KBA Report 37 - english
Transcript
KBA Report 37 - english
www.kba.com 2|2010 PRODUCTS|PRACTICES|PERSPECTIVES 37 Contents KBA Editorial 2 Obituary: Dr. Bolza-Schünemann 3 Breakthrough: our highly automated compact presses – the waterless Cortina and conventional Commander CT – are rapidly gaining converts among newspaper printers, not least the Straubinger Tagblatt, which inaugurated this Commander CT in May Business is picking up Print resurgent! he second quarter of this year saw an upsurge in demand for printing presses, not just in crisisresistant China but in other markets as well. Following a prolonged period of stagnation, sales by German press manufacturers are moving briskly once again. At the Ipex international trade fair in Birmingham in May there was an infectious atmosphere of anticipation. While this was no guarantee of a steep and universal upswing, it did signal the prospect of a relatively stable recovery in the print media industry, albeit with regional differences. At KBA, the volume of incoming orders for sheetfed presses doubled in the second quarter compared to the first. In the seven months to August, Chinese printers not only placed a succession of or- T ders for B1 (41in) Rapidas but also signed up for nigh on thirty largeformat presses. Demand has been brisk in the Middle East and Latin America as well. And there is evidence of an updraught in the USA, Russia and Europe. While this incipient recovery is more than welcome, we are still far removed from normal trading volumes. Greater optimism in the future of print also inspires more innovative thinking, and as so often in the past, KBA has reaped the benefits among newspaper printers in recent months. A lengthy debate on the pros and cons of satellite and tower presses, and the impressive market success of our waterless Cortina, have been followed by a breakthrough for our conventional compact tower press, the Com- mander CT. Alongside an order for a further Cortina with heatset capability for Sweden and a major contract from Express Newspapers Group (West Ferry Printers) in the UK for four double-wide Commander CT press lines totalling 22 towers, within a matter of weeks three German newspaper publishing houses opted for triple-wide Commander CT press lines with web widths of up to 2,100mm (82.75in) for the Berliner and Rhine formats. These are exciting times. Further information on new compact press lines and emerging market trends can be found in this issue. Klaus Schmidt [email protected] Sheetfed 32m Rapida 162a at TFP, Poland 4 Cartamundi, USA, expands with 14-unit Rapida 106 5 Ipex review 6 Stark Druck, Germany 8 Interview on web to print 10 Rapida 75: 11 jobs in 90 minutes 14 Rapida 106 for Jordi, Switzerland 15 QualiTronic Color Control with Instrument Flight® 16 Packaging printing in Egypt: Trio of Rapidas at El Sofa 18 €40m investment by First Print 19 Automated PDF control 20 Perfecting in France 22 Sheetfed energy audit 24 Climate-neutral printing 26 Rapida 205 in Belgium 27 KBA presses at Sansico, Indonesia 28 Hammer Packaging, USA 29 Australia’s first two-coater Rapida at Percival 31 Web Offset New C16 16pp web press Two Compacta 217s for Saudi Arabia Imprimerie Rockson, France, orders 80pp Compacta French book printer CPI chooses Commander CT Newspaper Hybrid Commander for Jordan Press Foundation West Ferry Printers, UK, orders 22-tower Commander CT First Commander CT 6/2 in Europe Commander CT 6/2 in Germany Heatset Cortina for Sweden First Cortina 4/1 goes live in Finland Customised Colora 3/2 for Colasanto, Italy 32 34 35 36 37 38 40 41 42 43 44 UV Offset Genius 52UV at Bohm, Germany 45 Shorts 46 Editorial On the death of Dr Hans-Bernhard Bolza-Schünemann Farewell to a master of press engineering Helge Hansen, president and CEO, Koenig & Bauer On 23 July one of the print industry’s movers and shakers, Dr Hans-Bernhard Bolza-Schünemann, passed away at the age of 84. When he retired in 1995 he had been president of Koenig & Bauer for more than two decades. He was subsequently appointed deputy chairman of the supervisory board, retaining this position until 2006. From 1964 until his retirement he was head of press engineering and development, and continued to bring his technological and entrepreneurial skills to bear right up until his death. KBA mourns the loss of an inspired engineer and visionary entrepreneur. “HBS” or “the Doctor”, as he was affectionately known to his staff, was an indefatigable driver of advances in press technology for more than half a century. The world’s widest-ever newspaper press – a Jumbo-Courier built in1974 – and the 15,000sph Rapida SRIII sheetfed offset press launched in 1976, whose technology was a good ten years ahead of its time, are just two of the manifold examples of Dr Bolza-Schünemann’s inventive genius, documented by over 250 patents. Once he had fixed on an objective he would pursue it with singleminded Hanseatic determination, sometimes over a period of decades. No proponent of the comfortable, risk-averse mainstream, he preferred to go his own way – a characteristic common to many great men. It was his focus and drive that kept KBA one step ahead of its bigger rivals in boosting sheetfed press production speed. Back in the early 1980s he sought to convince German and US newspaper publishers of the potential cost efficiencies delivered by triple-width web offset presses. Twenty years later he was delighted when 6/2 technology finally came into its own and KBA assumed a pioneering role in launching it on the market. Shortly before his death he had the pleasure of seeing our triple-width, ultra-compact Commander CT press enjoy considerable success among German newspaper publishers. It was the vindication of his longstanding belief in the technological and economic benefits of wider presses. Dr Bolza-Schünemann’s passion for engineering and technology remained with him until the end, as did his business acumen. It was he who laid the foundations for Koenig & Bauer’s dynamic evolution from a midmarket manufacturer of web and security presses 25 years ago to one of the world’s leading press engineering groups today. His first move, the acquisition of a majority interest in Albert-Frankenthal AG in 1988, was followed in 1991 by a similar scenario at Planeta-Druckmaschinenwerke in 1991. He was also the driving force behind Koenig & Bauer’s merger with KBA-Planeta in 1998, which he saw as a means of providing security and perspectives for the dedicated employees of this long-established east German company. The recent recession has proved him right. In his function as deputy chairman Dr Bolza-Schünemann also vigorously promoted further acquisitions in the new millennium (De La Rue Giori in 2001, Bauer+Kunzi in 2003, Metronic in 2004, Grafitec in 2005, LTG in 2006), being quick to recognise the benefits delivered by a broader product portfolio and customer base. His early adoption of a diversification strategy centred on KBA’s traditional business of innovative press technology, with a view to expanding its core technological capabilities while exploiting potential synergies to address both volume and niche markets, has had a stabilising impact in times of crisis and distinguishes KBA from all other press manufacturers. The same applies to the financial and dividend payment policy that Dr Bolza-Schünemann pursued as the acknowledged representative of the founding family. For him, the justified interest of shareholders in a commensurate return on their investment was always balanced by the welfare of both the company and its employees: the two goals were of equal import. His concept of shareholder value was informed by the long-term objective of safeguarding the future of the enterprise, and this was reflected in the annual dividend, which was always calculated with the interests of all parties in mind. Prior to the recent crisis this was not an attitude to which investors widely subscribed. However, it is one of the primary reasons why KBA’s capital-to-assets ratio remains well above that of other industry players even after two challenging years. Alongside his prolific activities on behalf of the company and the print media industry Dr Bolza-Schünemann also held many honorary offices, reflecting his intense social engagement. These are mentioned in more detail in his obituary opposite. We at KBA are deeply saddened by the loss of our former chief executive. However, his achievements will not be forgotten. Even as we bid farewell to a master of press engineering and the architect of the KBA group we know that the passion for innovation that inspired him will live on within the company. We owe Dr Bolza-Schünemann a huge debt of thanks and will do our best to maintain the course that he has set. Yours, 2 Report 37 | 2010 Obituary Dr Hans-Bernhard Bolza-Schünemann† 2001: Dr Bolza-Schünemann on a tour of KBA’s production plant in Radebeul with former German Chancellor Helmut Schmidt 1989: Dr Bolza-Schünemann talking to the British prime minister Margaret Thatcher at the commissioning of a big KBA web press by the Daily Mail in London Entrepreneur, inventor, industry representative and patron Dr Hans-Bernhard Bolza-Schünemann Dr Hans-Bernhard Bolza-Schünemann, former longstanding president of KBA, died on 23 July at the age of 84. With him the KBA group and its employees have lost a popular and highly respected senior executive, the German engineering industry an innovator and internationally esteemed representative, and the city of Würzburg an inexhaustible promoter and patron of the arts. ans-Bernhard Schünemann, as he was originally called, was born on 20 May 1926 into a printing and publishing family in Bremen. In 