And with packaging there is

no risk that print will be replaced by electronic media.

positions that each supplier is taking will be clear at drupa 2012.

To date digital printing has left packaging alone while expanding in publication print. Over the next year or so that is going to change as existing electrophotographic technologies clash with inkjet systems to win market share in a sector where the arguments in favour of short run and just in time printing are gaining ground. The

Traditional ways to produce packaging generate huge volumes of waste as up to 20 per cent of printed material can become obsolete before it is used.

Frequent promotions and shorter product life cycles only exacerbate the problem, unless companies can order just in time or closer to the point of use. Both favour digital production methods. Then there is the opportunity presented by personalisation, as a means of customer engagement and as identification in pharmaceutical applications for example.

Heidelberg’s strategy is based on developing machines and printing lines around inkjet technology, previewing these at Interpack. There main board member Stephan Plenz declared: “Digital packaging will more than triple in four years and its growth rates is expected to be bigger in the future.

UV inkjet printing is rapidly gaining importance thanks to its versatility in the choice of substrates and the fact that it can be directly integrated into packaging production lines.”

Size of market Alon Bar-Shany, vice president and general manager of HP’s Indigo division, reckons that digitally printed

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Print Pack Publish Asia • 10/2011

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Management/General packaging can take the same 10per cent share of the market that it has in label printing. Already HP Indigo presses are being used in flexible packaging and carton printing, but it is very early days. HP will be unveiling significant moves by drupa and will have presses in place at major flexo and carton printers before then. The prize is worth the effort. The worldwide market for digitally printed foils, cartons and labels stood at just â‚Ź2.5 billion in 2009, the vast majority of this from labels. The world packaging market is currently valued at $429 billion according to Pike Research and is expected to surpass $500bn billion in sales within five years.

Paper and paper-based packaging are the largest sectors with more than 40% of the global packaging market.

Many packaging companies have tested digital printing over the last decade, but almost all have abandoned these trials claiming that the business model did not exist or that the quality was not adequate.

But the problem of meeting demands for faster turnaround has remained, pushing litho press manufacturers into delivering presses with high levels of automation to handle short runs effectively. This means adding tools to monitor quality on press and to reject sheets that fall short, using scanners to check that what is printed is exactly the same as on the PDF that the client approved, and using all the plate changing, presetting and colour control tools that have become standard for commercial printers.

Packaging printers with this level of press are comfortable printing a run of 100 sheets among others where the job may need several pallets of board. And litho continues to offer advantages in terms of inline varnishing and foiling that digital does not yet offer.

The same is true in narrow web printing where what were once considered label presses are now printing boards for lightweight and small format cartons using flexo or UV letterpress technologies, sometimes combined with inkjet for dating, coding and adding a promotional message. The demand for higher quality and shorter runs of flexible packaging has brought manufacturers like Muller Martini into the mix with its VSOP litho press able to print on films with electron beam curing to meet the demand for faster turnarounds than is possible with conventional gravure and flexo presses.

However, all the interest, whether from manufacturers or printers is concentrated on the potential that digital offers. If quality was an issue a few years ago, this is changing fast and is no longer the barrier it once was. If quality is not the barrier, delivering the complete end to end solution remains an obstacle, especially at the finishing stage where innovation is still required.

The biggest problem has been that most cartons and film packaging have been produced in huge quantities because production of food or packaged goods depends on economies of scale and

big production runs. However, fierce competition for consumer attention in the mature economies is driving FMCG producers to use more promotional on pack marketing, more special versions, to develop ever more niche brands and to bring products to market faster in order to grab the consumer’s attention.

All this means shorter print runs and faster turnarounds, the same forces which have expanded the market for digital printing elsewhere in the print world. Add in a massive drive to reduce over production both from the point of view of cost and a desire to reduce environmental impact, and the forces are coming into position to make digital print for packaging highly viable. The same bell curve will apply, digital print for test marketing and in the launch phase which gives way to conventional production as volumes increase and back to digital for the long tail effect.

With the rise also of small scale regional and artisanal producers of drinks, home furnishings, confectionary and similar products, there is a new breed of company looking to buy packaging which is not on the radar of the multinational groups. It creates an opportunity for commercial and digital printers to expand into offering packaging print along with marketing print for a business.

Chocolates on demand This is where Irongate, a UK digital print and marketing services company operating Xerox presses, has been

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Management/General successful. It has set up a web to print portal in collaboration with chocolatier Thorntons. A customer can come on the Thorntons website and personalise a gift box of chocolates, selecting the flavours and styles and uploading an image and personal message. It has been a huge success, running at 3,500 boxes a each week leading up to Christmas, 1,000 in the week ahead of Valentine’s Day. The 'create your own chocolate box' promotion continues to be a key part of the Thorntons e-commerce offering.

While more sophisticated than many examples, the use of quality packaging to make a product stand out is a sweet spot for digital printing. Xeikon has been a leader in digital print for packaging and says that confectionery is ideal. “It allows bakers to create boxes that are branded with their store and that are versioned for special days, Mother’s Day, Easter and so on. They are selling a premium product so the price of the carton is less sensitive,” says Filip Weymans, business development manager.

At Drupa 2008 Xeikon had shown its technology in combination with a finishing line developed by StoraEnso for producing CD and DVD packaging inline. While the product never took off, arriving at the same time that CD sales plummeted in favour of downloaded entertainment, StoraEnso has continued to market the Gallop line but in conjunction with Xerox, one installed at pharmaceutical printer Goldprint in Belgium. “Pharmaceutical is a big driver of digital packaging,” Weymans continues, “helped by changes in legislation that drive companies to short run production.”

A US proposal that every pharmaceutical pack be personalised to the patient has been dropped, but traceability to overcome counterfeiting remains a driver of digital production.

However, while pharmaceutical has always been high on the prospect list for conversion to digital, and a number of pharmaceutical carton printers installed digital presses, these were soon found to be unable to deliver the colour quality needed and the print resolution fell short of that needed to reproduce the curved text and logos that litho had no problem with.

Project to go ahead There is now renewed interest in digital printing for this end. Simon Tokelove, head of asset management, at Chesapeake, a global carton producer, says: “Chesapeake has pioneered alternative technologies and processes as run lengths and order sizes have declined. Digital printing is challenging conventional printing for certain applications but it remains restrictive in terms of print format, productivity and finishing options.

“The adoption of digital technology for packaging is moving closer as manufacturers offer improved machine formats and higher print productivity.

However, more widespread adoption requires further developments in finishing technologies and a different way of thinking about the supply chain.

We have already invested in digital systems for labels and are now actively reviewing end of line applications. As a result, we expect to offer our customers a fully integrated digital carton solution within a year."

The breakthrough says Weymans has come with better print resolution, in Xeikon’s case stepping from 800dpi to 1200dpi, allowing digital presses to reproduce the smooth curves on text and corporate logos. One of the key customers following this step forward became Odyssey Digital Printing in Tulsa, Oklahoma. Xeikon pointed Achushnet towards this company when it asked the press supplier about

how to print short runs of golf ball packaging. Each sleeve can hold three balls and eight years ago could only be ordered in batches of more than 1,000. With the switch to digital printing, this has changed. Now a golf course can order balls that carry the course’s name and can sell balls that are branded to suit corporate golf day events or competitions. “It’s the kind of application that a creative print business can develop for the packaging market.”

Supply chain solution Traditional packaging printers are not used to dealing with the small numbers that digital offers, again providing an opportunity for new entrants to the sector. One of these is Mediaware Digital in Ireland which has a Xerox press connected to a Stora Enso Gallop finishing line. It produces personalised packaging for Microsoft, adding a customer name to each carton and printing only when an online purchase is made. Director Noel Candon explains: “Microsoft needed to address a supply chain problem. Now they only supply goods to order, and we print on demand. The quality is consistent, better than litho, and we have never had an issue even though we have printed thousands of boxes for them.”

Digital production says Candon allows his customers to expand into markets which they could never have tackled previously because of the high minimum orders demanded by traditional printers. He says: “One company we deal with had never sold outside of Switzerland, now we print in 22 languages for them using digital presses.

“In the smaller accession countries to the EU, they want to read packaging in their own language. A carton printed

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run, from a feeding pallet on one side to delivery on the other. That’s already happening and can be done if the industry moves to larger formats.

“Where the job is about adding variable content to a standard box, a line like the Stora Enso Gallop is ideal, but where a company is producing lots of different formats then a digital finishing device is needed. That is already happening in the corrugated sector, where we are cutting out unique shapes for point of sale displays, where the cost and run length does not allow a die to be made.”

in Russian will not be acceptable in eastern European countries. Digital lets us print in the 28 EU languages, in regional languages like Catalan for Spain, and to cope with changing ingredient lists.”

The iGen4 prints at 2,200 sheets an hour with perhaps six cartons per sheet, giving reasonable production capability, provided the product size is restricted because one of the biggest limitations to digital print taking larger shares of the packaging market has been format size. This is less of an issue with the webfed Xeikon, similarly for the webfed versions of the Indigo which have made a huge impact in labels and which the company aims to repeat in carton and flexible packaging.

The ElectroInk technology has proved that it can handle a wide range of substrates through the web fed label presses. “We see the opportunity in pharmaceutical, in test marketing and for event based marketing where specialist and custom versions of packaging are needed,” Bar-Shany explains. “We think that the format is wide enough for most applications, so we think that there’s a sensible opportunity and that digitally printed packaging is today where labels were a few years back.”

The finishing question At the same time HP is looking at

how to deliver the wider formats that flexible packaging printers are used to working with. It is also partnering with companies supplying finishing equipment. Bar-Shany names German platen producer Kama, provider of fast set up B3 systems which has adapted its platen to work with digital print.

But it faces competition from others that also that digital packaging will require innovative finishing systems.

One of these is Israeli start up Highcon which is developing a system called Direct to Pack. There are no details as yet, other than this will operate without a conventional die, will have zero set up time and will be a transformational technology for the folding carton sector. Others are working with lasers to cut out blanks in fractions of a second, but there is always a need to balance the thickness of the board and the power of the laser. The potential of the market will continue to drive developments. “A solution for digital packaging has to be about much more than just printing,” says Bar-Shany.

Jef Stoffels, director of corporate marketing at Esko Artwork would agree. The company’s Kongsberg digital cutting tables are frequently matched with presses in digital carton lines, either in inline or near line configurations. “The structural design can be sent to the cutting table and the process can be automated and left to

Inkjet is starting to make an impact here where small batches of outer casings can also be used to carry promotional messages to tie in with special events.

Sun Chemical has had a single pass inkjet machine as a replacement for flexo printed corrugated in beta and can expect to end that development phase soon. Likewise Agfa is continuing to find packaging users for its inkjet press.

By drupa 2012 many separate lines of development will be coming together, drawn by the fascinating and lucrative possibilities of transforming the printed packaging sector.

The future is short The drive is towards ever shorter production batches. This suits the needs of marketing departments in the consumer product companies and it suits the needs of their corporate social responsibility programmes because shorter runs means less waste and a lesser environmental impact.

Consumers in smaller countries do not want to see the same packaging as a customer in North America, but want to buy something in their own language with imagery that fits their lifestyles.

All this drives towards tighter supply chains with shorter print orders.

Digital print technologies are perfectly placed to satisfy these demands, but it digital will not have everything its own way. Other technologies and production techniques can also deliver shorter production batches. What is clear is that old style presses and old style management is not going to be enough as the packaging business changes. •

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PROFIT FROM DIGITAL PRESSES Real World Marketing Techniques Go ahead - ask them, ask those who count the most in any successful business. Ask your customers what new services they want. No doubt cost effective short print runs and faster turnarounds would appear high on their wish list.

After all, it's no secret that print buyers today want their jobs delivered now.

By Paul Dimmock, Graphic Communications Strategy Manager at Fuji Xerox

Digital presses require no film or plates and minimal make ready setup time.

They can save money and are providing many new services to such customers.

You've read about their benefits, more cost-effective shorter runs than is possible with traditional offset presses, variable imaging, shorter turnarounds and more. For commercial printers these devices are a way to attract new business customers, wedge a foot in the door with previously unreachable prospects and secure additional new business across other areas of the shop.

But what about profitability?

It doesn't happen overnight and some achieve better return results than others.

To be successful, you must know how to market this work. After all, the technology is new and potential clients need to be educated about its capabilities. Plus, the short runs in digital printing mean that to profit, shops must bring in more jobs than the number necessary to keep conventional offset presses busy.

In some cases, owners of digital presses aren't sure of the equipment's capabilities. So how do you market what you don't know? A good starting point is to work closely with your trusted equipment partner and make good use of their value add services.

Many print shops cultivate new clients after investing in digital printing. Some secure so many digital printing jobs they must expand into a new facility and invest in additional digital presses.

So what is it these shops are doing right that you possibly do not recognise ?

They don't look for markets, they create them. They don't wait for clients to suggest projects; they develop products themselves. In fact, some enterprising firms offer a selection of prepared

design and layouts tailored for specific print communication target markets.

To boost visibility, some businesses establish storefront locations that accept digital information and transmit them electronically to a remote digital press.

Many businesses guarantee same-dayor-better turnaround.

Sales tactics may need to be altered as well in the digital printing world, as many firms change who they sell to and who they employ to sell this type of work.

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Today this style of successful business provides many services includes photography, design, prepress services, production of full colour manuals, brochures, greeting cards, newsletters, catalogues, reprints, business cards, point of sale display, indoor/outdoor large format signage.

Looking back, Paul Dimmock, Strategic Marketing Manager at Fuji Xerox observed most digital press equipment was first utilized in prepress CtF/CtP trade shops and not in commercial print operations.

world, this style of specialized service has all but disappeared due to offset printers wanting to bring pre-press production in-house. Across Asia today a similar trend is being observed and on the rise.

Why was this? At the time the former lay claim to a wealth of digital prepress expertise. This was indispensable when operating newly developed colour imaging technology.

To enjoy industry longevity, the successful prepress businesses that survived and prospered well during the last decade were those introducing a full services approach to market. They reinvested in their company branding to differentiate themselves from the surrounding competition. The business was digitally re-engineered, the company image was re-invented, and this business added new market directions which attracted much change.

10 years on, across the world today Fuji Xerox continues seeing many industry changes and is playing a leading role in these developments. Possibly the biggest single change saw closure of the traditional CtF/CtP prepress trade shop services. In most parts of the western

However, following on from this Dimmock advises we are seeing more business in the traditional offset side now operating an in-house digital press to produce these short run lengths. And the bonus being the existing offset press investment is benefiting from the digital press.

Fuji Xerox has observed the key to success, and most would agree, is how to market your services. After all, this technology and the processes are very new.

Potential customers must be educated about what it offers. Dimmock goes on to say, "As a company, Fuji Xerox must educate the market using workable solutions, real cost estimations and projections when comparing to the existing print production process. This includes the affordability to run small quantities of four-colour jobs which complement the limitations found using the existing offset process.”

Key to this is industry supplier education for clients who are hesitant about accepting digital printing.

Globally, the digital printing market continues growing rapidly and we all agree on this.

Dimmock concludes "I'm very optimistic due to recent equipment improvements such as higher image quality and faster print speed, simple colour management control tools, variety of stocks and weights and operating cost reductions. “ The potential market for digital printed products includes, well, just about everybody. •

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Digital Technology

Premium-quality colour labels and packaging HP announced the industry's most versatile and productive digital label press, the HP Indigo WS6600 Digital Press, which is capable of printing more than 40 linear meters (131 linear feet) per minute in full colour and features a new in-line priming unit.

Other features for improved productivity include a new common digital front-end (DFE) from EskoArtwork, an improved white ink option and new converting solutions from AB Graphic International, a member of the HP Graphics Solution Partner Program.

HP also introduced the industry's most productive entry-level solution for digital labels, the HP Indigo WS4600 Digital Press, with an option for fullcolour throughput of more than 21 linear meters (69 linear feet) per minute.

Both the WS6600 and WS4600 deliver higher throughput via a new Enhanced Productivity Mode developed by HP.(1) "With the Indigo WS6600, we can produce jobs of over 10,000 linear meters with the outstanding quality that our customers are demanding and still deliver fast turnaround," said Roger Gehrke, executive manager of Digital Printing at beta user RAKO ETIKETTEN in Wizhave, Germany.

Participants in a blind-test packaging industry label sample evaluation said they preferred HP Indigo print quality over flexography by a four-to-one margin.(2) "There is increasing demand among top global brands to produce colour labels and shrink sleeves on HP Indigo presses, based on their superior quality and rich colour," said Alon Bar-Shany, vice president and general manager, Indigo division, HP. HP's first-ever in-line priming (ILP) unit for a label and packaging press, a solution that enables the use of standard, untreated paper substrates and

gives converters faster turnaround times and greater flexibility in the range of substrates they use. Featuring a new, custom-developed water-based primer from Michelman, the ILP option helps converters further improve their turnaround time and reduce costs. Customers can use the same substrates on their analogue and HP Indigo digital presses while eliminating the extra step of offline substrate preparation.

A new HP SmartStream Labels and Packaging Print Server, powered by EskoArtwork, version 3.0 that features key improvements(3) including 20 percent faster performance, a better user interface for seamless operation of multiple presses, enhanced colour management and variable data capabilities, and bidirectional connectivity to the EskoArtwork Automation Engine. It also integrates with Heidelberg CERM and Tailored Solutions LabelTraxx management information systems.

White Ink Plus for the Indigo WS6000 series, a more opaque version of the HP Indigo white ink that improves productivity by allowing converters to produce an opaque layer of white ink with only one impression.

additional capabilities in security printing applications for the pharmaceutical market and other industries.

Both the WS6600 and the WS4600 are available now. Many of the new options will be available in early 2012 as upgrade features for the HP Indigo WS6000 and ws4500 to protect and extend customer investments.

Innovations in label and flexible packaging converting AB Graphic International will be highlighting its Digicon Series 2 in line with the HP Indigo WS6000 series and featuring a new dual-finishing option that gives customers maximum production flexibility in determining how to convert each job.

Workflow solutions HP added two new HP Indigo partners to its HP Graphics Solutions Partner program to expand its workflow solutions portfolio. Color-Logic's Process Metallic Color System enables converters to create coloured metallic highlights and effects on labels and packaging, and Prisme Technologies' PrintSYS web-to-print workflow solution provides a turnkey, cloud-based procurement system. •

A new UV-light reactive invisible ink for the HP Indigo WS4600, providing

D0700

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Printed products are invaluable and irreplaceable, just like the resources used to produce them. So environmental awareness is a must in the printing industry – and has always been a key consideration for us and our customers. Heidelberg solutions from prepress to press and postpress cut waste, emissions, and energy consumption to a minimum.

“Think economically, print ecologically”. www.heidelberg.com

D070001-11-000000305.indd 1

4/20/2011 4:54:30 AM

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Digital Technology

Bringing digital quality to specialist printing Sylvia Muhr explains the heritage of Swiss manufacturer Polytype and its highly precise Virtu range of wide-format UV-curable digital printers, and how she sees the potential for them in specialist and industrial printing markets.

Formerly known in digital printing circles as WP Digital, Polytype was formed 50 years ago as a subsidiary of Wifag, which was founded back in 1904. Concentrating on the manufacture of printing machinery, the company has grown to the position it is in today by producing bespoke high-end specialist equipment for the newspaper, converting and finishing industries. The company has never been involved in run-of-themill production; its extensive production facility in Fribourg, Switzerland is designed to manufacture wide-format equipment to order for a range of industrial digital printing applications on a practically unlimited choice of substrates.

Polytype: the business Polytype’s growth comes down to a carefully considered plan for development and expansion, and the technical excellence of its machinery. Virtu, the digital printing business unit of the company, was purchased from Swiss manufacturer Spühl in 2008 when it realised the high value of digitally printing high quality graphics to industrial substrates, including glass, aluminium and Dibond.

The Virtu business unit is led by Frédéric Pavesi and is headquartered at Fribourg, Switzerland on the GermanFrench language border, with an expected turnover for 2011 of CHR 450 Mio. Polytype’s divisions in Switzerland, Germany, USA, Thailand and Brazil complement a network of distribution partners based around the world, including the UK, India and Australia. Its strategy with Virtu is simple: it seeks to work with customers as partners, recommending the best solution for their business, and always striving to exceed expectations of quality for both the equipment and its output.

Polytype’s experience in markets where consistent quality is paramount has prepared it well for specialist industrial printing environments, but the company's approach differs significantly from other digital ink-jet manufacturers.

"Even though the superior print quality of the Virtu range makes the machines particularly suitable for display production, that's not what we see as their best asset," Pavesi says. "It's the versatility of the system that is most important, and this combines with our approach as a supplier: we spend time understanding the business's proposition and take their specific requirements into account, tailoring the machine to their company's needs before delivery."

Digital ink-jet: new potential Committing to a change to digital inkjet technologies has been a multi-faceted question for those in the screen, offset and web markets since the process came to maturity. In order to answer questions from industrial producers of all flavours, Polytype's engineers have incorporated into the Virtu range their research into and knowledge of material behaviour, ink adhesion, colour management and workflow. Digital of-

fers a vast reduction in expenditure on consumables, such as screens and plates, but the Virtu RS25, RS35 and RR50 go further; ink use is kept to an absolute minimum, both in the printing process itself but also during maintenance and cleaning functions.

Digital UV-curable machines have a number of inherent advantages over competing ink types. Born a decade ago as a response to the environmental concerns regarding the use of solventbased systems, which emit volatile organic compounds (VOCs), this formulation comprises monomers, oligomers, colorants and an initiator which, when printed, is cured by exposure to ultraviolet light.

The ability to send a printed piece to finishing immediately is crucial in modern businesses, which demand the power to accept and complete jobs in quick succession. These conditions mean that materials printed on UV-curable systems adhere more easily to green concept requirements in architecture and other public settings, as well as global demands for sustainability, and an improved environment for the opera-

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Digital Technology tor. Polytype manufactures its own ink range ,developed specifically for excellent compatibility, durability and colour vivacity on a wealth of materials, including various types of glass.

Polytype's Virtu printers: under the hood Polytype’s Virtu printers are available in 2.5 and 3.5m widths as the Virtu RS25 and RS35 respectively. These hybrid machines feature an ultra-stable print table and can produce onto both flexible and rigid media of an unlimited theoretical length, allowing for oversized applications. The table, which can support material weights of up to 50kg/sq m at thicknesses of up to 95mm, contains a dual-power vacuum pump system which secures very dense substrates, such as glass, as easily as very stretchable or thin materials, such as textile or mesh. It also includes an ink collection tray, meaning that porous media and fabrics can be printed.

of batches and incredibly long applications, such as building or stadium wraps.

The Virtu RR50 also allows three 1.6 m rolls to be printed simultaneously, thereby increasing productivity and minimising machine downtime when super wide jobs aren't on the menu.

Polytype's approach: machines built for purpose Although this host of quality and productivity options comes as standard across the Virtu brand, Polytype customises every machine leaving its factory to the precise specification of its destination company. Pavesi uses a recent business, which was looking to install a full glass decoration system, as an example.

“This customer chose Polytype for two reasons: adhesion was one, but the other was because we delivered a wellresearched, start-to-finish production system which integrated all his requirements,” he comments. “We performed a

"A key demand in industrial printing for any output purpose is reliability," comments Pavesi. "We call the Virtu RS25 and RS35 true hybrid machines, as they are the only printers that can support incredibly heavy materials or roll media as well as oversized substrates.

Thanks to their robustly engineered feed mechanism and heavyweight handling options, the Virtu's robust build and low maintenance are not compromised by the exceptional quality that the machine is able to produce. Printing at a photographic quality of 1,200 dpi, flood-, over- and under-coating are as achievable as extremely small text sizes (down to 4 pt) and fine graduations, such as skin tones, at speeds of up to 80 sqm/ hour.

Polytype's 5m roll-to-roll machine, the Virtu RR50, offers these advantages for production onto flexible substrates, such as mesh and banner. Increasing the maximum roll weight from 500 kg (on its sibling Virtu RR25 and RR35 engines) to 750 kg allows for easy printing

number of ink tests, worked with thirdparty suppliers to integrate all different modules, used colour specialists to assess exactly what the eventual output had to look like, and built a software workflow to manage transport.

This customisation ethic extends through the company, from engineering to service and support, and its Swiss approach to service is a key element in Polytype’s portfolio; even with no contract an engineer will be on site to resolve issues within 24 hours, and all support agreements are tailored to the user’s needs, with response time reduc-

ing to between six and 12 hours.

Where quality meets industry Wide-format digital printing shouldn't be seen as limited to the production of displays. High quality reproduction is required for a number of end purposes, and industrial printing jobs are high amongst them. 'Industrial printing' itself is a phrase that sees a lot of use, but not a lot of definition. Safety displays, product marking, membrane switch panels, and other identification and control interfaces are the kind of job that a fast-throughput machine like the Virtu can handle without a problem.

In the neighbouring glass market, too, decoration for aesthetic purposes, such as architecture and retail, sits alongside specialist applications, such as television sets, PDAs, aircraft and vending machines.

Most importantly, digital technologies allow for greater inclusion of creative designs as a cohesive part of a house, office, retail space, gallery or other building, and their component elements. We are more aware in building our products, spaces and cities that we must capitalise on the great design heritage that is now an integral part of modern life. Digital print allows for design to capitalise on these factors without the encumbrance and expense of analogue printing processes. Designs, logos, protective coatings, decorative graphics and even visual illusions can be created and applied freely, adding value and providing more possibilities for new applications.

With this trend in mind, Polytype has built its Virtu systems around the principle that quality and stability are the cornerstones of modern printing businesses, but can provide notable cost savings and ecological benefits when compared with alternative processes. As a company, we are also excited by the potential for digital print to reach new specialist areas, and are certain that the Virtu system has only scratched the surface of the ideas being brought to reality in our ever-changing industry. •

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Management/General

What will be the theme for drupa 2012?

By Barney Cox

Previous drupa's have been defined by a dominant technology trend, last time in 2008 it was the inkjet drupa and prior to that the show has been defined as the JDF drupa, the digital drupa, the CTP drupa and others further back in the mists of time.

So what will the theme be for 2012?

The clearest theme to emerge is that there will be themes rather than one over-riding theme in 2012.

“It will be the & drupa,” says Kodak EAMER managing director Philip Cullimore. “The media is an & world – print & apps, print & online, print & tablets, print & mobile. And, it’s not just print & other media. There’s also the combination of different print processes, where the sum equals more than the parts. It’s digital and offset.”

Transformation and transition are also emerging as themes for drupa 2012, and how vendors can help with that change through business development tools.

"At Ricoh we believe that drupa 2012 will be about transformation,” says Ricoh Europe Director of Production Printing Business Group Graham Moore. “Technology will continue to progress but the challenge for the print service provider is bringing it all together and getting the real business development support to manage change. Examples of that transformation are from offset or digital to offset and digital, from supplying just print to supplying cross media services - and the related transition from print service provider (PSP) to marketing services provider (MSP)."

Maps and guides to the new business landscape “For printers to become marketers they need a lot of help, which is where the business development tools of the vendors become important,” says industry analyst Andy Tribute. “Historically drupa has been a technology show but it’s also about business processes and innovation ,” says Canon Europe Pro-

fessional Print Director David Preskett.

“We will show how our clients have innovated in business processes; visitors can get a taster that may we hope will inspire them and lead to further things.”

There is a recognition that for print to play its part in the cross-media world it has to prove that it is effective against, and with, other media. One of the phrases that will be everywhere at the show is ROMI – return on marketing investment.

HP GSB worldwide marketing director Francois Martin believes that the perception of print by brand owners is already starting to change. “It is moving from being seen as slow moving medium in competition with on-line that also creates waste to one that adds value with desired documents that create positive feeling and emotion when properly used,” he says. Alongside the increased focus on the purpose and the business of print there will, of course, be lots of the latest technology on dis-

play, as whatever application you print and whomever you produce it for, better tools are an essential way of meeting the latest challenges.

Offset stands its ground Digital, and inkjet in particular, may have been in the limelight at the last drupa, and will be this time, but it’s important to remember despite the inroads digital print has made just how much printing is still produced using analogue processes, and isn’t ready to go digital yet either. We’re nowhere near the turning point where digital print volumes overtake offset argues Agfa Graphics Head of Product Marketing Ralph Hilsdon. “The change is coming but you will see offset standing its ground.”

The focus in offset press development has been to improve the automation, which can reduce operating costs.

Much of that focus is on reducing make-ready and changeover times to support shorter runs and quicker turnaround times. It isn’t the only benefit

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Management/General bour and ultimately the cost needed to produce a given volume of pages, whether that is through bigger presses or through automation,” says Goss International Marketing Manager Greg Norris, who believes the next step may eliminate some changeovers and makereadies altogether.