1949 he took a degree in physics at the Technical University in Braunschweig. This was followed by a PhD in mechanical engineering at the Technical University in Stuttgart in 1951, after which he joined Koenig & Bauer as a design engineer. In 1956 he was made assistant vice-president for sheetfed engineering, in 1957 deputy executive vice-president for engineering and development and in 1964 a full member of the board. This last appointment followed his legal adoption in 1959 by Dr Hans Bolza, the great-grandson of company founder Friedrich Koenig. Hence the surname Bolza-Schünemann. H Visionary entrepreneur As president of KBA from 1971 to 1995 Dr Bolza-Schünemann positioned the company among the topmost players in the global printing press industry, partly through some spectacular innovations in press technology and partly through the acquisition of other press manufacturers (Albert-Frankenthal, Maschinenfabrik Mödling, Planeta Druck- maschinenwerke) with roots dating back to the cradle of press engineering in Würzburg. In 1995 the architect of KBA’s breathtaking expansion retired and joined the supervisory board, where he remained a member until 2006. However, he continued to apply his outstanding engineering skills, eg in the development of the 74 Karat digital offset press. His ideas, his expertise and his innate ability to motivate never failed to impress even younger members of staff. Prolific inventor and engineer As the fifth generation to head the company, Dr Bolza-Schünemann identified strongly with the innovative ambitions of the two founders, Friedrich Koenig and Andreas Bauer. Perhaps more than any other he helped drive technological advances in the print media industry through groundbreaking innovations, registering over 250 patents. For example, he was the force behind KBA’s pioneering of keyless inking technology for newspaper and sheetfed presses. His outstanding achievements were acknowledged in 1960 with the award of a Ring of Honour by the VDI (The Association of German Engineers) and in 2003 with the Leonardo da Vinci Prize by the AIPI (Association of Italian Industrial Engineers). Universally esteemed representative Dr Bolza-Schünemann was also active for many years, in an honorary capacity, on the boards of the Fachgemeinschaft Druck- und Papiertechnik (Association of German Manufacturers of Printing and Paper Equipment and Supplies) and the FGD (German Printing Machines Research Association), and was elected Drupa president in 1995. He vigorously promoted the interests of regional businesses as a member of the Würzburg-Schweinfurt Chamber of Industry and Commerce executive committee from 1968 to 1990. From 1983 to 1987 he was the Chamber’s chief executive. Tireless patron Dr Bolza-Schünemann shared with his wife Renate a love of classical music and the theatre. He found relaxation and inspiration attending performances at opera houses the world over. A tireless promoter and patron of the arts in Würzburg, he co-founded the local Johann Sebastian Bach Society in 1966. He was a longstanding honorary member of the board, and from 1990 chancellor, of the Academy for Music in Würzburg. In conjunction with the Koenig & Bauer Foundation he privately helped to fund a wide range of cultural activities throughout the region, drumming up support and sponsors. Another of his interests was to further the careers of young engineers. Countless honours His honorary activities brought countless awards, including the Distinguished Service Cross of the Federal Republic of Germany, the State Medal for outstanding services to the Bavarian economy, the Bavarian Distinguished Service Award, the Grand Golden Badge of Honour of the Republic of Austria, honorary fellowship of the University of Würzburg, the Grand Service Medal of the VDMA, the Golden Ring of Honour of the WürzburgSchweinfurt Chamber of Industry and Commerce, honorary senatorship of the University for Print and Media in Stuttgart, and honorary citizenship and the Ring of Honour of the City of Würzburg. Klaus Schmidt [email protected] Report 37 | 2010 3 Sheetfed Offset | Poland Extending some 32 metres (105ft), at its installation TFP’s Rapida 162a was the longest sheetfed offset press in Poland. Since then another Polish printer has taken delivery of an almost identical press line The Rapida 162a at TFP is mounted on a 420mm (16.5in) plinth, the feeder (shown here) and delivery are embedded in an automated pile logistics system TFP fires up first two-coater Rapida 162a in Poland 32-metre giant for top-quality packaging printing ´ has become the first user of a 7B (64in) Rapida 162a two-coater press in Poland. Primarily a flexo operation up until then, the market TFP in Kórnik, near Poznan, leader in high-grade packaging pushed the button some months ago on a six-colour version with two dryers and a triple delivery extension. Extending a mammoth 32m (105ft), it was the longest large-format sheetfed installation in Poland. he addition of the Rapida 162a substantially broadened the range of products and substrates the company can handle, which now includes paper, carton and E-flute corrugated. On top of T this the two coaters support an extensive choice of inline effects. Highly automated – and versatile too The giant Rapida with automatic plate changing is engineered to print microflute corrugated and heavy board, and is mounted on a 420mm (16.5in) plinth to allow for the extra thickness of the piles at the feeder and delivery, which are embedded in an automated pile-lo- gistics system. Coating plate change is also extensively automated, which dramatically shortens makeready times. The two dryers and delivery extension feature IR hot-air and UV dryers. Quality is controlled via ErgoTronic ACR with video sensor, QualiTronic Professional inline sheet inspection with integrated colour measurement and control, and DensiTronic Professional online density measurement and control. TFP has expanded continuously since 1992, gaining ISO 9001 and ISO 14001 accreditation on the way. Back in 2000 the company clocked up another first in Poland with the purchase of a Masterflex six-colour flexo press which is still the only press of its kind with this particular configuration. TFP’s investment in the high-performance Rapida 162a represents a similar milestone in offset. Martin Dänhardt [email protected] Virtually all press functions can be controlled from the console, with inline quality monitoring via QualiTronic Professional 4 Report 37 | 2010 Sheetfed Offset | USA Website: www.cartamundiusa.com Pictured left to right at the high-performance Rapida: Steve Young, CEO of Cartamundi’s US operation; Bob Nickel, director of innovative technologies, R&D; and Neil Clements, general manager Cartamundi, a major card producer and rising commercial packaging printer, installed a new customised Rapida 106 five-over-five B1 sheetfed perfector press with full UV capabilities, coating and board kit at its new facility in Dallas, Texas Industry leading card producer optimises inline finishing, consistency and productivity Cartamundi expands product offerings with ten-colour perfector press Cartamundi, a major producer of playing cards and rising commercial packaging printer, has installed a new customised Rapida 106 five-over-five B1 (41in) sheetfed perfector press with full UV capabilities, coating and board kit at its new facility in Dallas, Texas. The purchase was prompted by the smooth functioning of an identical machine at the company’s main production plant in Turnhout, Belgium. artamundi has seven production plants worldwide. A 14unit B1 Rapida that went live at the main plant in 2008 is one of the longest configurations in this press class and, like its counterpart in Dallas, has five printing units followed by a coater, two interdeck dryers, a further five printing units, a second coater and an extended delivery. Cartamundi placed the order for the new Rapida 106 perfector press because KBA could fulfil their specialised manufacturing needs as well as their dedication to unique C applications and customer service. Cartamundi prints daily on a variety of substrates, which in addition to paperboard include APET, RPET, PET, PVC, PP, HDPE, cellulose acetate, styrene, foils and foil laminates. Process control enhances cost efficiency The new Rapida 106 five-over-five perfector press at Cartamundi provides the company with highquality printing on two sides for ultimate productivity, extreme effi- ciency with inline colour controls and total automation, and optimal inline finishing. It also offers all processes in fewer steps, higher production due to its one-pass configuration, more consistency, and measurable quality using KBA’s premier automated technology tools. These include QualiTronic Professional on both sides of the sheet and DensiTronic PDF, which allows prints to be compared easily with the customer’s original PDFs or proofs. This virtually eliminates the risk of recurrent errors and thus Cartamundi recently moved into its new made-to-order, secure, environmentally controlled 300,000ft² manufacturing space avoids needless waste when processing costly substrates. Ecological production For more than 200 years Cartamundi has been the worldwide leader in quality card products for casinos and the general public. Its manufacturing facilities, international branches, local agents and distributors are represented in more than 50 countries, including Germany. In the US the company recently moved into its new 300,000ft² (around 30,000m²) home. This made-to-order, secure, environmentally controlled manufacturing space offers an unparalleled experience for its customers. “The new KBA Rapida 106 