This more agile form of web-offset may mean it can win some work that used to be the preserve of sheet fed presses too, proving that it’s not just analogue vs. digital but it’s also important to consider the type of paper transport employed and whether it makes sense to use sheet fed/cut-sheet or web-fed/ continuous feed.

The inkjet drupa (again) If 2008 was the inkjet drupa, then what will 2012’s predominant digital theme be? It will be the inkjet drupa, again. “2008 was the inkjet concept drupa, 2012 will be the inkjet delivered drupa,” predicts Fujifilm Europe Graphic Systems Marketing Communications Manager Graham Leeson. “On show will be more inkjet machines for many more applications.” In the past four years, inkjet has made significant inroads into the digital printing market and is set to continue. though. Every step towards automation helps to reduce the unit cost of the printed piece, an important factor when fighting to maintain a margin and print itself needs to prove its cost-effectiveness as a marketing medium.

“We will see improvements in sheet fed offset, to the point where you can almost eliminate the operator,” predicts Andy Tribute. He believes features such as on-press measurement, will evolve to measure and control colour faster, and to be able to read the whole sheet to identify print quality defects such as hickeys. These developments will help to continue to reduce the run length at which offset is viable to a couple of hundred sheets, firmly in the territory occupied by digital today.

Reducing makeready and changeover times through automation is crucial for getting work through the press hall quicker but is only of limited use if the sheets then need to sit around for an age before they are dry enough to be handled for the next stage of produc-

tion. Look out at drupa for several different approaches to eliminate that dead drying time. One approach is through UV-cured ink. The latest generation of lamps and associated inks are designed to run cool and long, promising low power consumption, longer lamp life, wider stock choice and no need for expensive cooling and ozone extraction.

UV is just one option and may only be practical if you are investing in a new press. Those not in the market for a new press should check out the latest development from ink suppliers, which promise rapid setting of conventional inks in some of their latest formulas.

You can bet that even if they cost more than a bog standard offset ink, in comparison to toner or inkjet their price pales into insignificance. Another example of how offset suppliers are making the process more viable for shorter and shorter runs and quicker and quicker turnarounds to fight against the encroachment of digital.

Web-offset will also see developments.

“The focus is on reducing waste, la-

“In 2008, high-speed production inkjet printers only accounted for about 10% of the global digital colour print volume,” says InfoTrends Group Director Jim Hamilton. “That figure is rising rapidly and by drupa 2012 will be a quarter of the total volume and by 2014 will be more than a third.”

Developments in continuous feed inkjet have been rapid with most suppliers such as HP moving from a single machine to a range of widths, speeds and capabilities. Tribute believes that the next category of inkjet presses to emerge will be for more affordable continuous feed products with a speed of 50m/m with a price tag of $500,000, extending the range of printers who will buy the devices, the applications they are used for and the volumes of print produced using this technology.

But what of the cut sheet B2 inkjet machines? Leeson explains: “Continuous feed got off to a quicker start after the last show because the quality requirements and therefore technology employed is less cutting-edge than for sheet fed.”

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The question is, will Fujifilm and Screen’s machines be joined by other B2 sheet fed inkjet machines? At the time of writing it was too early to call, although there will be developments.

The picture that is emerging is that the next generation digital presses, which we may see at drupa 2012, will be aimed at the applications that are currently the mainstay of the market, and as such are produced on B2 sheet fed offset presses. However, just because that is the form factor of the leading litho technology, doesn’t mean that it necessarily follows that whatever replaces the B2 offset press as the printing industry’s workhorse needs to be the same in all respects except the imaging method.

Automation and integration Regardless of the printing processes employed joining up – that is integrating – the ordering, managing, producing and distributing a job are crucial to meet demands for lower cost, more effective and faster to market printed products. Once those processes are integrated, it also makes it easier to automate them. “One key aspect of digital print that is often overlooked is its ability to be used in automated workflows,” says InfoTrends' Hamilton. Reducing operator intervention and expanding the tasks that a single operator can handle holds critical importance in today’s production environments.”

But it’s not just in production where the benefits can come from automation and integration. As run lengths reduce and the number of jobs swell administration and customer service become increasingly significant costs of each job, putting the emphasis onto upstream systems and how you deal with clients. “We will continue to see further automation in the workflow, and more integration of systems, es-

pecially beyond the walls of the business to customers and between content systems and business processes,” says Agfa’s Hilsdon.

Hybrid printing, more than the sum of the parts There is undoubtedly competition between digital and analogue print processes. The wise visitor to drupa will investigate thoroughly the latest devel-

opments ¬- whether it is offset’s shift to shorter runs, or digital’s migration to higher volume - which may mean that they need to reconsider their own production capabilities. At the same time, it is becoming clear that it isn’t just an either or situation but as Kodak’s Cullimore said it’s the & drupa. There are benefits of using the two technologies together. That may be in hybrid printing systems that use digital to overprint

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Management/General

variable data onto offset, or by running both analogue and digital presses and routing the work to the most appropriate for that job.

“The transformation of printed pages to digital is not a jump from analogue, it includes blending and merging,” argues Cullimore. “For some printers it’s just not possible to move their applications totally digital, hybrid systems that use digital to customise higher-volume products, can add something to litho.

Goss’ Greg Norris adds: “We see an opportunity to integrate web offset with digital print in hybrid systems.” While there may still be a battle between the two processes in certain sectors, there is also agreement that they each have strengths, and the best approach is to combine them.

“We describe the job splitting between offset and digital printing as follows: printers can use their offset press for long-run jobs,” says manroland Vice President Corporate Marketing and Communications Thomas Hauser.

“Consequently, when they also have a digital printing press, their offset operations are more profitable. The workflow is the central point in a mixed production environment. We want our customers to use existing workflows with a joint metadata workflow that controls the digital printing press and finishing equipment. Thus offset users can remain in their familiar environ-

ment with the digital printing press seamlessly integrated in the offset dataflow.” manroland isn’t alone in that. While it’s partnership with Oce may have been the first to be announced between an offset and a digital vendor it was followed by Heidelberg teaming up with Ricoh, and KBA with RR Donnelley, the former to resell Ricoh digital printers to complement offset and the latter to develop new digital printing platforms that combine KBA’s prowess for building presses with RR Donnelley’s digital and hybrid printing experience and intellectual property. There may yet be more alliances where firms that were thought of as adversaries become partners.

Many themes = many reasons to go “To benefit from a trade show, one needs to get away from the day-today pressures of business and take the chance to meet people and exchange ideas,” says Canon’s David Preskett.

You can see applications, you can network allowing you to share information. Big exhibitions are one of the few opportunities to get away from your business and gain a clear insight to future business ideas and innovation.”

Canon’s Preskett adds: “I think it’s difficult to call a theme. It only really becomes apparent a few days into the show when it becomes clear what it is

that the visitors have come to see.“ Whether it’s automation drupa, the & drupa, the cross-media drupa, the inkjet drupa, the litho strikes back drupa, the transformation drupa, or any other drupa, the show is what you make it.

To make the most of it you have to be there to experience first-hand, to form your own opinions and to take away what is relevant to your business. It’s your drupa, see you in Dusseldorf.

Professor Frank Romano’s drupa through the ages 1972 - The small commercial press drupa 1977 - The colour electronic prepress drupa 1982 - The phototypesetting drupa 1986 - The fully-composed-film drupa 1990 - The digital drupa 1995 - The improved productivity drupa (CTP, DI presses, digital colour printing) 2000 - The press and workflow automation drupa 2004 - The JDF drupa 2008 - The inkjet drupa 2012 - The inkjet on steroids and inline finishing drupa

Barney Cox is Senior Consultant On Demand Printing & Publishing Europe at global imaging consultancy InfoTrends.

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Sheetfed Offset

Bigger and Bigger for Heidelberg site in Qingpu • Third construction phase officially opened at Qingpu site near Shanghai • Plant expansion serves growing demand from Chinese print shops • Local production portfolio covers all standard machines required by Chinese market • Heidelberg tapping into new customer segments in the industry's most important future market On September 28, 2011, Heidelberg celebrated the official opening of the third construction phase at its Qingpu site near Shanghai in China. The completion of this phase extends the plant's production area to some 45,000 square meters – a threefold increase in the space of just four years. This expansion enables Heidelberg to serve the growing demand from Chinese print shops.

The company has been manufacturing small- and medium-format presses and folding machines in Qingpu since 2005. For the past year, Heidelberg has also been producing presses in the 70 x 100 cm (27.56 x 39.37 in) format class at this site, so it now covers all standard machines required by the Chinese market. Around 400 staff work at the site. The machines made there, primarily for the local market, comply with the globally standardized Heidelberg quality criteria. In the future, Heidelberg is planning to gradually increase the proportion of such standard machines that are exported to neighboring countries.

“China is now our number one individual sales market and plays an important role in our business development. The demand for print products is growing all the time in China and has more than tripled over the past ten years. Every third machine sold by Heidelberg in

from left: Bent Mortensen, President Heidelberg Asia Pacific, Stephan Plenz, member of the Management Board responsible for the Heidelberg Equipment division, Thomas Frank Senior VP - sheetfed & Postpress, Asia Pacific China now comes from Qingpu. Offering locally produced machines has enabled us to tap into additional customer segments in our industry's most important future market. Our strategy of taking full advantage of the potential in emerging markets is thus paying off,” said Heidelberg CEO Bernhard Schreier at the opening ceremony.

Qingpu integrated in Heidelberg’s production network The Qingpu site is an integral part of the Heidelberg production network

comprising the Wiesloch-Walldorf, Amstetten, Brandenburg, Leipzig, and Ludwigsburg sites in Germany and Nové Mesto in Slovakia. This ensures that, even with a growing proportion of local suppliers, all processes and quality standards satisfy the globally standardized requirements at Heidelberg.

“Our customers can always rely on products from Heidelberg being of the highest quality, irrespective of whether a machine originates from Germany or China,” said Stephan Plenz, member of

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Bernhard Schreier the Management Board responsible for Heidelberg Equipment and thus for the Qingpu site. “This is confirmed by the more than 1,000 presses and folding machines already supplied from Qingpu. To ensure high quality standards, we train our staff with support from Germany and approve all our suppliers in accordance with very strict standardized criteria,” he added.

Heidelberg is the only press manufacturer based in either Europe or Japan to have its own production facility in China. As a result, it is further consolidating its leading role on the world's strongest growth market in the print media industry. “By operating its own production facility at the Qingpu site, Heidelberg is able to benefit from cost advantages while also minimizing the foreign exchange risk and import disadvantages,” said Plenz.•

Symbolic printing unit assembly during the official opening of the new assembly hall at the Heidelberg site in Qingpu. From left to right: Stephan Plenz, member of the Management Board responsible for the Heidelberg Equipment division, Qingpu Plant Manager Stefan Hasenzahl, the local government representative from Qingpu, and Heidelberg CEO Bernhard Schreier.

Chua Lian Seng

Stephan Plenz

Stefan Hasenzahl

For Export According to Bent Mortensen President Heidelberg Asia Pacific, "The products that are now being offered from the Quingpu plant are the SM 52, SM 74, the range of the standard Polar 115 cutters as well as folding machines for finishing. We expect these standard Presses which really means Heidelberg Quality, but with out all the automation we see from Europe, will be a fantastic fit into our developing markets here in the Asia/Pacific region. We feel strongly that not all printers need or require as much sophisticated automation, and this can be passed onto our customers in terms of price savings on our equipment, while maintaining the German standard of "top" quality. We look forward to introducing these products to the market here."

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Digital Technology

Toppan Security Printing receives ISO 12647-2 Certification With a history dating back to the early days of the Singapore Straits Settlement, as the Singapore Government Printing Office, Toppan Security Printing Pte Ltd has since become one of Asia’s leading security printers.

Its comprehensive product line includes highly-secure printed documents, security printing solutions, book printing and magazines production.

The company comprises of three main business units: security printing, publications & commercial printing and data printing. Together these units form a highly successful printing entity of regional renown.

In view of increasing requirement from its clients for ISO certification, Toppan Security Printing recently decided to pursue the ISO 12647-2 certification.

Below is an up close and personal interview with Mr Chia Tuck Mun, the Production Director of Toppan Security Printing, in regards to the ISO 12647-2 certification achievement.

What are the reasons or contributing factors that lead Toppan Security Printing in pursing the ISO 12647-2 certification?

Chia: In view of increasing customers’ demand for high standards in terms of color integrity and repeatability, it is necessary for us to achieve the ISO 12647-2 certification. Today, the market has become increasingly competitive and quality is one of the key differentiator that enables our company to retain customers and win new opportunities.

How does the ISO 12647-2 certification help Toppan Security Printing in the business operation?

Chia: After going through the ISO certification process, we concluded that there is less waste and faster makeready in our production process. Work-

Toppan Security Printing Team received ISO 12647-2 certification award from Heidelberg flow is standardized through the Print Color Management (PCM) service. Areas on press optimization and process calibration, generation of ICC color profiles and proofing were covered to ensure standardization as specified in the ISO 12647-2 standard.

Among other suppliers, why did Toppan Security Printing choose Heidelberg for the ISO 12647-2 certification service?

Chia: Heidelberg is the only ISO 12647-2 registrar to deliver turnkey service on Heidelberg equipment. Unlike other ISO Certification service providers, Heidelberg does not require any additional software or consumables to achieve the standard.

From consulting to implementation and ISO 12647-2 certification, does Heidelberg bring value to your company?

Chia: Yes, the integrated efficient color quality standard in our business has

certainly given us a stronger and better positioning in the market. Most importantly, we are able to meet our customers’ demand.

Do you see any improvement in the production processes after the ISO standardization and certification?

How have these improvements benefited Toppan Security Printing?

Chia: We see improvement in our overall production efficiency. Now, we have a more reliable and reproducible print production in place.

Were there any challenges faced during the process of ISO 12647-2 certification and how did Toppan Security cope with it?

Chia: Yes, we did face challenges. Our people need discipline to upkeep and maintain the ISO12647-2 standard at all times. Alongside, Heidelberg plays a very important role as a consultant, be it hardware or software to educate and advice whenever necessary. •

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Litho & Digital – A Complementary Mix

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Management/General

By Andrew Tribute

Today it is becoming much more common to find printers using more than one printing technology. In most cases this is adding sheet fed digital printing to complement a predominantly offset printing operation.

This allows offset printers to profitably handle very short run work and also to get into new markets where offset printing is not appropriate. This includes business to consumer operations such as photo books and also to enter into variable data printing for one to one marketing, direct mail and even adding Internet based services.