41-inch, ten-colour, full-UV perfecting press with multiple coaters is an extremely efficient addition to our pressroom. It has dramatically expanded our print offerings and improved overall workflow here in Dallas,” says Steve Young, CEO of Cartamundi’s US operations. Eric Frank [email protected] Report 37 | 2010 5 Trade Fairs | Ipex Not shown at Ipex, but a topic of discussion: KBA’s new high-automation C16 16pp commercial web press addresses the shift towards shorter print runs and turnaround times A signal for print: this year’s Ipex was surprisingly well attended, and the upturn in many parts of the world brought KBA a string of new orders Upbeat KBA shows raft of new sheetfed products Competitive edge in productivity, energy efficiency and inline processing Under the banner “Champions in Print” KBA strutted its stuff at this year’s Ipex in years since Drupa 2008 our engineers have been busy developing new automation Birmingham with some dazzling exhibits that included the Rapida 106 – the world modules for our entire range of formats. The main focus at Ipex was on acceler- makeready champion in B1 – and the Rapida 75E (E = Economy & Ecology), the ating job changes, enhancing inline finishing and quality control, cutting the con- energy-saving champion in B2. The economic crisis notwithstanding, in the two sumption of energy and materials and reducing manual input. any of the products exhibited in Birmingham revealed our technological edge over competitors. One example of many is the Rapida 106, which boasts a sidelayfree infeed, a CleanTronic Synchro high-speed multiple washing system tation and control system, DensiTronic PDF (see page 20). Another product making its debut at Ipex in a Rapida 106 was a quality-enhancing closed-loop colour measurement and control system comprising KBA QualiTronic Color Control and Instrument M and a flying job change capability. In large format there is our new energy-efficient dryer with heat recovery, the VariDryBLUE, and a simultaneous, dual-beam washing system which slashes makeready times. For both formats we have developed an online quality documen- Makeready champion: unique features that include Flying JobChange, automated coating-forme change, CleanTronic Synchro high-speed washing and new AirTronic high-performance delivery rank the Rapida 106 at the top of the medium-format champions league 6 Report 37 | 2010 Flight®, developed by Swiss software specialist System Brunner. By prioritising grey balance this new software tool delivers much greater colour accuracy and visually perceptible colour fidelity compared to other systems on the market (see pages 16-17). An all-rounder for growth markets: with an output of 16,500sph (speed-enhancement package) and the ability to handle substrates from 0.04mm (lightweight package) to 1.2 or even 1.6mm (board package) the Rapida 105 is selling well in emerging economies and needs shun no comparison with other presses in its class Rapida 106: Flying JobChange and other novelties For many visitors to the show one of the big attractions in the B1 (41in) format was the Rapida 106 six-colour coater press boasting DriveTronic SPC dedicated drives, Plate-Ident plate recognition and register-true positioning with simultaneous infeed, and Flying JobChange. During press demos the switch from one poster design to another with our Flying JobChange capability in the fifth and sixth printing units was completed in seconds. The Rapida 106’s coater appeals to press operators who frequently have to change coatings and don’t want to get their hands messy. Viscosity-based coating feed control from the console, automatic cleaning of the coating circuit and automated changing of the coating plates are not a given in medium format. Other new features included CleanTronic Synchro, a system for simultaneously washing blanket and impression cylinders during plate change, and a high-performance delivery, AirTronic, that can be preset remotely from the console and can handle lightweight stock at high speeds, even during perfecting. Rapida 105: popular all-rounder for growth markets The Rapida 105, a robust and reliable all-rounder that can be configured with a speed-enhancing package for raising output to 16,500sph, is particularly popular in China, India and the Middle East, as a string of orders at Ipex testified. The five-colour coater version exhibited printed postcards and pictures of London. Featuring automated plate changing, ACR video register control, automatic washing and DensiTronic colour measurement and control, it delivered enormous time savings during job changes. The Rapida 105 can also be configured with some of the optional extras available with the Rapida 106, eg DensiTronic PDF, automatic coating feed, automatic coating circuit cleaning and nonstop facilities at the feeder and delivery. Other flexibility-enhancing options include capabilities for printing lightweight paper from 0.04mm (0.0016in) to solid board up to and consumes less space and energy than a half-format press. Its practical level of automation makes for easy handling. Genius 52UV: the ideal tool for unusual applications Energy-saving champion: the new E version of the Rapida 75 B2 press unveiled at Drupa 2008 features an array of upgrades for enhancing automation, sheet travel and makeready. It is now available with an optional output of 16,000sph and the ability to handle stock up to 0.8mm thick. One of its many strengths is that it consumes half the energy of comparable presses More business options in B3: the ecological and uniquely flexible Genius 52UV can print unusual products on a wide range of sophisticated substrates and enhance differentiation in the growing web-to-print and digital print markets 1.2mm (48pt) thick and corrugated up to 1.6mm (60pt) thick. Rapida 75E: energy-saving dynamo Alongside optional extras for enhancing speed to 16,000sph and the stock range to 0.8mm (30pt) the B2 (29in) Rapida 75E unveiled at Ipex sported a raft of advances: a new, noise-insulated KBA feeder, automated format setting, shell-free transfer drums, air-blast sheet guides plus new sheet brake in the delivery, semi-automatic coatingforme change and remote maintenance via the internet. Together, these slash makeready times by more than 30%. The five-colour coater version shown in Birmingham had an extended delivery, automatic plate changing, inking-unit temperature control, roller and blanket washing and an ErgoTronic console. During Ipex it printed various jobs ranging from inline-perforated schedules to posters of London with matt and spot coat- ings. The Rapida 75E’s claim to the title of energy-saving champion was underpinned with detailed comparisons, a power consumption display at the delivery and (like all Rapidas) alcohol-free operation, attested by a green eco-globe on the printing units. Rapida 75C and Rapida 66: affordable technology in small formats The Rapida 75C (C = commercial) targets smaller printshops where space is at a premium, automation is not a primary concern and the budget is limited. Available in two-, four- or five-colour versions, it has no coater and is less extensively automated. Its maximum rated speed is 13,000sph and it is controlled from a touch-screen at the delivery. Rounding off the smaller end of the Rapida range is the SRA2 (26in) Rapida 66, which has almost twice the format of an A3 press – four A4 pages fit on a sheet instead of just two – for virtually the same price, The smallest, most unusual and most versatile press on the KBA stand at Ipex was the B3 (20in) Genius 52UV built by KBAMetronic, which caters to printers seeking fresh options for niche applications with out-of-the-ordinary products and substrates. This neat little press is also winning converts in the web-to-print sector. Typical Genius substrates include various types of film up to 0.8mm (0.03in) thick, expensive paper, aluminiumcoated board and even wood. The Genius 52UV supports creativity like no other press in its format. Smart cards, mousepads, stickers, lenticular images, plastic menus or short runs of packaging patterns on board – the pallet is almost endless. One big advantage of its dampenerand alcohol-free operation is that start-up waste is normally no more than ten sheets, and live demos at Ipex proved this time and time again. This is a crucial benefit when printing short runs of costly materials. The five-colour coater version on display at Ipex printed lenticular, mousepad and Chromolux film, solid board and PVC – just a small cross-section of its normal range. Some 150 Genius 52UV presses have been sold to date. Green printing and workflows Although there was no dedicated green printing zone on the KBA stand at Ipex, we remain deeply committed to ecological print production and energy-efficient press technology. Environmentally friendly waterless offset, alcoholfree wet offset and reductions in noise, dust and carbon emissions are an ongoing focus. The same applies to the optimisation of printshop workflows and processes. KBA-Complete and its alliance partners demonstrated proven packages embracing LogoTronic Professional, Hiflex and Logica Sistemi dedicated software and web-to-print systems. Klaus Schmidt [email protected] Report 37 | 2010 7 Sheetfed Offset | Germany rich Stark set up an eponymous artwork and book printing business in Pforzheim in 1946. Fritz Heer joined him in 1948 and they changed the name to Stark Druck. Since then the firm has steadily expanded, pursuing new advances and investing in cuttingedge production technology. Today Stark Druck is one of the biggest web offset enterprises in Germany and a major innovator in sheetfed offset. E Continuous growth By 1970 