For the conventional offset printer what one finds however is the normal mode of operation is to find the offset and digital technologies are run separately using different workflows and where the printing technology to be used is chosen at the time of quoting for the job rather than at the time of production. The trend in future, as we will see at drupa 2012 from 3rd to 16th May, will be for much of the work to be done for a common workflow to be used and for the technology to be selected at the time of production. For this to happen the output from the two technologies must look

the same in terms of both image quality and colour compatibility.

In the launch this year of Heidelberg’s partnership with Ricoh, the common

workflow and colour compatibility at digi:media in Düsseldorf was a principal theme of the Heidelberg message under a marketing term call HEI Flexibility. This was shown by a demon-

(Image Integrated Golf Package – The Heidelberg/Ricoh Golf Invitation Job) (Image Integrated Golf Package – The Heidelberg/Ricoh Golf Invitation Job)

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Management/General 29 stration of production of a marketing package for a golf event where the different items in the package were printed using offset and digital printing and where the look of the different outputs was near identical. The work was all driven from Heidelberg’s workflow with common colour management. The work shown also linked in Heidelberg’s digital inkjet packaging press in the same workflow plus a range of Heidelberg finishing systems.

In the UK Heidelberg has also demonstrated how this workflow can be extended up the value chain by linking up with Cloud based web to print company Red Tie for online ordering and communication with the print buyer or specifier.

Where Digital Printing Should Fit The Heidelberg example above was a demonstration of what can be done, and today we are seeing such things happening from many printers in the industry using a range of different equipment. The use of digital printing to carry out work that would previously have been printed by offset where digital printing is a more suitable process because of the short run nature of the work is only part of the way digital printing is complementing offset. It is an example of how printers have found it necessary to implement digital printing in order to provide a more complete service to their customers while staying profitable. This is offset transfer where it is not profitable to print short run work using offset technologies. Today the digital printing from all the suppliers can match four-colour offset printing for quality and colour reproduction.

While digital printing has been the technology in the limelight at the past drupa events, offset technology has continued to develop and become more efficient and more suited for short run printing. Some digital printers have also seen the need to invest in offset to handle a wider range of work. In these cases it is often seen that a digital printer will add offset printing with D.I. technology from for instance Presstek. One reason for this is digital printing companies don’t want to have offset printing skills and the Presstek D.I. presses can be run almost like digital presses with offset costs. Jeff Jacobsen the Chair-

(Image Flyeralarm – The Flyeralarm Web Site for Ordering Print) man, President and CEO of Presstek states the following. “We have a term called bridging the gap. Customers are having great difficulty as 80% of all printing in four-colour is under 5,000 impressions and to do that efficiently you cannot do it with electrophotography because the toner is too expensive and inkjet is not there yet.

Between 500 and 20,000 impressions DI will give you the absolute highest quality at the lowest cost per piece.”

Sheet fed digital printing has developed hugely over the past decade.

While major attention has focussed on the high productivity presses from HP Indigo, Kodak and Xerox we have seen key developments in the mid volume and light production areas. A recent announcement in the light production space has come with a joint development of a new next-generation printer using existing proven technologies from Canon and Océ. We are now seeing additional functionality being added to these presses. This can be with a fifth printing unit for adding the equivalent of a coating or varnish.

An example of this can be shown with the Xerox 1000 Color Press where the clear dry ink allows for special effects like spot varnishing and special effects to be added to prints. The Kodak

Nexpress also offers a similar functionality. We are also seeing larger sheet sizes being offered. The Xerox iGen4 EXP handles sheets up to 66 cm in length permitting a wider range of work to be handled on the press.

The Kodak Nexpress SX also offers a similar sheet size capability.

This however is only part of the way that digital printing can complement offset printing and enhance the offerings that printers can provide for their customers. The key for the printers building their businesses today is to be able to offer a wide range of integrated services and products rather than just high-quality printing. The key to this is through enhancing the workflow to become accessible to a wider range of customers and to become easier to work with. This is using workflow to reach new buyers for whom buying print is a normal procedure, as well as making it easier for print buyers to work with the printer.

Apart from the high street quick printer, printing has predominantly been a business to business (B2B) operation.

Internet based ordering and workflow and digital printing is now making printing a business to consumer (B2C) operation.

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Digital Technology hanced web to print working and multiple media communication.

Imposition Optimisation Creates a New Business One area of web to print that we are now seeing is specialised workflow software to optimize the loading and scheduling of work on the press. In the past few years, particularly in Germany there has been a major rise of web to print where printers are using specialised software to gang multiple jobs on the same press. In this they are mainly using large format four-colour offset presses rather than digital presses for the work. One company well known for this is Vistaprint but I feel the best example of what is happening is Flyeralarm who run multiple large-format KBA and Heidelberg offset presses, as well as digital presses, with all work being ordered online via their web sites and online stores around Europe. Currently they process an average of 10,000 orders per day of which 99% are ordered online. One of the keys to such efficiency is the very fast make-ready and low manning levels of modern largeformat offset presses.

Precision Printing – Changing the Business Model A very good example of this can be seen from Precision Printing a UK based printer. Precision was a typical medium size offset printer and they first invested in digital in 2005 with an HP Indigo press. For a number of years their digital business was just complementing the litho business for short run printing that matched their offset printing. Following the last drupa in 2008 Precision changed their business operations by developing their own workflow for automating all their processes, and adding a very advanced web to print ordering operation through an alliance with Italian specialist Pixelartprinting. This has allowed Precision to double their turnover in five years with only a small increase in staff. Their offset printing turnover has hardly changed in that time despite an increase in capacity through a new Heidelberg 10-unit press. The increase has come through moving to a B2C operation with online ordering and automated production via its workflow allowing a huge number of small jobs to be processed

via their four HP Indigo presses. At the same time the addition of variable data printing has allowed Precision to offer a much wider range of services to its B2B customers.

Web to print software and integrated workflow is the key for making print businesses more efficient and allowing them to widen their markets as Precision has done. This type of workflow will be one of the key items on show at drupa from a range of companies.

Kodak will be one of the key ones showing such software with its Unified Workflow Solutions that link up the market leading Prinergy commercial workflow with the InSite portal solutions, together with Darwin variable data and Kodak web to print solutions to drive offset, flexo and digital printing systems. Most of the main industry vendors will be showing similar workflow approaches that reach up and down the value chain to allow printers to widen the scope of their businesses. I would also expect to see many small systems providers showing a range of new software products in the drupa Innovation Park for en-

Companies like Flyeralarm have developed their own workflow and job ganging software to create this massive area of business. Today such software is available from certain software suppliers to allow other printers to enter this high-volume web to print area. Litho Technics has a solution for automatically generating complex imposition plans for ganging multiple jobs together on one sheet. One user is MPG Books, a leading UK book printer. They needed to increase the capacity from 400 to 600 book titles per month and saw gang printing as a solution. They achieved this while reducing staffing in the planning area as well. Colin Gammon, MPG Books Technical R&D Manager stated “The software has helped us to remain highly competitive by cutting our labour costs in half. The AutoLayout feature allows us put more work on a single sheet, which reduces spoilage and speeds job turnaround,” One can also see the solution integrated into some other suppliers’ workflow packages.

This includes Fujifilm Europe adding it to its XMF suite of workflow solutions and EFI using it with some

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© Kodak, 2011. Kodak is a trademark.

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Management/General It is anticipated that with the entry of manroland and KBA into the digital market that book and magazine printers will be more likely to install highspeed inkjet presses to help change the business models of the customers in books, magazines and newspapers.

of its MIS systems. In the UK MIS supplier Tharstern is also developing a work ganging imposition extension to its systems.

Traditional Suppliers Going Digital One of the key trends to be seen at drupa is some of the leading offset press suppliers entering the digital market place. Heidelberg and its partnership with Ricoh have already been announced and the first systems have already been installed. manroland has announced a partnership with the Canon owned company Océ to sell high-speed inkjet presses into its markets. KBA will also enter this market through a partnership with the world’s largest printer R.R. Donnelley.

R.R. Donnelley has developed its own inkjet presses and is licensing its inkjet technology for KBA to build its own presses. These manroland and KBA inkjet presses will be aimed at the traditional high-volume offset printers in books, direct mail, magazines and newspapers with the aim of changing the business models for printers in these markets.

So far the majority of high-speed inkjet presses have been sold to transactional printers and few commercial printers have invested in this technology. In the USA in particular some book printers have installed such systems, predominantly from HP and Kodak. They have used them to change the business models of publishers so run lengths of colour books up to 5,000 copies now become viable on this technology allowing print buyers to reduce their levels of inven-

tory of offset printed books where ordered run lengths are usually longer in order to get a lower price per book. A good example of this is King Printing, a small USA book printer. They were the first book printer to invest in highspeed inkjet presses for book printing and now have two presses with a third on order. They anticipate that with the success of this technology in helping their publisher customers change their business models that they will may phase out their offset printing operations and become a total digital printing company. Aditya Chinai, the President of King Printing states the following: “We are becoming inventory managers for our customers as they look to cut their warehousing and costs. With inkjet the frequency of orders increases and the quantity of run decreases. We may see 10 orders for 50 copies of a title instead of one large run. It is now print for order rather than print for speculation.”

Where Does Offset Fit in Future?

This is perhaps the key thing that printers need to understand about the impact of new workflow approaches, web to print and digital printing is that it allows them to work with their customers to help them change the way they do business. The new business model for printers is to be a multiple media communications supplier in which print is just one way of communicating. Printers’ customers are being offered a whole new way of communicating and a range of new suppliers. The new web to print and workflow tools allow a printer to be able to make it easier for the customers to work with them, or for the printer to offer a wider range of services to become a more complete supplier. This is not saying offset will disappear, far from it. Offset will remain the major element of most printers’ businesses, but without digital printing and automated Internet based workflows, customers will move away from just offset centric suppliers.

While many analysts and the press will once again call drupa 2012 the “Inkjet drupa”, in reality it will be “Digital drupa”- that is an event built around how digital workflow and printing technologies will spearhead the change of printing to become a multiple media communications industry.

AGF A GR APHICS

Hands up all those

who could use

:Azura

:Azura is already the most popular chemistry-free system available today.

So what’s holding the rest of you back?

With print runs of up to 100,000, it’s unlikely it’s because :Azura isn’t robust enough.

And with an ability to hold up to 240 lpi, surely the quality would be suitable for all but the fussiest customers? What’s more, with no chemicals in the process there are hardly any variables to worry about either, meaning more consistent and stable images, too.

Whoever you are though, you’re certain to benefit from the almost non-existent disposal needs thanks to the unique Thermofuse system that creates an image without chemicals.

Not to mention the greater productivity, because of the reduced downtime needed for cleaning.

Which we think all adds up to making :Azura the best choice for chemistry-free, hands-down. :Azura. The standard in chemistry-free platemaking.

Agfa Asean Sdn Bhd Level 1, MENARA AmFIRST, Jalan 19/3, 46300 Petaling Jaya, Selangor, Malaysia.

Tel : +603-7953-5800 Fax : +603-7953-5900

Agfa Singapore Pte Ltd 10 Changi South Street 2, Level 3, Singapore 486596.

Tel : +65 6214 0110 Fax : +65 214 0770

www.agfagraphics.com

Print Pack Publish Asia • 10/2011

34

Sheetfed Offset

The Scotsman in us: save, save, save Paper is the largest cost factor in printing.

That’s why the simple equation applies: less paper waste reduces expenditure. Processcompliant system components from printcom help here. They ensure smooth, coordinated production and lower paper consumption.

Overcapacity, permanently growing competitive and price pressure, higher material and energy costs, the trend towards shorter runs, high quality expectations from customers, and the demands placed on printers as a services provider: Companies can only keep pace with these developments by continually improving their efficiency, and there is savings potential everywhere.

Where do you waste your paper?

How can printers influence their waste paper ratio? On the one hand, there is paper waste prior to printing. Paper is

improperly delivered or damaged in the warehouse, during transport, or during preparation for printing. Careful handling of this valuable commodity helps to avoid losses. The factors that influence paper consumption during printing are more complex. There are many areas where paper waste occurs: during makeready, restarting, production, stopping the press, washing the rollers and blankets, and in the finishing operations. The better the interplay of processes, substrates, operators, technology, and process-compliant system components works, the more positive

is the waste paper ratio. Alone with ten percent less paper consumption, the cost structure of a job can be improved by more than five percent.

But how? There are many causes of paper waste, such as the ink-water balance, inking-up, smearing and doubling, restarting after washing, or register problems, and each printing company should analyze these for themselves.

With the aid of a matrix calculator that records types of paper waste and their influencing variables, one can produce a detailed analysis of the actual situation including a definition of the target values and the necessary improvements. Either technical press retrofits for automated and faster makereadies, or inline color measuring and control can help. Or else success can already come through using other consumable materials, system components that are individually matched to the type of production and press. With printcom, manroland has been testing, analyzing, and delivering high-quality, compatible, process-compliant system components for the entire printing process for more than 15 years. Reduced paper waste is only one of the benefits here.•

Print Pack Publish Asia • 10/2011

Sheetfed Offset 35

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Sheetfed Offset

Steady growth pays off in recognition Shanghai Jinhuitong Gift Box Packing Co. Ltd. was established in November 2002, launching an Innovation Design Center at the same time. With the goal of becoming a ‘one-stop service provider that manages everything from design to production,’ Shanghai Jinhuitong Gift Box Packing started its challenging journey.

In 2009, the company changed its name to Shanghai JHT, and after the company’s transformation into a publicly traded company, Shanghai JHT Corporation was established in 2010.

Steady growth pays off in recognition Initially, Shanghai JHT primarily provided various design services to customers. General Manager Zhang Jiu Zhi has over 20 years of experience in a variety of business fields. Under the leadership of Mr. Zhang, Shanghai JHT slowly expanded its scope of work and recruited many talented people to the company. Proactive teams were created and after about eight years of effort, the company’s own office building was built in Shanghai. The company had transformed itself from a small business with about 10 people to a company with over 500 employees, and was now designated a ‘5-Star Package Design Company’ by the Shanghai Package Technology Association.

Clearly, Shanghai JHT was making an impression as a comprehensive package provider driven by innovation.

One-stop package design and printing service Shanghai JHT is known for paying close attention to its clients’ market positioning and consumer needs when creating innovative designs that match the product image. Shanghai JHT is proud to provide one-stop package design and printing services to customers. Today the printer focuses on creating food packaging and gift packages using regular paper and art paper from 80 to 400 gsm as well as

Zhang Jiu Zhi, general manager various other printed package products for different industries. Prominent domestic and foreign brands such as Germany’s Braun, Shanghai LaoFengXiang, Shangri-La Hotel Group, Bosch, Nu Skin, Gillette, South Beauty Group and Nescafé are some of Shanghai JHT’s clients. To offer products that will appeal to its highend customers, the printer not only creates unique packaging ideas but also guarantees top-class printing quality.

LS-440 ‘the right choice’ To accommodate its expansion, Shanghai JHT began researching the equipment of the leading printing press manufacturers. After careful evaluation and comparison, Shanghai JHT purchased a Komori four-color Lithrone S40 sheetfed offset printing press to establish a pilot factory in 2004.

Soon after the press started to operate, it was clear that the right choice had

been made. The printer is very pleased with the Komori Lithrone S40’s performance, particularly the stable sheet feeding and delivery, high register accuracy, excellent ink feeding and superior print quality.

The Komori LS-440 has the ability to smoothly print both thin sheets and heavy stock, and can easily meet the demand for various types of package printing. The short makeready and the fact that the press rarely produces paper waste at print start-up were also major points for Shanghai JHT. In 2006, the company again invested in Komori, this time introducing a fivecolor Lithrone S40 with a coater unit and quickly achieved increased package printing productivity.

Building its own brand To attain its goal of producing superior products that are ‘created in China,’

Print Pack Publish Asia • 10/2011

Sheetfed Offset 37 of a printing company. “Our two existing Komori presses perform with complete reliability and superb printing quality. And the services provided by Shanghai AFA are so thorough that we can purchase Komori presses with utter confidence,” says Mr. Zhang.

Shanghai JHT is working not only to provide first-class printed package products to customers in various industries but also to establish its own brand. ‘JHT Tea Boxes’ comprises a line of tea packages for the tea industry. A onestop business model that includes the innovative design, manufacturing, and sales of products has been established.

‘JHT Creative Paper Products’ is a product line owned as an independent asset for which the printer has complete control of all production steps, including design, research and development, production and sales. It is an example of the company’s success in transforming its innovative design capabilities into actual products. With subsidiaries in Beijing and Fuzhou, Shanghai JHT is building a system with superior marketing capabilities, innovative development and comprehensive services.

Purchasing the Komori Lithrone G40 In 2009, Shanghai JHT obtained ISO 9001 certification and was recognized as a ‘company with new and superior technology in Shanghai.’ Having achieved the international standard for quality management, it resolved to continue producing the highest quality printed products and also do everything possible to protect the environment. Purchasing the Komori six-color Lithrone G40 sheetfed offset printing press with aqueous coater unit was one of the most important strategic decisions Shanghai JHT ever made. The new Lithrone G40 reflects Komori’s determination to protect the environment in every aspect of its design.

The Lithrone G40 is superior in other areas as well, such as print quality, ease of operation, and productivity, and easily meets the various needs

The six-color Lithrone G40 that Shanghai JHT Corporation is purchasing is equipped with an aqueous coater unit that can provide a coating that both protects the printed products and enhances the surface gloss. The treatment increases the added value of the printed products and helps support the brand value of its customers.

The G40 arrived at Shanghai JHT Corporation’s factory in May 2011, and the press is expected to tackle the enormous work of printing food packages.

The new era of ‘Created in China’ Shanghai JHT is determined to contribute to the innovative print industry of China by maximizing the value of its products. In the words of Chairman Yang Zhong Tong, “We, the innovators of Shanghai JHT, must utilize our own abilities and say goodbye to the era of ‘Made in China,’ and vigorously push forward into the new era of ‘Created in China.’”•

Speed or quality?

Roll-to-roll or flat-bed?

What about oversized media?

Display or industrial printing?

Green or cost-effective?

You no longer have to choose.

Open up to a world of new applications: Virtu can print to virtually any substrate, from textile to glass.

Its robust table and roll unit allow you to print to flexible, rigid and oversized substrates at photographic quality, and it minimises use of its high performance, non-toxic UV-curable inks to save waste and money.

Polytype works with your business to understand what you need to print and tailors a machine which harnesses all this power to your needs. Now, you don’t have to compromise when choosing your wide-format printer.

Polytype SA: Virtu Business Unit 26, route de la Glâne CH-1701 Fribourg, Switzerland

www.polytype.com info@polytype.com Phone: +41 (0)26 426 11 11

Print Pack Publish Asia • 10/2011

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Sheetfed Offset

From the oldest german printing and publishing house to an efficient, future-oriented media company The nearly four hundred year old history of Mintzel-Druck is equally the history of an entire industry. For Peter Gänßlen, preserving traditions means responding to an ever changing market with innovative concepts. ORIS products play an important role in the entire production chain.

When Peter Gänßlen took over the oldest printing house in Germany in 2009, an era came to an end and things were not going too well for the company, which had been run as a family business for 375 years. High production costs, partially outdated machinery and an unfavorable customer structure got the traditional business into economic straits.

"Tradition is a good thing, but that alone will not help a company survive these days. Our industry has gone through fundamental changes over the last years, like never before. Now, radical measures not always decide on success or failure, but rather a whole bundle of measures, which eventually have an effect." Gänßlen speaks from experience. In the beginning of 2000 he had already taken over the printing operation of the Oberschwäbische Publishing House, and successfully restructured it.

You can tell that the chosen path is effective, as a brand-new Heidelberg 5-color press will be installed shortly.

"In a degressive market, which we currently find in Germany, the quality of products and services is a unique selling proposition and highly important to ensure the future existence and success of a company", says Gänßlen.

It was therefore not surprising that one of the first measures taken was to completely standardize the entire color management workflow from prepress to printing. In 2009, the company was officially certified by Fogra complying with the process standard offset printing (PSO). At the same time, a quality management system, fulfilling the requirements of the DIN ES ISO 9001:2000, was introduced and is binding for all employees. "For our customers, a stringent quality management is probably even more important than keeping the process standard offset. In some cases, we quite

Print Pack Publish Asia • 10/2011

Sheetfed Offset 39

consciously decide to leave the PSO. For instance, to achieve a more brilliant result and more intensive colors on uncoated papers, we over-ink deliberately.

In this, ORIS Ink Saver gives us a whole new range of possibilities, as it allows us to control the inking more precisely.

All of our data is process-optimized with ORIS prior to platemaking. Saving ink only plays a minor role for us. What is much more important is to keep a constant grey balance during the entire print run, which would be hard to achieve otherwise, even though our presses are equipped with the latest control systems. Another important effect for us is the accelerated drying process. Using less ink helps to avoid offsetting of the printing ink, so we can go to finishing more quickly. In many cases, we can thus produce entire jobs within a day. We have a Kodak CTP system for plate-making and use the stochastic Stakkato screening for many jobs, which in itself already saves ink. Initially we were skeptical, whether ORIS Ink Saver in combination with Stakkato screening, would not reduce the chromatic colors too much. This did not prove itself to be true in practice, quite the contrary. I had been successfully using ORIS Ink Saver and ORIS Color Tuner already in my company in Weingarten, so in the course of restructuring Mintzel-Druck, it was one of the first measures to install ORIS there as well.

Looking at the printing industry today, you soon realize that a company cannot survive just by putting ink on paper.

Apart from printing alone, it must offer the customer an individually tailored service package to be able to survive on the market today. For example, we offer, in cooperation with ClimatePartner, to print climate-neutral, with which we currently are uniquely positioned in the area.

Global competence.

Local excellence.

april 7– 9, 2011

aug 31 – sept 3, 2011

may 3 – 16, 2012

düsseldorf, germany

bangkok, thailand

düsseldorf, germany

www.digimedia.de

www.pack-print.de

www.drupa.com

may 3–6, 2011

nov 14 – 17, 2011

brno, czech republic

shanghai, china

www.bvv.cz/printexpo-gb

www.allinprint.com

We have also responded to changing customer needs by investing in digital printing as well, and have installed a Konica Minolta bizhub pro C 5e about a year ago. Today we also produce all of our form proofs on it. Previously, form proofs were printed in black and white on a plotter and then manually glued together and folded. Such form proofs now account for about 30 % of the throughput on the Konica Minolta. The major part however, is sellable prints. Without ORIS Press Matcher // Web, this would be inconceivable. We have perfectly matched the system to ISO coated V2 and our offset printing, and can now provide the customer with identical short runs, dru1202_90x260_4c_GB_Sing.indd 1

Messe Düsseldorf Asia Pte Ltd 3 HarbourFront Place #09-02 HarbourFront Tower Two Singapore 099254 Tel: +65 6332 9620 / 6332 9643 Fax: +65 6337 4633 / 6332 9655 E-mail: mdrep@mda.com.sg Internet: www.messe-duesseldorf.de/MDA

07.09.2010 11:28:36 Uhr

Print Pack Publish Asia • 10/2011

40

Sheetfed Offset

while he can actually wait for it. I was actually most amazed, when I realized that within twelve months we produced well over one million prints on the machine. With ORIS Press Matcher // Web we achieve a consistency and color accuracy, without such a throughput and customer acceptance would not have been possible. We have a very broad customer spectrum coming from all of Germany and the near foreign abroad. Only a minor part comes from our region. We are mainly positioned in the upper quality segment." Michael Niepel, who is responsible for prepress and digital printing at Mintzel-Druck, can report nothing but good things about the latest ORIS Press Matcher // Web version. "Particularly the new color stabilization feature greatly improved the quality even more. All toner-based systems normally show minor shifts in the grey axis. That is why you always have minor color variations within a print run, particularly apparent in technical tints. The new color stabilization feature almost completely eliminates these color shifts. Actually, it is now hardly possible to tell the difference in quality to offset."

Until recently, ORIS Ink Saver and ORIS Press Matcher Pro were two independent applications, which have now been combined in the ORIS Press Matcher // Web application.

Peter Gänßlen did not waste much time to upgrade to the latest version and to add the FileOut option.

"Mintzel-Druck is PSO-certified as the company in Weingarten has been.

Anyone who passed the certification knows how complex it is to keep these standards in daily production. Even if you meticulously comply with the specifications, you still may encounter problems in certain areas. ORIS FileOut now allows us to take countermeasures and apply the necessary fine adjustments automatically within the workflow", explains Gänßlen.

Half a year ago it was decided to concentrate all printing activities at the facility in Hof and to replace one of the existing Heidelberg SM 102-4 with a new Heidelberg 5-color press.

Still, all prepress activities remain in

Weingarten. Carsten Przygoda, who has been working for Peter Gänßlen for fifteen years in various companies, processes all orders from there. To produce hardcopy proofs, he uses an Epson 4880 with ORIS Color Tuner // Web, a configuration, which is also being used in the Hof location.

"Switching to the web-based version of ORIS Color Tuner was simply ideal for our constellation. Via the web we can access each other's system and directly print a color-accurate contract proof.

In combination with the integrated ORIS Softproof, which we use on Eizo monitors, we can now accurately and reliably communicate color between the two sites", explains Przygoda.

Mintzel-Druck is a prime example of a successful printing company, which managed a turn-around in the shortest possible time, despite locational disadvantages and a rather unfavorable initial situation. Judging by the major investments made recently, the company sees itself well positioned for the future.•

Print Pack Publish Asia • 10/2011

Management/General 41

Print Pack Publish Asia • 10/2011

42

Web Offset Technology

The case for 96-page web offset production Driven by printers demanding a major leap forward in press technology to improve their competitive positions and the value of their printed products, Goss International was the first to respond with the gapless Sunday press concept for high-speed, wide-web production.

The Goss Sunday 5000 - the world's first 96-page web press - is the latest milestone in this visionary effort to maximize productivity, reduce waste and transform web printing into an automated, high-tech industrial manufacturing process.

Sunday 5000 presses, in production since 2009 with a web width of 2,860 mm (112 inches), incorporate more than two decades of Goss wide-web innovation and accumulated process knowledge. Multiple systems in operation and the first repeat order for a second press prove the economic and competitive advantages of the 96-page format, the Goss innovations that enable it, and the ability of Goss International to support successful installations.

High-pagination makes sense Goss International began discussing the concept of a 96-page press with forward-looking web printers in 2005 and then surprised the industry at large when it was the first supplier to announce plans to develop such a press in 2007. Some doubted the technical feasibility of such a wide offset press.

Many questioned the business sense, given the impact of economic recession and the expansion of alternative media in the ensuing years.

Proactive printing companies recognize that the opposite is true: that offense, rather than defense, is necessary to confront economic and media challenges. They continue to focus on optimized capacity rather than overcapacity, and an increasing number realize that the 96-page platform represents a much needed path to more

cost-effective and competitive print production.

Overall demand for traditional commercial web products may not return to pre-2007 levels, but the stabilization of volumes, the rebound in some sectors and an expanded application range reflect the ongoing viability and strength of web offset printing. This volume will be concentrated among printers that invest in technology that allows them to take significant cost and waste out of the process, produce a wider variety of products, manage shorter run lengths, and take volume away from other processes such as sheetfed or gravure. The 96-page web press format addresses all of these opportunities.

2,860 mm is an optimal width The 2,860-mm (112-inch) web width of the Goss Sunday 5000 press allows up to 12 full-size magazine pages across the cylinder and four pages around the

cylinder in long-grain orientation (for A4 products, this width allows as many as 13 pages across). Goss International research compiled by studying the job records of web printers worldwide from 2000 to 2010 indicates that this is an optimal format for doublecircumference production.

This research data has confirmed that press systems producing an even number of sections in 16-page increments (32- and 64-page presses, or duplexed 48-page presses) are the most compatible with page breaks required by publishers, advertisers and print buyers. Companies operating press systems in these formats maximize productivity by utilizing the full web width for more than 80 percent of their jobs.

In contrast, printers operating 72and 80-page presses run narrower webs far more frequently, sacrificing efficiency and productivity. The logic

Print Pack Publish Asia • 10/2011

Web Offset Technology and research results are consistent for tabloid production, with an even number of eight-page sections being optimal.

The efficiency of the 2,860-mm width carries over to the bindery, where Goss Sunday 5000 presses reduce finishing costs for high-pagination magazines and catalogs. These products are typically produced with sections of up to 48 magazine pages due to the barriers to folding larger sections with higher quality paper stocks in excess of 90 grams. Producing two 48-page sections simultaneously (or a single 48page tabloid section) on a Sunday 5000 press utilizes the full web-width and allows high-quality finished products to then be built in the bindery with the fewest possible number of sections and the fewest number of bindery stations.

Prior to the availability of the 96-page press, some web printers opted for duplexed 48-page systems to achieve optimal versatility and efficiency.

However, a single-web press with the same capacity offers the advantages of fewer printing units, paper webs and crew members.