Stark Druck had a payroll of 70 and was printing some 5 tonnes (5.5 US tons) of paper a day. Today the payroll is more than five times bigger and output has increased tenfold to 500t (550 US tons). Regular investment in new kit and the systematic optimisation of the production workflow have delivered huge productivity gains. Managing partner Tino Heer, who is Fritz Heer’s grandson, says: “We are now the biggest web printer in Baden-Württemberg and among the top five in Germany, We are also one of the most innovative.” One reason for the firm’s uninterrupted growth is its focus on the German mail order sector and the jewellery industry, of which Pforzheim is a major centre. In the 1990s and at the turn of the millennium these comprised around 90 per cent of Stark’s customer base. That is because some years earlier Fritz Heer had teamed up with Bruno Bader and Eugen Müller to set up a Pforzheim-based mail order company, Bader, which had all its promotional work printed by Stark. This has changed in recent years, and now some 50 per cent of the firm’s customers are in the retail trade (furniture and food). Michael S Müller, Tino Heer and Wolfgang Grunert (l-r) at the Rapida 106 two-coater press Stark Druck in Pforzheim: sheetfed and web Two-pronged approach the key to success Entire books could be devoted to the history and technology of German print provider Stark Druck in Pforzheim. The company successfully deploys both web and sheetfed presses to drive growth, and its autarkic sheetfed offset subsidiary, Stark Brillant, is upgraded and expanded on an ongoing basis. This combination of different technologies allows Stark Druck to respond with agility and speed to shifting demands in the marketplace. Responsible for maximising product diversity and quality at Stark Druck: plant manager Michael S Müller (left) and managing partner Tino Heer (centre), pictured here with Wolfgang Grunert, managing director of KBA agency Werner Grunert in Karlsruhe New structures bring success Until 1983 Stark Druck was a sheetfed operation. But as the volume of work from mail order companies steadily rose, it moved into web offset and steadily expanded this side of the business. Catalogues were largely transferred to the web presses, although some sections were still printed in sheetfed. Stark Druck developed a two-pronged business model allowing it exploit the strengths of both technologies. 8 Report 37 | 2010 When the jewellery industry in Pforzheim experienced a slump in the mid-1990s, this impacted severely on sheetfed activities. So the company set about winning new customers and developing new products. In 2008 the sheetfed division was spun off as Stark Brillant and has expanded independently. While continuing to print parts or sections of hybrid sheetfed/web products, Stark Druck has expanded and diversified it portfolio to encompass magazines and books, promotional literature for the tourist trade and automotive industry, plus a raft of other products. “Despite the recent widespread recession our sheetfed operation has been running at maximum capacity, and with a global recovery underway there is every chance that we can expand still further,” says Tino Heer. “Not long ago we started drumming up business in the chemical and pharmaceutical sectors, and at the same time we attained EN ISO 9001 accreditation along with ISO 14001 for environmental management. In the process we optimised our entire production Michael S Müller (l) and press operator Nico Pitzalis checking the print quality off their latest KBA press, a four-colour Rapida 142 flow, and as a result we have an ultra-lean cost structure. We deliver guaranteed quality excellence.” Technological diversity enhances flexibility At present the sheetfed operation in Pforzheim has a five-colour Rapida 142 with a single coater, a fivecolour Rapida 106 with two coaters and two dryers, and a four-colour Rapida 142. The different configurations and coating capabilities deliver a high level of flexibility in meeting customer specifications. Says Mr Heer: “In recent years these have become much more sophisticated. Coating and finishing – with and without UV – are more or less the norm. UV work now accounts for 17 per cent of output, and rising. The proportion of standard four-colour work has also risen, and here price plays a major role. That is why we invested in the four-colour Rapida 142 at the end of last year. It’s a bread-and-butter press we can run twenty-four hours a day.” Some 70 to 80 per cent of Stark Druck’s routine work is four-colour. The Rapida 142’s lower hourly rate compared to more sophisticated presses is one reason for its consistently high level of utilisation. “The four-colour 142 is the perfect complement to the other presses,” says Mr Heer. “Take magazines for example: we prefer to print the covers on the five-colour Rapida 142 using special inks and a coating, and the inside sections on the fourcolour. We also print a lot of hybrid web and sheetfed products using the broadsheet delivery.” cally, the quality required is what dictates the choice of press. Where the highest possible standards are specified we use our KBA sheetfed presses.” Mix and match More options with large formats Stark Druck schedules jobs on its web and sheetfed presses according to customer specifications, cost and time frames. As a result print runs of no more than 10,000 sheets are often assigned to a web press, while longer runs are printed sheetfed. One key factor is the substrate weight. According to Mr Heer, “grammages above 135gsm are printed in sheetfed, but we have been known to print weights as high as 250gsm on a web press using the broadsheet delivery. Basi- There are a number of reasons for Stark Druck’s strong focus on large format, and the company’s workflow is organised specifically for it. One is that a large-format sheet can accommodate multiple blanks. Another is that large-format presses can handle special products such as posters, placards and big art calendars. The finishing department is equipped accordingly, for example with four big folding machines that are 940mm (37in) wide. For managing partner Tino Heer, sales manager Alois Klumpp and plant manager Michael S Müller (l-r), an optimum product quality is the topmost priority When kitting out the pre-press department the primary objectives were to accelerate throughput and optimise quality. An Artcom workflow and a Prinergy server support maximum product diversity from commercials to packaging. One special feature is Sandyscreen’s eponymous raster, which was originally developed for newspaper production but subsequently modified specially for Stark Druck. It has since become a guarantee of excellence in image quality and is used for around 30 per cent of output, but this figure is steadily rising. For ctp work Stark Druck has installed two Kodak Magnus VLF platemaking systems which are embedded in a PDF workflow and used for both sheetfed and web presses. Tino Heer has supreme confidence in his firm’s capabilities. “Cutting-edge technology for maximum flexibility, duplicate kit as a back-up for just about every item of technology, perfect colour management and a highly developed environmental awareness allow us to accommodate virtually every customer demand. We don’t just make claims, we deliver on the promise and in many sectors have a clear edge on our competitors. Our success is underpinned by co-operative alliances with leading players such as Meyle + Müller in Pforzheim.” Stark Druck is an enterprise in a continuous state of flux. Routine investment in cutting-edge technology, quality accreditation and a concomitant optimisation of its production workflows are an integral part of an ongoing programme. So it is hardly surprising that the firm has set itself ambitious targets for the future. Says Tino Heer: “We have a close and longstanding association with KBA’s agency Werner Grunert. So we can rest assured that they will provide the best possible advice on any new press projects we may plan in the future.” Michael Scherhag [email protected] Report 37 | 2010 9 Sheetfed Offset | Web to print One of the biggest online printers in Europe, flyeralarm operates a total of 14 large-format sheetfed offset presses. Its web shop offers a 24-hour delivery service for certain products Plant manager Michael Deml believes print has a future Interview with Michael Deml, manager of Druckhaus Mainfranken’s Klipphausen plant “We’re not undermining print, we’re expanding its market potential!” Druckhaus Mainfranken in Marktheidenfeld, Germany, is a specialist service provider to flyeralarm, a successful online print enterprise which was established five years ago in nearby Greussenheim but relocated to Würzburg in spring 2009 while retaining the original production plant. Flyeralarm, whose web-to-print business model fuelled rapid growth in recent years, is networked with a number of other printers, most of them in Bavaria. n 2007 Druckhaus Mainfranken opened a production plant with adjacent flyeralarm finishing facility in Klipphausen near Dresden, I conveniently located with easy access to the A4 autobahn. Alongside a 46 Karat press and a Winkler & Dünnebier envelope machine, Works III, as it is called, operates eight large-format KBA Rapida 142s, all of which are four-colour versions with automatic plate changing and Concentrated fire-power: Druckhaus Mainfranken runs eight Rapida 142 four-colour presses in Klipphausen alone 10 Report 37 | 2010 other automation modules for highspeed job changes and consistently high quality. In just a few years flyeralarm and Druckhaus Mainfranken have fired up a total of fourteen Rapida 142 four-colour presses. Other equipment at the companies’ production plants includes large-format presses from another manufacturer, small-format Genius 52UV und Anicolor presses, two Kodak Nexpress digital presses, offline coaters and high-performance pre-press, finishing and mailroom technology. Not long ago KBA’s director of marketing & corporate communications, Klaus Schmidt, paid a visit to the Klipphausen plant and spoke to plant manager Michael Deml about his work in the Mainfranken subsidiary and the peculiarities of web to print. Michael Deml (l) explaining the company’s production workflow to Klaus Schmidt (centre) and Günter Drossel Pictured at one of the large-format Rapidas during a tour of the factory (l-r): KBA marketing director Klaus Schmidt, plant manager Michael Deml and KBA Radebeul head of press installations Günter Drossel Schmidt: Michael, with flyeralarm and Druckhaus Mainfranken largely focused on Franconia and the rest of Bavaria, the Klipphausen plant could be seen as a diaspora in Saxony. Does it mean you’re planning to serve flyeralarm customers in the new federal states and points even further east? Deml: No, we don’t see our business as regional. Production and logistics at each of our plants are highly specialised. In Klipphausen we print flyers, leaflets, posters and letterheads, and also make envelopes. Our equipment is engineered for maximum cost efficiency and speed in both production and distribution. At the same time the pace at which our company is growing frequently forces us to adapt and shift production at our various locations, and we are at pains to maintain this flexibility. A lot of the products offered online can be delivered anywhere in Europe within 24 hours. So if you order business cards by midday on one day they’ll probably be on your desk by midday the next. Schmidt: Can you briefly describe the Klipphausen plant? How much production space, how many employees and what kit do you have there? Deml: We have around 5,500 square metres of production and storage Druckhaus Mainfranken’s factory in Klipphausen is located just a few kilometres from Dresden and within easy reach of the A4 autobahn space. The hall housing pre-press and press was already there when we took possession, and had previously been used by a haulage company. The second hall was built to our own specifications and contains the entire finishing department, the mailroom and the paper and board store. So basically there are two companies at the Klipphausen location – Druckhaus Mainfranken with roughly 65 employees engaged in pre-press and press, and flyeralarm with around 110 employees engaged in everything relating to postpress. In the pre-press department we have a Kodak Prinergy workflow with three Magnus VLF platesetters plus automatic pallet loaders because we consume between 6,000 and 7,000 plates per week. The press hall houses eight Rapida 142s, all for four colours. Then there are seven full-scale Perfecta guillotines and nineteen folding machines. Each of the folding machines is preset for specific jobs so it doesn’t usually have to be converted. the advantage of large format for web to print? Schmidt: Looking at the press technology in flyeralarm and Druckhaus Mainfranken production plants it is evident that large-format, 6B presses dominate – something which is more generally associated with packaging production. What is Deml: Whatever sector you work in it is vital to maximise your time and cost efficiency. Which is why we have equipped all our presses with automatic plate changers for maximum speed and flexibility during job changes. The new Rapidas also Deml: We were quick to realise that, for certain products, this format is more cost-effective. Large format gives us much greater flexibility, which is important for the gang formes that make up part of our job structure. Also, it enables us to minimise fixed costs. This is why we went for large format right from the start – and were among the first in our sector to do so. The print quality and makeready times associated with big presses like our Rapidas can easily stand comparison with medium format, and their productivity is awesome. Alongside the fourteen Rapida 142 four-colour presses our press fleet includes ten B2 and six small-format presses, so we have the right format for every product. Schmidt: What does it take to be as successful as flyeralarm and Druckhaus Mainfranken in a new, highgrowth sector like web to print? Report 37 | 2010 11 feature inline density control. When printing flyers this can cut waste by as much as ten per cent. Also, the press crews feel more confident because they don’t have to pull sheets so often for colour control. But our efficiency extends beyond the press room. Much of our success may be attributed to scrupulous preparation: a lot of printers print gang formes, but we optimise imposition not only with regard to maximum format utilisation but also job volume. By staggering jobs we ensure that the print run is the same for each of the products on a gang forme, so there is no waste. And there is a third point: customer proximity. We maintain a number of regional service centres – in Dresden, Würzburg, Munich, Düsseldorf, Frankfurt, Salzburg, Vienna, Valencia, Bolzano and, shortly, in Berlin – where less experienced customers can get advice on design and production. Each of our production plants has a quality department to address irregularities in production and also customer complaints, though these are on the decline. This is one of our top priorities because if a customer is dissatisfied with your online service, you’ve lost them for sure. In general we undergo a continuous process of improvement and development aimed at maintaining our market position and growing market share. Schmidt: Are you and your press operators pleased with the big Rapidas? Is Klipphausen’s proximity to KBA’s factory in Radebeul an advantage? Three Magnus VLF platesetters from Kodak pump out up to 7,000 plates per week Functioning logistics: the paper and plates for the next job have already been delivered to the feeders of the big Rapidas post-commissioning acceptance test on your new Rapidas. This seems to be standard practice at Druckhaus Mainfranken. What are the benefits? Deml: Acceptance tests on presses are all part of the routine at big companies because they promote trust between the user and the manufacturer. Everyone, the press operators included, knows that the press has been inspected and approved by a neutral authority. We receive a report that objectively describes the current state of the press. I believe this is a benefit for both sides. If we subsequently sell the press on we can prove that it was in perfect condition when we acquired it. Schmidt: Why aren’t the large-format Rapidas at Druckhaus Mainfranken and flyeralarm configured with “Whatever sector you work in it is vital to maximise your time and cost efficiency.” Michael Deml (33), who helped to set up the Klipphausen facility, was born in west Germany, and since his family still lives in Neumarkt he has plenty of time during the week to develop the business still further 12 Report 37 | 2010 Deml: The main reason we dispense with coaters is process optimisation: for most of our products we can save not only on coating but also on energy by allowing the prints to dry for a few hours prior to finishing, which eliminates a lot of potential problems. However, it does mean that the data supplied by the customer must comply in full with our quality specifications. We try to pre-empt errors via quality control and by offering a free basic data check or low-cost professional data check. If an aqueous or UV coating is expressly specified we can deliver a high standard of quality using the two offline systems. Schmidt: Flyeralarm in Würzburg uses KBA-Metronic Genius 52UV and Heidelberg Anicolor smallformat presses for short runs and special products. Why are digital presses the exception rather than the rule at big online printers, setting aside the photo books that are often cited as successful examples of digital print? Deml: We are delighted with the Rapidas. They are reliable, easy to handle and deliver a superb print quality. We have certainly bet on the right horse. Our proximity to the manufacturing plant is definitely an advantage. Contacts at every level, from fitters to print instructors and management, are much closer than they would be if we were several hundred kilometres apart. Schmidt: You recently had the BadenWürttemberg Printing and Media Industries Federation carry out a coaters? Normally we rarely deliver non-perfecting versions without a coater in Europe. On the other hand you have just bought a second Colibri unit for offline coating. Why is offline better than inline coating in your line of business? Whether multisection posters or small business cards, short or long runs – a lot of the jobs are handled by the B0 (56in) Rapidas Deml: While there is no doubt that the digital print market is spreading from small to large format, in web to print it is still a peripheral phenomenon. We only use digital presses for runs of 1 to 100 prints, ing and information, how do you view print’s long-term prospects? The nineteen folding machines in the finishing department support a huge choice of products so a handful of presses is enough for the whole group. Anything above can be printed in offset, which has the edge in unit costs. Schmidt: While global players were the first to be hit by the financial and economic crisis of September 2008, it was not long before domestic print providers felt the knock-on effects, which continue to this day. Did you also notice demand subsiding in your online