Not only 2x48 and long runs The advantages of printing 96 magazine pages per impression might suggest that the Goss Sunday 5000 press is designed exclusively for highpagination products in this format.

In fact, printers now use the press to produce magazine, tabloid, square tabloid, slim-jim, and digest products in an equally varied range of page counts.

Goss combination and former folding technology and, in particular, Goss

AIRDOT Ä      

B-600 G-900 G-955 CS-700 WB-800 UV-200

Goss Autoplate technology (shown here), gapless sleeve blankets, DigiRail digital inking and the Goss Web Center workflow automation system were among the Goss innovations that served as ‘building blocks’ for achieving the 2860-mm (112-inch) web width of the Sunday 5000 press. ingenuity in multi-ribbon angle bar configurations enables this versatility.

Operators using Goss combination folders can divide the 2,860-mm Sunday 5000 web into as many as four ribbons per folder.

Versatility extends the application range of a 96-page Goss Sunday 5000 press to retail inserts, catalogs, direct mail, books and specialized or niche-products. At current sites, printers routinely use the multi-ribbon capability to produce four separate catalogs or retail flyers per impression, at up to 180,000 copies per hour. Sunday 5000 press users have also been able to proactively promote the wider format to publishers and advertisers and present them with new, more efficient page-count and product

possibilities.

Short-run agility compounds the versatility and output capacity and further extends the application range of the 96-page Sunday 5000 press. Goss automation enables the productivity of the expanded web width to be achieved without a corresponding increase in operator effort, makeready time and start-up waste.

From another perspective, Goss automation allows a company that moves from standard 48-page web production to the Goss Sunday 5000 platform to double its productivity with no increase in crew size and labor requirements.

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43

capacity, the Goss Contiweb FD paster was the first to accommodate paper reels that are up to 1,524 mm (60 inches) in diameter and it provides automated roll handling, consistent tension for wide webs, and average successful splice rates exceeding 99.5 percent.

Goss folder ingenuity, including multi-ribbon angle bar configurations, extends the application range of Goss Sunday 5000 presses to magazine, tabloid, square tabloid, slim-jim, digest and specialty products in an extensive range of page counts.

Goss Automatic Transfer and nonstop edition change options provide additional market-driven opportunities to excel in short-run, versioned applications.

Automatic Transfer technology allows continuous fullspeed operation, without stopping the press for version or job changes.

Alternatively, with the non-stop edition change option, a press slows down but does not stop for automated version changes with minimal waste.

Innovative enabling technologies were required With the first Goss Sunday 5000 press installations proving the logic and viability of the 96-page web offset platform, a natural question is: ‘Why didn't press suppliers offer this option sooner?'

The answer lies in the technical challenges. No press supplier could simply decide to pursue a 2,860-mmwide system because it was a good idea. Developing this press required extensive process knowledge and practical experience in high-speed, wide-format splicing, lithography, web handing, drying, folding and process automation.

The Goss Sunday press sleeve blanket, introduced in 1992, was step one. This revolutionary technology eliminated the vibration, cylinder bounce and associated print defects that previously limited the width of two-around and four-around presses to 1,016 mm (40 inches) and 1,450 mm (57 inches) respectively, opening the door to higher quality at higher speeds on wider webs.

The original Goss Sunday 3000 press pushed web printing from 75,000 16page impressions (2x4 magazine pages) per hour to 100,000 iph on presses that were first 50 percent (2x6) and then 100 percent (2x8) wider. Goss Sunday 4000 press models provided corresponding advantages in the four-around format.

Today, more than 50 percent of the approximately 3,500 commercial web printing units with a web width greater than 1,450 mm (57 inches) in operation worldwide are Goss printing units.

Goss International also introduced fully automatic plate changing in 1995.

Accumulated experience from more than 4,700 Goss Autoplate printing couples now working reliably in realworld production environments is evident in the Goss Sunday 5000 Autoplate system. Changing the plates with more than three square meters of surface area is a fast, accurate and easily repeatable push-button process for a single operator.

Goss DigiRail digital inking has been installed on well over 5,000 printing couples and is another key innovation supporting the move to a 2,860-mm web width. DigiRail technology enables faster presetting and gives operators more accurate control, minimizing the potential complexity of managing color and ink density across such a wide web. The presetting accuracy and stability even allows some jobs to be run without color bars.

Splicing and drying innovations are also key building blocks for the Sunday 5000 platform. With a 7,500 kilogram

Within Goss dryers, integrated chill rolls improve print quality by suppressing condensate, while advanced web guiding improves tension and minimizes web breaks. Goss dryers were the first to incorporate integrated afterburners and to recover and reuse evaporated solvents as fuel. Today, the Goss Ecoset dryer for a Sunday 5000 press requires less energy and produces lower emissions than most competitive dryers for 16-page web presses.

More valuable and more competitive Goss Sunday 5000 press installations confirm that printers have been able to install and integrate the new Goss wide-web systems within their workflows and quickly achieve efficient operation and profitably. The 2,860mm (112-inch) width has proven to be compatible with common formats and page breaks, allowing optimal utilization of the full web width.

A vision for enhancing the value of printed products is the foundation for Goss International's leadership in developing wide-web press technology.

As media and economic pressures have confronted the print sector, wider Sunday press formats supported by innovative Goss enabling technologies have continuously provided printers with important competitive advantages.

Printers that have installed the latest Goss Sunday 5000 platform are realizing that the 96-page press presents another opportunity to bypass incremental improvements and achieve groundbreaking new standards for productivity and cost effectiveness.

With three presses in full operation in three locations and one printer investing in its second system, the Goss 96-page option is proving to be the right approach to the demands of the market and the advantages of highquality, wide-web production.•

Print Pack Publish Asia • 10/2011

Packaging Technology

45

Print Pack Publish Asia • 10/2011

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Web Offset Technology

manroland at IFRA Expo 2011: full control at the push of a button At IFRA Expo in 2008, manroland launched the concept of the future: One Touch – printing at the push of a button with only one operator at the control console.

Meanwhile twelve newspaper printing houses are producing with COLORMAN autoprint presses and have thus taken significant steps towards full automation.

What’s behind autoprint? The vision of fully automated newspaper production featuring changeover with APL (Automatic Plate Loading) and APL logistics, as well as InlineControl systems that, while the press is running, control cut-off and color register, web tension, ink density, and amount of dampening solution. This ensures consistently high print quality. The remarkable thing: all process steps, from the publisher through prepress, platesetting, printing, right up to and including postpress operations are integrated and networked in the printnet workflow jointly developed by manroland and ppi Media. This means all modules are centrally controllable – production transparency down to the last detail. autoprint users work faster and more efficiently, they also become more flexible and boost their productivity.

In view of the economic situation of many publishing houses, another key topic will be retrofits: manroland offers new options for reconfiguration, for moving to full color or to increase a newspaper’s page count. There is

also a wide variety of further retrofit solutions, mainly concerning control modernization or new drives. Last but not least, manroland will present upgrades for new or better production possibilities, and offers refurbishment.

Océ: new business opportunities in the newspaper market Highly productive Océ inkjet printing systems are sold through manroland’s worldwide Market Organization, utilizing the advantages of the company’s high profile in the graphic arts industry. Using the combined expertise of manroland as the global market leader in web offset, and Océ as the global market leader in digital webfed printing, the partners develop joint workflows (offset and digital) as well as system components (e. g. fold) and thus offer the world’s first total solution for high-performance digital printing.

Océ offers the most extensive inkjet portfolio for the graphics industry. At IFRA Expo Océ is to demonstrate how to open up new business opportunities in the newspaper market. Fields of

application for digital printing emerge from decentralized national and international short-run newspaper printing. Only this will in many cases enable immediate availability and justin-time production to be combined with minimized logistics costs. Furthermore, personalization and individualization concepts can be implemented for the first time in hybrid workflows. ppi Media: publishing software with the highest level of handling comfort manroland subsidiary company ppi Media will present publishing software with the highest level of handling comfort. From integrated ad processes to multimedia editorial solutions and innovative prepress products, all the solutions feature intuitive operation, extensive automation, and a broad range of functions.

Tensor presses for high-growth emerging countries Tensor will present its products together with manroland. In August 2010, manroland and Tensor reached a distribution agreement with manroland acting as a Sales & Service Partner for Tensor presses in high-growth emerging countries. The markets targeted by manroland are in Central and South America, the NAFTA countries Canada and Mexico, as well as Southeast Asia and southern Africa.

The cooperation is part of manroland’s strategy for strengthening its brand and its position in markets with dynamic growth rates. Tensor’s products round off manroland’s portfolio with competitively priced and highly efficient presses.•

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Wide Format / Proofing Technology

Versatility and productivity are key features The latest addition to Agfa Graphics’ successful Anapurna family of wide-format UV-curable ink-jet printers is a dedicated flat-bed engine, designed to accommodate the growing market needs for printing on rigid substrates.

The Anapurna M2540 FB is a new timesaving machine featuring a revolutionary quick-change vacuum bed technology, six colours (CMYKLcLm) and white ink. It is priced to attract entry-level purchasers as well as established users switching to the latest UV technology.

With a maximum print speed of 45 m2/ hour, the Anapurna M2540 FB can print sizes up to 2.54 x 1.54m, with substrates up to 4.5cm in thickness and 80kg in weight. The machine’s eleven retractable register pins simplify quick and accurate positioning, particularly when working on double-sided jobs.

Such is the versatility of Agfa Graphics’ Anapurna M2540 FB that it has been designed to accommodate small as well as large applications. This addresses the growing demand for niche output, such as the production of promotional goods and gifts, coasters and DVDs. The excellent adhesion of the UV-curable ink and its fast and efficient curing means that glass, ceramics and wood can also be printed, making it suitable for architectural and interior décor as well as exterior signs, displays and publicity.

"When we designed and engineered the Anapurna M2540 FB, we made sure that it features everything a user needs when working with rigid substrates," states Willy Van Dromme, Director of Marketing Wide Format at Agfa Graphics. "The result is a dedicated flat-bed printer with a competitive entry level price point, making it the ideal machine for companies who want to print all sizes of applications up to a maximum of 2.54m in width, with a fast return on their investment. With the same low ink consumption of 8.1 ml/m2 as the An-

apurna M2050, it delivers class leading low ink costs per m2" Thanks to the robust engineering, the Anapurna M2540 FB simplifies working with rigid substrates that must remain completely stable during the production process yet also allow for fast changeover. The powerful vacuum bed incorporates two zones each containing four switchable compartments, complemented by a reverse airflow function for swift removal of finished prints and moving of heavy substrates.

The printer’s industrial build also features ioniser elements to prevent the build-up of electrostatic charge on the media which can affect droplet control and subsequent precision ink lay-down.

And to protect the print-heads from hitting the media, shuttle safety sensors are positioned on both sides of the print carriage, thus eliminating unwanted strikes.

"We’ve paid very close attention to details such as the versatile vacuum bed, register pins, and the ability to load and off-load jobs quickly and easily," Van

Dromme continues. "As well as being able to produce high quality output on all rigid substrates, we know that time savings are a vital element to all print businesses, and the new Anapurna M2540 FB addresses these workflow and production elements for greater overall efficiency."

Agfa Graphics' new production printer will appeal not only to display producers and sign-makers but also to other market sectors driven by the need for high quality, durable full-colour output using UVcurable ink technology. It is as suitable for packaging prototypes, promotional goods’ manufacturers as it is for industrial specialists who need fast throughput and the ability to work with a vast range of rigid substrates.

The Anapurna M2540 FB flat-bed solution completes the Anapurna family of cost-effective UV-curable wide-format printers. Agfa Graphics also offers its comprehensive Jeti range of machines and the high-end :M-Press Tiger and MPress Leopard inkjet presses. ••

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Management/General

Making a Big Impression Trends in Large Format Printing Many industry pundits spoke of drupa 2008 as “The Inkjet drupa,” and in many ways, it was. Following drupa 2008, a number of vendors brought to market four-colour high-speed inkjet solutions that were shown at drupa in product or concept form, and those products are still coming to market.

As we approach drupa 2012, what are the technologies we can expect to see that will drive change in the printing and publishing markets? Once again, we can expect to see a significant position for inkjet in the array of new technologies exhibitors have on display. This time, however, while there will still be a large presence in the production sector, we can also look forward to a “big” presence in the large format market as digital offerings in that sector continue to mature, improve in price/performance, and displace conventional analog sign and display graphics technologies, such as screen printing, for many applications.

The Large Format Market Digital large format printers are not new to the sign and display graphics market.

What is new is the rate at which the technology has advanced in terms of quality, speed and the range of applications that can be addressed using digital—rather than analog—manufacturing processes.

Just as the offset printing market has seen demand from buyers for shorter runs, faster turnaround times and more relevant content that drives production to digital processes, the same transformation is occurring in the large format market. And the technology is there to deliver against those demands.

Innovation continues as well. For example, EFI claims its new LED “Cool Cure” curing for its VUTEk line operates at the same speed as UV lamps but with decreased power consumption, ability to print on thinner, less expensive

substrates due to reduced heat, and less cost due to no bulb replacements. Scott Schinlever, EFI’s Senior Vice President and General Manager of EFI’s Inkjet Solutions, expects to see other suppliers come to market with LED by drupa, saying, “There is not a lot of downside to LED curing if done without compromising core functionality.”

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FUJIFILM Graphic Systems has introduced a product that could be viewed as a cross-over between commercial printing and the signs and display graphics market. The FUJIFILM J-Press 720, a half-size (29”) sheet-fed inkjet press is designed for commercial print applications, but its sheet size and quality also make it suitable for smaller signs and display graphics, especially point of purchase (POP) materials. This type of approach may be an easier way for commercial printers to enter the signs and display graphics market, since the press can also be used to produce traditional short run commercial print products as well. In addition, FUJIFILM is the exclusive distributor of Inca Onset printers in the U.S., and offers its own Acuity Series flatbed/roll-fed UV printers and UVISTAR Series roll-fed printers worldwide.

Much of this technology advance is driven by market requirements. In June 2011, research firm InfoTrends completed a study designed to collect more information about the buyers of large format products. The study was designed to both gain an understanding of wide format graphics buyer requirements and to

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Management/General track changes in those buying patterns since the previous study conducted in 2009. Although this is a North American study, it highlights buyer requirements that are likely to be similar around the globe. More than 300 buyers responded to the survey that was the basis for the study.