business or has this market bucked the trend? Deml: The economic crisis had only a minor impact on our business. Market pressures forced a lot of print buyers to forego extras or individual products and to focus on price, which brought us additional custom. You must realise that over 80 per cent of our customers are businesses, which have their print work designed by professional agencies or freelancers, while we handle the actual production. A lot of smaller printshops also advise their customers and prepare their data, but have us print the products. Schmidt: Michael, flyeralarm and Druckhaus Mainfranken are successfully exploiting the internet to win new orders. With online players increasingly contesting print’s dominance as a vehicle for advertis- “We are delighted with the Rapidas. They are reliable, easy to handle and deliver a superb print quality.” Flyeralarm in the best meaning of the word: the gang formes are cut and packed to order at one of seven guillotines Deml: Yes, we are very close to the internet. But despite online competition we believe print has a future. Although a lot of print is moving online, the volume of paper consumed by the print market remains relatively constant. The main difference is that print runs for individual products are shrinking and they are becoming outdated faster. Having said that, our low prices and quick delivery have enabled us to create an additional volume of print where nothing existed a few years ago. Today a lot of private individuals and small firms have business cards, envelopes and letterheads printed, mostly in four colours. Previously, such short-run work would have been too pricey. Updates are also more frequent because they are now relatively cheap. Our own web shop is continually being updated by an in-house team of experienced programmers, so we can rapidly respond to a surge in requests for a product that is not yet in our portfolio. Parallel to this we also work proactively, constantly asking ourselves if there are any products we could offer that are not yet on the market. That’s a signal to our colleagues in smaller printshops: while we may take some customers from you, we’re also generating new demand! We give print pros in smaller businesses that can no longer keep pace with advances in press technology the chance to offer their regulars competent advice and service even if they do not have the necessary equipment – and could not compete on price if they did. Print is tangible, it is emotive and an indispensable part of the media mix, particularly in customer communications. Online printers strengthen print, create new categories of customers and products and open up new markets. Schmidt: Thank you for this interview. Simple tools provide an overview of express and standard production Martin Dänhardt/Klaus Schmidt [email protected] Report 37 | 2010 13 Sheetfed Offset | Productivity Not even printing eleven 300-sheet jobs within 90 minutes for a time-conscious online printer caused press operator Benjamin Nelles to work up a sweat at the Rapida 75 in the Radebeul customer centre Rapida 106 makeready world champion inspires emulation Rapida 75 completes 11 jobs in less than 90 minutes There is still no press capable of matching the record fifteen 520-sheet jobs in just 59 minutes set by the makeready world champion in B1, the Rapida 106. Now our B2 (29in) Rapida 75 is striving to emulate its big sister. During a print test at our Radebeul customer centre on 19 March for a German web-to-print customer a five-colour coater version with extended delivery pumped out seven 300-sheet jobs in just 55 minutes, and followed this up by taking a mere 30 minutes to print four runs of postcards and business cards. The Rapida 75 thus completed eleven different jobs in well under 90 minutes. hile some high-performance B2 presses with automatic plate changers may be marginally faster, the Rapida 75 achieved this feat with semi-auto- W matic ones. The seven jobs printed on 350gsm matt art paper (160lb Bristol) entailed a pile change at both the feeder and the delivery. After 70 sheets ink densities were measured and adjusted with DensiTronic, and register checked via automatic video-based colour register control. With no further stoppages output was of saleable quality after Alongside coating in all its manifestations, minimising makeready with the Rapida 75 was a key focus of the small-format open house held at our Radebeul customer centre in late April, at which customer centre manager Wolfram Zehnle gave a detailed briefing 14 Report 37 | 2010 around 100 sheets. Throughout the entire print run the measured values remained stable within the tolerances defined by ISO 12647-2 (process parameters for offset). During makeready and the actual production run the Rapida 75 maintained an output of 15,000sph. This print test on the Rapida 75 demonstrates that a highly-tuned press is not necessarily essential for an above-average output and costeffective short-run production in B2. What gives the Rapida 75 its edge is its practical array of features geared to fast job changeovers and ease of operation, its footprint, which is the smallest in this format, and its energy consumption, which can be as little as half that of comparable presses. These last two assets will no doubt appeal to companies that are keen to adopt climate-friendly production but are limited for space. Martin Dänhardt [email protected] Sheetfed Offset | Switzerland ordi was established back in 1897 in Belp, in the Swiss canton of Bern. Its main line of business is periodicals. Today the company offers its customers a onestop magazine service encompassing concept, design, editing, image generation, and subscription and ad procurement. There is even a risksharing option in the event of poor sales. With a payroll of 75 and annual sales of around €11m ($14m), Jordi numbers among Switzerland’s many mid-cap enterprises. And all the indicators point to continuing growth. In November the entire company will relocate to spacious new premises. Its total investment in this new media centre, including the new Rapida 106 eight-colour perfector press with coater and associated infrastructure, exceeds €9m ($11.6m). From which it is clear that the inhabitants of Belp believe one hundred per cent in the future of print. J When the unexpected happens The logic was compelling: for a successful printer in the B2 (29in) format with a ten-colour and a fourcolour perfector in its press room, and plans to run three shifts on a permanent basis to maximise productivity, any replacement for the four-colour press must be capable of supporting a high continuous output well into the future. This would only be possible by expanding into medium format. So initially the focus was on the most obvious candidate, a non-perfecting B1 press to complement the ten-colour B2 perfector. But after analysing Jordi’s order structure, KBA agency Print Assist recommended installing an eightcolour perfector with coater as a replacement for both existing press lines. As plant manager Gabriel Jordi points out, this occasioned some surprise. However, as they examined in more detail the various issues involved, management soon realised that the proposal submitted by Print Assist and KBA made a great deal of sense. Gabriel Jordi says: “While our original intention of adding a straight-on press and retaining the ten-colour perfector would have meant a much smaller initial capital outlay, we would have had to replace the ten-colour press An eight-colour Rapida 106 coater press with extended delivery will come on stream at Jordi in November Jordi in Belp takes Rapida 106 Going for growth with cutting-edge KBA technology When Swiss print enterprise Jordi purchased a Rapida 106 it caused some surprise among members of the trade: until then this innovative family business had been considered a Heidelberg “fortress” that was all but impregnable. However, KBA and its Swiss agency Print Assist offered some compelling arguments in favour of a Rapida. by 2012 at the latest. The more we thought about it, the more the idea of an eight-colour B1 perfector with coater grew on us.” Further arguments But that didn’t mean the contract was in the bag – far from it. There followed a screening process during which economic and technical arguments tipped the balance in favour of the Rapida 106. Says Gabriel Jordi: “As far as technology was concerned, other makes of press also scored well. However, KBA offered us better options with the Rapida 106, and that is what won the day. Key criteria included quality control, density measurement and control, dedicated drives and flying job changes. CleanTronic Synchro, which supports fast, simultaneous washing of the blankets, impression cylinders and rollers, was another big plus.” The Rapida 106’s powerful output also won plaudits. As Gabriel Jordi explains: “In perfecting mode the press can pump out 15,000 sheets per hour. In straight-on mode this rises to 18,000. To my knowledge no other perfector is capable of performing at this level. Other, not insignificant features are the Rapida’s no-sidelay infeed and Plate-Ident plate recognition system, which prevents plates from being allocated to the wrong unit or being mounted in the wrong order.” New era begins in November Jordi will be bringing the new Rapida 106 coater press on stream in the new production plant. Gabriel Jordi does not disguise the fact that this will be something of an adventure: “With the Rapida 106 we’ll be expanding our product range substantially. On the one hand that is a big advantage, because we’ll no longer have to run three shifts a day, only two, which will give us much greater flexibility