Applications and Buying Patterns The study revealed that banners, posters and signs remain the leading large format applications, with photography gaining an increasing share as compared to 2009 (in 2011, 42.6 per cent of respondents reported purchasing photography applications, compared to 30 per cent in 2009). Drawings, proofs, flags and textiles showed sharper declines, with other applications remaining relatively stable.

On average, respondents reported purchasing large format applications 5.4 times per year, a slight increase in frequency over 2009. In the 2011 study, the average number of prints per order reported was 36.5, a number that favours digital production over legacy analogue processes.

Quality, price and speed are the three key drivers for selection of a signage and display graphics print provider. In 2009, price was the top selection criterion. This shift was also noted by Linda Bell, CEO of Inca Digital Printers, who said, “There has been a definite shift.

Customers are more familiar with the technology, and more demanding about what they want the technology to do.

They are interested in having different types of print and finish and a higher quality output than we have seen in the past. Because they already have a certain expectation about speed, it is now less about speed and more about quality.”

To that end, Inca has recently introduced higher quality printers with slower

throughput; the S20 and S40 models also offer a choice of gloss, satin and matte finishes. Bell adds, “If you can push quality up to offset levels, it will open an even wider market for large format.”

Speed is still important, however, and most suppliers to the market continue to increase the equipment throughput with wider print beds and faster speeds. EFI’s Schinlever said, “For print heads and the printing systems themselves, price/performance is increasing exponentially. For printer vendors such as EFI, Durst, Inca and others, it is not far-fetched to say that we will ultimately have something as fast or faster than a full-blown screen press–which will make integrated workflow solutions beyond the printer all the more important.”

Enhancing Signage with QR Codes One of the more interesting findings in the InfoTrends buyer research was the fact that 20 per cent of large format signage and graphics buyers have used QR codes and other interactive media elements in their large format graphics, and of those, more than 90 per cent plan to continue the use of interactive elements.

Seventy percent of buyers would consider using QR codes or other interactive elements in their large format graphics. This presents a huge opportunity for print providers in the large format graphics market to both educate buyers on the value of interactive elements as well as add this service to generate more value for the buyers and new revenue streams for themselves.

Digital Displays Not a Threat One perceived threat to the sign and display graphics market has been the emergence of digital (electronic) signage that many feared would displace printed signage. That transition, however, has not occurred, according to the InfoTrends study. Only 11 per cent of respondents have purchased digital displays, although 38 per cent indicated they plan to. These

purchases, however, appear to have little impact on printed large format graphics, with 76 per cent of respondents indicating that they use digital displays along with printed large format graphics.

The Digital Technology Mix These digital dynamics are driving a wedge into the traditional screen printing market at an escalating rate, and many screen printers are adding digital technology to their production portfolios. Just as in offset, there will be applications suitable for screen printing for the foreseeable future that are just not practical to produce with digital technologies. But the range of applications that can now be produced digitally is increasing exponentially. Many believe that the only applications screen printing does that can’t be done digitally revolve around use of niche specialty inks such as metallic and fluorescents, which are not likely to be available for digital for some time. In terms of specific applications, apparel will be the last big one to fall in terms of transitioning to long-run digital.

Ink Types One way to segment the large format market is to examine the various types of inks used. InfoTrends segments inks into three major categories: • Aqueous, which includes durable aqueous as a subsegment, such as HP’s Latex inks • Solvent/Eco-Solvent, once owning the largest share of the market but being eroded by durable aqueous and the third category, UV curable inks.

• UV Curable has captured the market and UV printers represent the lion’s share of shipments of new equipment in the large format market as print providers migrate from solvent.

UV is gaining ground faster in Europe than in North America, but less quickly in emerging markets such as China and Latin America where regulatory control

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Consumables

is less strict. InfoTrends’ Tim Greene says, “In North America, digital large format is still a fairly high margin business as compared to China, where solvent is the technology of choice and printers are paying one-tenth the price for a liter of ink than a North American printer would pay. The Chinese have driven price down, selling large format for as little as 35 cents per square foot, where it used to be as much as US$3 to US$4 per square foot.”

Greene also points out that printers in highly regulated markets such as Western Europe and North America are using what he calls cross-shoring to meet certain customer requirements, perhaps ordering printing produced in a less environmentally sustainable manner in Poland with the end product being shipped to the UK. In this case, the printer meets both the customer requirements and regulatory requirements, since the print is not being produced in the UK. “China started with solvent inks, while North America and Western Europe started with aqueous inks,” Greene adds.

“Solvent looks to remain the primary technology in China and other emerging markets due to lower ink costs, while developed markets are moving away from aqueous and solvent to UV and—as the technologies mature—we expect to see durable aqueous making significant inroads as well.”

One technology to watch is durable aqueous. While HP has a leading position in that segment with its Latex inks, Greene reports that similar formulations are being developed by companies

such as Sun Chemical and Sepiax, adding, “These inks are good for use with some Epson piezo-based printers, and that includes many Roland DG, Mutoh, Mimaki and Epson devices in the market. Many of these devices could be moved to durable water-based ink, replacing eco-solvent, simply by flushing the system and changing the print heads.” Durable aqueous inks could be a game changer that could slow the growth of UV, while accelerating the decline of solvent inks. It will bear watching to see whether leading service providers ultimately find value in migrating their systems to durable aqueous as this technology matures.

Interestingly, in a joint FESPA / InfoTrends study conducted in 2011, the most common type of equipment in use by printers surveyed was still solvent, and only a third of respondents reported having aqueous technology. This is despite the fact that the trend worldwide has been a move to UV curable inks. According to Roland DG’s Andrew Oransky, Director of Marketing and Product Management, “While UV technology promises to eventually replace solvent for many applications, it will be some time before the price points of UV printers match the levels we are seeing currently for solvent inkjet printers. For this reason, solvent inkjet printers will continue to be in demand, especially from small to mid-sized shops where an investment in UV technology is too cost prohibitive.”

Prints Aren’t Finished Till They Are Finished!

Finishing is also an important aspect of

large format production and can add both margin and value to an otherwise mundane project. For example, adding grommets to vinyl banners can add US$1 per square foot to the value of the project. Savvy large format providers are doing installation including backlit applications, and using laser die cutting to finish point of purchase materials, vehicle wraps and more. They are also applying different finishes to the piece, either through lamination or using technology such as offered by Inca Digital that allows a choice between matte, satin or gloss finish. Although these more complex operations can be harder to manage from a cost and profit standpoint than a “print, stack and ship” approach, a print provider who can offer this full range of services stands to grow both revenues and profits as well as build market differentiation and customer loyalty.

For most operations, printing and cutting are two distinct processes. Roland DG offers a unique patented print/cut platform that combines digital printing capabilities with a contour cutting mechanism to streamline the production process, allowing graphics to be produced from design to finished print in an automated manner, eliminating several otherwise manual steps. Its new VersaStudio 20-inch desktop printer/cutter allows graphics professionals to access the technology for less than US$10,000 and is ideal for producing fully finished oneoff samples or mock-ups.

Market Share Global market share ranking for vendors by ink type showed: • The global market leaders in waterbased or aqueous inkjet are HP, Canon and Epson. HP is the only big brand in the latex market and has sold more than 5,000 latex-based printers, according to InfoTrends.

• In eco-solvent, Roland DG is number one, with 2X the market share of everyone else in North America. Mimaki and Mutoh hold global market share positions 2 and 3, respectively. Roland DG’s Oransky reports that Roland DG’s global market share in eco-solvent is 41.9 per cent, with a global UV market share of 5.6 per cent.

• UV finds Océ with the lead in global market share, followed by Mimaki, HP and EFI. One advantage of UV printing using a flatbed printer is the ability to print directly to rigid substrates up to 2

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inches thick, eliminating the need to later mount and laminate output. UV printers are available in flatbed, roll-to-roll, or hybrid models that easily convert from one to the other.

These suppliers will be well-represented at drupa 2012, but visitors should also take the opportunity to visit smaller manufacturers, such as Czech-based Grapo Technologies, as well as look for innovative new products and technologies on display in larger vendor stands.

Evolving Markets Driving Change One thing is clear: the large format market is evolving and successful players are driving that evolutionary change on two planes, according to the FESPA / InfoTrends study.

The study reflects that service providers can develop strategies to evolve in two directions: “On one side is the ability to improve their operational effectiveness, to develop greater speed, improve image quality, gain efficiencies, reduce the environmental impact, and improve their customer service standards. On the other side, strategies could be developed to help create new services, build new products, engage new customers, and set up new business models.”

Evolutionary Strategic Directions The strategic decisions these companies make will impact the types of equipment, customers and applications they will choose to pursue. In addition to the quantitative data acquired by surveying large format service providers, this study also presented case study examples of companies that have chosen these evolutionary paths. Three of these, representing market entry from three different starting points, are summarized here as examples of the evolution the industry is undergoing in terms of both technology and the competitive playing field.

Devising New Revenue Streams UK company Alderson Print Group is an example of a non-traditional competitor in the signs and display graphics industry, an increasingly common phenomenon. In the case of this commercial printer in business since 1963, large format was perceived as a growth strategy to compensate for declining offset revenues. In 2009, the company established a dedicated point-of-sale division utilizing a combination of a KBA sheetfed offset technology and a range

of HP roll-fed wide format digital inkjet equipment.

Alderson used this new division to garner more revenues from existing customers, becoming more of a one-stop supplier, as well as an entree to gaining new business with new customers. Since the division was established, it has doubled year-over-year sales and now accounts for 20 per cent of the firm’s £30 million in sales. This 20 per cent of revenues is generated by a headcount of 30 out of a total staff of 236. A key challenge for Alderson, as for many commercial printers who choose to take the large format path, is the need for significant additional space to accommodate production and finishing, as well as for fulfillment and distribution services these new customers demand.

Massive Graphics Located in New Brunswick, Canada, Massive Graphics is a digital shop with seven employees driven by an innovative leader. The company uses three large format printers, two Mimaki eco-solvent printers and one Agfa flatbed printer, and does work in the exhibition and retail markets. In 2010, Massive Graphics saw an opportunity to integrate QR codes into its offerings. Although the company does not sell QR codes at an extra charge, its customers recognize that using QR codes in their signage and graphics campaigns is more effective.

QR code expertise also positions Massive Graphics as a consultant to its customers, frequently helping clients on the design side to make effective use of QR codes on large format printed signage.

QR Codes also make it easier to provide a link to information on the Internet in multiple languages—a requirement and often a challenge in French- and English-speaking Canada.

QR codes also deliver metrics. Companies want to know they are getting a direct response and QR codes are a great way to deliver that intelligence since accesses to the codes are tracked.

In a very short timeframe since this large format company began offering QR codes, it has come to be seen by its customers as capable of producing much more comprehensive and effective campaigns, elevating its value, and with little risk, since the addition of QR codes requires little additional investment on the part of the printing firm.

BIG Opportunities for Making a Big Impression Large format inkjet printing is an exciting segment of the printing business. It is growing, it can offer higher margins than many other segments, and the technology continues to evolve to allow even more innovative customer solutions. drupa 2012 will be an important venue for print service providers of all types to investigate the full range of options for entering this lucrative market space.

Visitors should take full advantage of the opportunity to educate themselves about equipment, inks, finishing solutions, applications and more as they seek the best path to profit for a new business opportunity, or look for ways to enhance their existing large format services.

Visitors should also look “beyond the box” at tools and solutions that will help streamline their operations. Most, if not all, suppliers to the large format market offer a wide range of prepress, workflow and finishing solutions that make the large format printing process more efficient and cost-effective. •

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NEWS Three Square Technology won the Grand Award in 9th Hong Kong Digital Print Awards

9th Hong Kong Digital Print Awards was the end on August. The competition jury which is organized by the scholars and professionals from the industry selected all the outstanding works from each group on August 31. Agfa Graphics Asia: Jeti agent Three Square Technology Ltd. (3SQ) entries "Body lines" received the highest honor of the Grand Prize, while its other works "Titoni gold watch" obtained Silver Award in a special printing materials’ group.

Three Square Technology Ltd was established in 2004, specializing in image processing and printing device sales and technical support. 3SQ team has been close to the development of the industry, not only to provide customers with advanced technical equipment, but also research and develop a variety of application of inkjet printing in the different media, providing customers with the most suitable inkjet printing solutions and value-added services.

The two works of 3SQ are printed by Agfa :Jeti 1224 UV HDC industrial flatbed inkjet printer. "Body lines" highlights :Jeti 1224 UV HDC digital flatbed printer's special printing effects by using its high accuracy of white ink printing in the same position repeatedly and stacking up to the form of embossed ink lines. :Jeti 1224 UV HDC is the fastest photorealistic industrial grade flatbed display graphics printer in its class. It can print on any type of flat media, media max thickness up to 5 cm. Another award winning "Titoni gold watch" presents metallic quality completely by printing on the aluminum board featured gold base, and also stands out while printing white ink on the some special area.

There are six categories for 9th Hong Kong Digital Print Awards: sheet-fed and combination printing, electrostatic printing (books hardcover), electrostatic printing (books softback), variable-data printing, inkjet printing, and special materials printing. Except 3SQ, the :Jeti and :Anapurna customers of Agfa Graphics Asia : Standard(Chan’s) Corp., Ltd, Fingerprint Ltd and Intech Graphics also obtained a variety of awards.

Hotfoiling paradigms are upside-down

Pantec GS Systems announces their satisfaction with the course of Label Expo 2011 as their going inline philosophy is finding more and more followers and the inline hotfoiling process becomes widely accepted in the premium label market.

The specialist for efficient, high quality refining demonstrated RHINO, an inline flatbed hotfoil embossing system, opening printers eyes that itís possible to go inline for high quality hotfoiling, reaping benefits such as lower cost per label and shorter lead times.

Peter Frei, CEO of Pantec GS Systems, is very pleased about the enthusiasm the machine demonstration aroused by the printers. ìWe had well-respected, experienced printers on our booth who could not believe that our stamping process can really achieve outstanding results on open, structured paper at 120 m/ min with perfect register and microembossing structures. High speed with foil saving for large volumes not only allows higher press usage, but economizes foil massively. It is also the basis to go inline to printing presses for premium wine labels, as RHINOís revolvable head allows multistroke for single pass manufacturing of ambitious designs, with combinations of foil and blind embossing, still running at a speed of 40-60 m/min.î Inline hotfoiling therefore is an increase of efficiency, improving the performance of the printing line and reducing lead times for the job.

This is additionally complemented by cost savings derived from flat bed technology, as Frei explains: ìFlat bed hot foiling allows use of cheaper foils and tool costs are a fraction compared to rotary.î The powerful foil saver rounds off the list for saving potentials. Tools, foil, saver and speed enable payback times of below a year. ìMany printing companies focusing

on premium labels with a high percentage of foiling have put RHINO on top of their investment list in the past yearî, Frei proudly summarizes.

Therefore Peter Frei strikes an enthusiastic balance on the show: "We had a very intensive week at Label Expo 2011.

We were shortlisted for the final of the Label Industry Award for New Innovation. With our demonstration we could convince so many people that there is an alternative to traditional foiling and the number of leads and high potentials is excellent. The printers feedback to RHINO is exciting, as they confirm that definitely a new foiling area in the label business starts with an unprecedented efficiency."

About Pantec GS Systems Pantec GS Systems, located in Kradolf, Switzerland, is specialised in efficient, high quality refining for the printing industry, providing leading inline systems for Hot Foil Stamping and Embossing, Foil Saving, Hologram Application and Security Perforation.

Outstanding print performance with nyloflex® NExT

Visitors to the Flint Group stand at ProFlex, Stuttgart, and Labelexpo Europe in Brussels, were able to witness at first hand some of the many excellent results that have been achieved using Flint Group Flexographic Products new and innovative exposure technology, nyloflex® NExT. Print samples obtained from several

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Web Offset Technology

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NEWS logic controller (PLC) carries out the complete automation as well as the visualization.

First class bookblocks and an efficient production thrill bookbinders all over the world who produce with the Ventura MC Book sewing machine from Müller Martini. Motion Control Technology together with a series of control devices ensures the high reliability.

Fanless and passively cooled Müller Martini now uses a new control unit that neither needs hard drive nor electromechanical components. The robust system is fanless and completely passively cooled. Therefore no overheating can occur. The control unit contains new driving components with integration of all the safety features.

European customers during exhaustive print trials using varying ink systems and substrates were displayed at both shows receiving universal approval from both print experts and customers alike. nyloflex® NExT nyloflex® NExT is a new, high intensity UV exposure technology from Flint Group, which enables precise reproduction of the digital layout onto the finished printing plate by exposing the printing plates with UV-A-LEDs. This innovative way of exposing offers great possibilities to establish a new quality standard for flexo platemaking. The high level of UV emission leads to a significant improvement of the reproduction of finest relief elements. The reproduction of high resolution surface screening provides superior print quality with much better ink laydown. The improved mechanical properties and the precisely defined surface of the flat top dots ensure a consistent high print quality and long print runs.

In comparison to typical digital dots, the physical characteristics of flat top dots enable reduced dot gain tolerances, which are usually caused by varying impression settings. Due to the precise reproduction of image data a 1:1 image transfer onto the printing plate can be obtained, which clearly extends the colour gamut and improves the contrast of the printed image.

The nyloflex® NExT technology does not require any additional consumables, which is a huge advantage compared to competitive technologies. It is suitable for

all standard digital flexo plates in all plate formats and plate thicknesses and can be easily integrated into an existing digital workflow.

To benefit from this new technology, Flint Group Flexographic Products offers two types of nyloflex® NExT Exposure units: • nyloflex® NExT Exposure F III, the mid size exposure unit with format 920 x 1200 mm (36 x 47 in).

• nyloflex® NExT Exposure F V, the large size exposure unit with format 1320 x 2032 mm (52 x 80 in).

The market launch of the new technology is planned for November 2011.

Industrial Book Sewing: Ventura MC with new automation platform

The Ventura MC features a new automation platform. This programmable

Clear step-by-step guidance with the order and set-up assistant The visualization on the screen is more modern and streamlined. Symbols and menu navigation correspond to the operator interface used in all new Muller Martini machines. They are standardized, so that the operators are quickly familiar with different machines and can be flexibly deployed within the organization.

Step by step the operators are guided through the order or set-up assistant.

The logic and streamlined system shows only what is relevant at the moment. With this automation platform even untrained operators can quickly set up the machines.

The assistant offers possibilities for users of any level. Experienced staff can avoid the logical step by step guidance and enter the data straight into the production menu. Any possible modification the system suggests is also shown to the operator.

Remote Maintenance with Martini’s Remote Service Portal

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Print Pack Publish Asia • 10/2011

SOLVENT UV.

NEWS

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The new EFI™ VUTEk® GS3250r replaces superwide solvent printers and multiple wide-format printers with 3.2 meter UV roll-to-roll productivity and true 1000 dpi print capability for high-margin, closely viewed applications. Or choose a faster printing mode for outdoor applications. Either way, you profit from increased production speeds and lower costs on a wider range of substrates and applications.

Digital economics means you get the best ROI and hourly breakeven in the industry – monthly payback can be achieved with less than one hour of run time per day.

And with EFI integrated digital inkjet workflow solutions from job acquisition to production – and industry-leading inks and service – you’re always ready to print to win.

Scan or visit efi.com/economics5 to discover the future of superwide printing.

Or call +65 6100 1689 for more information. ©2011 EFI. All rights reserved.

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NEWS to 782mm (30.81”), with scalability being achieved by mounting print modules across a bar. Print head alignment and image stitching is achieved through Domino’s i-Tech StitchLink micromotor controller technology, which allows for easy and accurate set-up of high quality images. The K600i has a native print resolution of 600dpi with three or four greyscales, which combined with its fantastic linear speeds, sets new standards for printing onto a wide range of substrates.

Access to the Muller Martini Remote Service Portal (RSP) is completely integrated into the new visualization. To ask for the factory’s support the user sends a “request” directly from the Ventura MC Book sewing machine. Then the factory gains access to the RPS to view and use operator screen and to retrieve information. Often service intervention can be avoided, the user is quickly helped and can go on producing.

“Pneumatic Island” for optimum air supply Both, the control platform as well as the pneumatic system was revised. Müller Martini Book Technology now uses a “pneumatic island” from Festo that optimally controls the air supply of the Ventura MC. In addition, higher process reliability and significant energy saving is achieved with the new suction system of the signature infeed. Previously, the operator had to close the suckers not needed and now they switch off automatically. The new automation platform allows for even safer operation of the Ventura MC and offers the operator a clear, fast and intuitive operating environment.

K600i full width high resolution ink jet printer gets intelligent

Domino will be showcasing the latest version of its recently launched K600i single colour piezo ink jet system at Labelexpo Europe. Moving away from remotely mounted individual ink jet print heads to a solution covering the full web

with a single digital ink jet module, the UV curable 600dpi K600i operates at double the speed of most high resolution digital systems at 50 to 75 metres per minute.

Designed for sheet or web printing, the K-Series’ variable data printing capability supports barcodes, 2D codes including QR Codes, numbers, graphics, logos and personalised data onto labels, tags, tickets, forms, security products and direct mail.

Key to the appeal of the K600i is its capability to accommodate different print widths by stitching heads across the web.

Print widths range from 108mm (4.26”)

Incorporating Domino’s i-Tech intelligent Technology, the K600i CleanCap automated print head cleaning and capping technology removes the need for daily manual maintenance while reducing risks for print nozzle blockages.

When not in operation, the print head is automatically moved into the CleanCap where the head is capped, ready for next use.

In addition, the unique i-Tech ActiFlow ink circulating system lets the UV curable ink move around the print head, even when printing has stopped. This prevents air bubbles becoming lodged within the print head, commonly causing jet-out and print quality degradation, maximising print time while minimising the need for maintenance.

“Demand has been increasing for labelling applications including variable data – from simple stock control, promotional games, anti-counterfeit data through to complete printing of labels for

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brand owners – and the K600i reflects the increased R&D investment Domino has made to satisfy this demand,” comments Philip Easton, Director of Domino’s Digital Printing Solutions.

Typical web applications for the K600i include digitally printing single colour language variants for short run production, which helps to reduce complexity, changeover time and inventory requirements compared to conventional flexo solutions, while in the sheet fed arena, the system is ideally suited to sheet-to-sheet game card and security printing applications. In common with all K-series models, the K600i has a compact modular design to facilitate integration with a range of host machines.

The K600i joins a range which includes the K100, K150 and K200 variants.

These are available with UV curable and low volatile solvent inks and have been successfully deployed in a variety of applications since its 2006 introduction, such that the range now accounts for and estimated 30% worldwide market share in its target markets.

A top-quality, professionallevel die cutter available at an entry-level price

German based KAMA GmbH is launching the new ProCut 74 SE together with distribution partner Heidelberg to expand its range of automatic die cutters for job printing, label printing and packaging printing. This "Special Edition" (SE) is designed as a cost-

effective entry point for professional post-press processing, and performs die cutting, creasing and perforating operations as well as blind embossing to highest quality standards.

first time to Thai customers. Heidelberg sales staff and customers took advantage of the C751 launch highlighting the strength of the partnership between Ricoh and Heidelberg in Thailand.

"Many printshops are keen to modernise their processing services and are looking for a solution which offers a rapid payback," explains KAMA CEO Marcus Tralau. "Not everybody wishes to take their first steps in the print finishing market with a high-end machine."

Heidelberg closed a number of orders for Ricoh digital production presses alongside commitments for offset technology at the show and many hot leads are in hand to follow-up during the next few months. Given strong customer relationships, a professional sales force and a dedicated digital support team, Heidelberg Thailand have within only a few months established themselves as a leading supplier of digital production print machines to the Thai Print Media Industry.

Replacement for long-serving cylinders As a result, the new ProCut 74 SE is a perfect high-performance replacement for long-serving platen press and cylinders. Offering the ultimate in register accuracy, the flat-bed die cutter can process up to 4500 sheets per hour and out-performs the outgoing cylinder cutters by a factor of two to three. Changeovers on the user-friendly machine from one job to the next are quick and easy. "With the new basic die cutter, customers can reach the breakeven point much more quickly than most would expect," explains Tralau.

About KAMA The company KAMA GmbH from Dresden in Germany employs around 100 members of staff and develops and manufactures feature-packed automatic die cutters and folder gluers for the graphic arts industry. KAMA machines for post-press and finishing are used successfully in more than 60 countries around the world.

Heidelberg Digital Sales Success Continues in Thailand

The Heidelberg booth was the main attraction at the hugely successful Pack Print International exhibition held in Bangkok from August 31st to September 3rd. The expo’ saw more than 20,000 people attend from Thailand and many neighboring countries with visitors keen to see Heidelberg’s “Short Run Solution” area showcasing a Ricoh Pro C901 digital colour production press, a Speedmaster SM52-4+L Anicolor offset press, a Suprasetter A105 CtP imagesetter and a Polar 66 cutter as an integrated short run production solution. The Ricoh Pro C751 was also displayed on the Ricoh stand next door to Heidelberg.

The light production C751 is the brother to the C901 and was shown for the very

Troels Jensen Heidelberg’s regional business manager for digital was enthusiastic about the outcome. “We always expected our launch in Thailand to go well, but success has come faster than anticipated. Our customers are quick to see the opportunity in digital and have confidence in Heidelberg’s proven performance in offset to support them as they enter the digital market”.

He concludes “So far Heidelberg Malaysia and Thailand are selling Ricoh as we roll out our plan in Asia and the positive feedback and willingness of our customers to purchase early on in our launch phase gives us great confidence for the future.”

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Categories

For Sale - Sheetfed Offset For Sale - Web Offset For Sale - Bookbinding For Sale - Paper Stock For Sale - Others Wanted - Sheetfed Offset Digital Printing

2002 Manroland r905-6 Contact: Ho +65 9489 3535 E-mail: weeminghua@gmail.com

For Sale - Paper Stock PaPer StoCKS For Sale coated / uncoated Contact: Betty +65 6863 9203 E-mail: trading_pf@craftprint.com

For Sale - Sheetfed Offset 2000 Heidelberg SM 102-8P Press 8/0-4/4 Contact: Ho +65 9489 3535 E-mail: weeminghua@gmail.com

For Sale - Bookbinding 1996 MM trendbinder 18 Stations, Book Block Feeder; 18 Clamps; Milling; Hot Melt Spine/Side Glue; Gauzing; 2 Pressing Stations; Drying conveyors 60m; Zenith 3-knife trimmer 3672; CB 16 Stacker Contact: Ho +65 9489 3535 E-mail: weeminghua@gmail.com

2003 Manroland r705lV 2 x UV interdeck and 1 x end of press Call: Ho +65 9489 3535 E-mail: weeminghua@gmail.com

2001 MitSubiSHi 3Fr PreSS 8/0-4/4. Contact: Ho +65 9489 3535 E-mail: weeminghua@gmail.com

PaPer StoCKS For Sale

157gsm matt bon, 33.5x23.5, 417 reams@ $50/ream (Korea); 70gsm woodfree NPI, 34x34, 1395 reams@$35/ream (Jap); 70gsm lagoon woodfree (green), 25x35.5, 566 reams@$30/ream (Indo) Contact: Henry Poon +65 9649 3615 E-mail: henry@stamford.com.sg

inK PuMP SYSteM teCHnotranS

w/ feeding pipes up to 8 printing units Contact: Lee ST +65 6865 2010 E-mail: stlee@csgraphics.com

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For Sale - Others KODAK APPROVAL XP4 2400 AIT Software Ver 2/800XL Contact: Lee ST +65 6865 2010 E-mail: stlee@csgraphics.com

Digital Printing

Rates & Payments

When you need to move into digital printing, call on us for all the advise you need. At Fuji Xerox, we are here to help you understand and not blind you with the usual sales pitch.

Fuji Xerox, your partner for the digital future.

S$40.00 per column cm including b&w pictures (min 2 column cm) By cheque or bank transfer payable to: P3 Asia Classifieds Pte Ltd UOB Account no. 344-304-914-9

Contact Us

www.fujixerox.com.sg

Wanted - Sheetfed Offset HeiDeLbeRg CD 102-4 PReSS 2002 or younger. Specs; Condition; Location & photos Contact: weeminghua@gmail.com

Adrian +65 9680 1819 adriangoh@p3asia.com.sg No. 71 Geylang Lorong 23 THK Building #07-02 Singapore 388386

HeiDeLbeRg SM 74-4H and/or 5H presses. Max 10 years old Specs and impression count Location of machine Contact: weeminghua@gmail.com

GOOD LUCK TO EVERYONE THAT ENTERED THE 2011 Asian Print Awards

Look for details coming soon or go to www.asianprintawards.com.sg

DID YOU WIN THIS YEAR!

TERMS & CONDITIONS: P3 Asia Classifieds Pte Ltd reserves all rights to accept or decline adverts. We will not accept any liability whatsoever regarding mistakes, copyrights of articles and branding, and timing of publications. Payment must be made within 14 days of receipt of e-invoice.

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