in scheduling production, and also the room for manoeuvre that’s been lacking in recent months. But in the medium term we must naturally try to win more orders so as to utilise the free capacity to the full.” Another comment by Gabriel Jordi shows just how impressed management at Jordi was by the options afforded by the Rapida 106: “The Rapida won’t be operated by a combination of minders and helpers – we are planning to create teams composed entirely of experienced operators. The press has enormous potential, and the manifold options available, such as Flying JobChange, can only be exploited to the full by an outstanding press crew.” The purchase of the Rapida 106 is a demonstration of supreme confidence, because the press will be the core of the entire print operation for years to come. Jordi’s example shows that even mid-cap enterprises can gear up for the future with cutting-edge, versatile press technology. Peter J. Rickenmann [email protected] Report 37 | 2010 15 Sheetfed Offset | Quality KBA’s QualiTronic Color Control with System Brunner’s Instrument Flight made its debut at Ipex on a Rapida 106 six-colour coater press QualiTronic Color Control has corrected all the density differences inline KBA QualiTronic Color Control with System Brunner’s Instrument Flight Precise closed-loop colour control to defined standards Standardisation, quality assurance and inline colour measurement and control the Instrument Flight software developed by System Brunner of Switzerland are topics of almost daily debate in the print media industry. KBA’s QualiTronic are familiar, established tools for delivering a superlative colour quality. Nothing Color Control, a density-based inline colour measurement and control system, and new there, you might say. hat is new is the high-precision inline package created for KBA sheetfed presses by marrying these two systems. Officially unveiled on a Rapida 106 sixcolour coater press at Ipex 2010 in Birmingham, it aroused considerable interest among visitors to the fair. This, and the response from industry players, indicate that there is an unfulfilled demand for inline colour quality monitoring and control systems capable of accommodating offset’s well-known idiosyncrasies to deliver a uniform, visual colour impression for the observer, thereby extensively automating the printing process in accordance with a predefined standard. Multicolour offset printing with the four process colours cyan, magenta, yellow and key has been the dominant method for many years uncommon because each printed image can differ from all the others. As a rule a measuring strip incorporating a repeat pattern of solid patches is usually printed alongside the image and the individual colours measured within it. This is a simple W 16 Report 37 | 2010 now, and various norms and standards have long been defined for all the essential parameters relating to printing inks (colour space, optical densities, dot gain, the relevant permissible tolerances). On-image colour measurement is relatively way of defining the parameters for the measuring device. The concept underlying this popular measuring principle is that the solid densities measured in the control strip depict the colour quality in the actual image. In reality, however, and with the exception of packaging, images rarely feature solids. So in practice there are often colour differences in the printed image that do not occur in the measuring strip and therefore cannot be detected by the colour measurement and control system. A frequent cause of colour differences are fluctuations – manifested as tonal variations or changes in two- QualiTronic Color Control plus Instrument Flight on the screen and Techkon Spectro Drive on the sheet-inspection desk at a KBA ErgoTronic console System Brunner’s Instrument Flight option enables a press to deliver prints of the highest quality or three-colour overlap prints (trapping) – in the halftone dots of the individual colours. These influence the colour balance, ie the overall colour impression in the halftone dot and overlap print. Even though the solid values measured remain unchanged, the observer immediately detects changes in a grey solid created from three colours, or in colour shifts in skin tones. Evaluation of solid measuring patches is not enough Evaluating the solid patches in the measuring strip is therefore not enough. However, if patches for grey balance, tonal value and trapping are incorporated in the measuring strip, then image-relevant influences become visible – and measurable – in the strip and the impact of dot gain or changes in ink trapping can be recognised. Qualified printers are well aware of this and apply such knowledge in practice, in one form or another, via compliance with the process standard for offset. But what is new about the combination of QualiTronic Color Control and Instrument Flight, and what distinguishes it from other systems on the market, is that it is precisely these measuring patches that are scanned inline on every printed sheet within the sheetfed press and evaluated by Instrument Flight in real time, with corrections instantly carried out where necessary by means of inline colour adjustment in the press. Instrument Flight analyses the grey balance patches, for example, and from the measured values calculates and specifies the adjustments which would result in a neutral grey. What makes it special is that Instrument Flight automates this process and supports closedloop control within the press by modifying the reference values for cyan, magenta, yellow and black solids. The entire concept of Instrument Flight is based on the premise that the assessment of a printed image depends at all times on the subject depicted. For example, human colour perception is more sensitive where contrasts are weaker, and fluctuations are initially detected as a shift in the grey balance in mid-tones. Colour balance during the actual print run can be influenced by adjusting dot gain and trapping. Multidimensional colour control balances process dynamics The combination of QualiTronic Color Control and System Brunner’s Instrument Flight delivers more than 30 measured parameters, supporting multidimensional colour control. As a result it is possible to counteract the process dynamics of offset printing and maintain the correct balance within the image, thus achieving image consistency. The parameters measured and corrected in each ink zone include CMY and grey balance in mid-tones and shadows, dot gain at 50 per cent, solid densities, threecolour trapping and ink contamination. But there is no need to remember all that theory in the press room. As already mentioned, the print control strip contains measuring patches for grey balance, trapping and tonal values as well as solids, and these are scanned on every sheet by the QualiTronic Color Control inline colorimetry system. From the measured values Instrument Flight automatically calculates the optimum reference values for solids. QualiTronic Color Control then responds with its characteristic speed, instantly triggering the necessary adjustments. Inline standardisation And these are not the only innovations: inline measurement and control with the combined QualiTronic Color Control and Instrument Flight package effectively standardise the entire offset printing process. Regardless of the debate on the standard to be applied (System Brunner’s Eurostandard is in widespread use), compliance with the ISO norm is essential. On top of this the user must know exactly what standard of quality is being delivered at any moment in time, and what remedial action must be taken if the quality falls below this standard. QualiTronic Color Control with Instrument Flight provides clear, unambiguous data. A four-page flyer on QualiTronic Color Control with System Brunner’s Instrument Flight can be downloaded from http://www.kba. com/en/produkte2/bogenoffsetdruck3/qualitronic.html. Dr Steven Flemming [email protected] Colour control based on grey balance and various other parameters helps counteract the substantial colour deviations that can occur in 4c offset images even during production runs where solids are kept constant (the original is in the centre) Photo: System Brunner Instrument Flight is a registered trademark Report 37 | 2010 17 Sheetfed Offset | Egypt afa was founded in 1979 by Samir El Bialy, formerly production manager at the largest and oldest printing company in Egypt at that time, Moharam Press. His entrepreneurial skill, business acumen and far-sighted investment strategy soon established El Safa at the forefront of the Egyptian packaging industry, gaining recognition nationwide and beyond. ISO 9001, 14001 and 18001 accreditation was to follow. A string of certificates and awards are evidence of the company’s success. Although Samir El Bialy has since relinquished the reins to his sons Sherif and Karim, he still remains closely involved in the company’s activities. S Three-pronged concept for success Sherif El Bialy, the new managing director, studied in Germany and has ambitious plans. “The success of El Safa is founded on training and knowledge, co-operation and motivation. Our 380 employees are committed to our goal of offering customers the best possible service based on the most advanced production technology available. We dominate the Egyptian packaging market, and currently export around 28 per cent of our output to 22 countries extending from the Arabian peninsula to Iran, Pakistan, a number of African states and European countries such as Germany and Sweden. We work with international brand names like Nestlé, Unilever and Kraft, and we are growing with their success. So we must be able to address all their quality and delivery specifications.” Alexandria-based El Safa For Printing & Packaging is the market leader in Egypt Abdalah Al-Hareri (left), KBA sales engineer for the Middle East, with El Safa director Sherif El Bialy Taking the lead in packaging with KBA Trio of Rapidas at El Safa in Alexandria El Safa For Printing & Packaging, a family enterprise in Alexandria, has consolidated its position as market leader in packaging print with the installation of three medium-format Rapida presses since 2006. Sales have climbed to €32 million ($41.3m), and 12 million sheets are printed every month. Paper and board consumption is around 28,000 tonnes (30,800 US tons) per year. Rapidas the key to growth Sherif El Bialy keeps a weather eye on current trends in pre-press, printing and converting: “Our ongoing objective is to enhance productivity and develop attractive, cost-effective and ecological products for our customers. We used to work with litho presses from other manufacturers, but KBA’s pre-Drupa event in 2004 and a visit to its customer centre in 2005 persuaded us to team up with KBA in future. We are still benefiting from that decision today.” El Safa installed its first sixcolour Rapida 105 coater press in 2006. “This flexible and wellequipped B1 press matched our demand profile in every respect. With its high-speed package for a 16,000sph output, CX board-handling capability and semi-automatic plate changing, ErgoTronic ACR autoregistration, DensiTronic Professional colour measurement and control and LogoTronic management information software with CIPLink interface, it was a genuine innovation in the Middle East. We were very proud of our pioneering role and ordered a second, identical press just six months later.” First Rapida 106 in the world El Safa took delivery of the first seven-colour Rapida 106 worldwide several months before the official press launch at Drupa 2008 18 Report 37 | 2010 At the end of 2007, months ahead of the market launch at Drupa 2008, the company took delivery of the world’s first 18,000sph Rapida 106, a seven-colour coater press which eclipsed even the outstanding performance, production flexibility and easy handling of its predecessors. “The Rapida 106 was a major breakthrough,” says Sherif El Bialy. “Its configuration, with fully automatic plate changers, rainbow printing capability, automated coating forme change, washing systems for the blankets, inking rollers and impression cylinders, and automated pile logistics at the feeder and delivery, offered us a raft of totally new options. We were particularly impressed by its ability to handle a wide range of substrates from ultrathin paper to various grades of board and metal-coated stock. We have even gained a foothold in security printing. Our operators received intensive training in Radebeul to familiarise themselves with the capabilities of this high-tech press, and are delighted with its easy handling.” Summing up, he says: “Today we are printing in a different league. Our experience with KBA presses and service forms a sound basis for close collaboration in the future. Our management plan includes firing up two further presses in 2011, and we have already decided to add a second Rapida 106 plus our first ever large-format press, a Rapida 162a for printing detergent packaging et cetera. We can hardly wait to move up into large format.” Gerhard Renn [email protected] Sheetfed Offset | Packaging Cairo is one of the largest cities in the world, with an estimated 16 million inhabitants First Print’s 20,000m² facility in Obour City First Print general director Louai Ali Abdel-Wahid (front right), technical manager Reda El Assal (on his right) and their press crew are full of praise for the Rapidas’ high output Modern packaging production in Egypt First Print: €40m investment in new production plant The dynamic growth currently experienced by the print media industry in the “Land of the Pharaohs” is exemplified by First Print, which since being launched in 2008 has expanded its press fleet with one five-colour and one sixcolour Rapida 162a plus a six-colour Rapida 105. division of Egyptian group First Co. For Industrial Development, First Print is now one of the country’s leading suppliers of board and packaging products. A total of €40 million was invested in First Print’s production plant, whose location near Cairo international airport, with direct access to Cairo’s ring road, was chosen for its logistical advantages. High-tech printing, guillotining, die-cutting and laminating kit occupies 20,000m² (215,000ft²) of floor space on three storeys, with each department organised as a dedicated cell embedded in a digital workflow. The spacious, impressive building provides attractive workplaces for some 500 employees. Alongside First Print the First Co. group also has board- and paperprocessing divisions, First Corrugated and First Paper. Two further divisions – First Metal and First Service – are to be added later this year. A KBA was also First Print’s preferred choice for medium-format technology last year, when it installed a Rapida 105 ‘Deal with the top’ a successful strategy General director Louai Ali AbdelWahid is proud of the company’s achievements and his cutting-edge presses: “Our philosophy is to ‘deal with the top’. We print medium to long runs for industry leaders in the food, household, medical, pharmaceutical and cosmetics sectors. Our customers include McDonalds, Procter & Gamble, Unilever, Cadbury, Disney and Henkel. To meet their quality demands we need the best equipment at every stage of production. We have ISO accreditation not only for quality and environmental management but also for occupational health and safety standards. And we have successfully completed McDonalds’ supplier qualification programme, which is considered one of the toughest standards for primary packaging quality.” First Print’s final selection of machinery and equipment for its print centre was preceded by a sixmonth planning phase during which exhaustive market research was conducted and numerous visits made to European plants. “We wanted to create the best possible technology base for addressing the needs of both domestic and export markets. In addition to the Middle East we also serve customers in Turkey, Tunisia, Africa and Europe. We are aiming to grow our share of the market and expand into other countries,” explains Mr AbdelWahid. The decision in favour of KBA was unanimous. “KBA is the market leader in large format, and also offers customised technology in medium format,” says Mr AbdelWahid. “But KBA presses’ most striking features are their flexibility and reliability. On top of that, KBA offers its customers in the Middle East the best possible after-sales support, with on-the-spot personnel and service technicians. Its 24/7 service hotline also inspires confidence and trust.” All geared up for flexible production The first Rapida 162a was delivered in March 2009, and was followed by the six-colour Rapida 105. The second large-format press was fired up in February this year. Mr AbdelWahid says: “The Rapidas are all mounted on a plinth and configured with double-length delivery extensions, coaters, IR/hot-air or IR/UV dryers and nonstop pile formation at the feeder and delivery. Special extras on the Rapida 162a include microflute corrugated and heavy board capabilities. An array of automation modules, including plate changers, ErgoTronic ACR video register, DensiTronic Professional ink density control and LogoTronic management information software with CipLink, helps maximise productivity. The second Rapida 162a also features inking-unit temperature control to support waterless offset, and special rollers for low-alcohol printing.” At present First Print operates a two-shift system, but is expanding to three shifts in 2011, when Mr Abdel-Wahid expects sales to double from €20 million this year to €40 million. “Our future lies in expanding our large-format capacities still further, and with KBA we have a high-powered partner at our side capable of providing all the technical support we may need in handling specialised work, for example metallised substrates,” he says with evident satisfaction. Gerhard Renn [email protected] Report 37 | 2010 19 Sheetfed Offset | Print quality Pre-press or managing director Volker Knoop, DensiTronic PDF is the crowning application in sheetfed quality assurance. While most printers rely exclusively on colour measurement or control, and only a few include an additional comparison between the printed sheet and a reference sheet, Mensing compares every printed image with the customer’s original PDF. A scanning resolution of 36 measuring points per square millimetre means that the document comparison reveals minute errors in the printed image which a standard inspection with the naked eye would probably fail to detect. The press operator scans the first good sheet off the run using the KBA DensiTronic PDF system. Within seconds, the automatic evaluation software flags even the smallest deviations from the original PDF. Alongside any foreign particles or register marks which may have been exposed with the plate the system also detects die-cutting contours, individual blank numbers and dot gain in packaging barcodes (when printing on thick, cheaper board). The automatic flagging of detected differences gives the operator a quick, compact overview of all productionrelevant deviations. He can then decide whether to go ahead and print the job or contact the quality assurance department. F Certified print quality Mensing conducts automatic quality inspections at a minimum of three stages in its streamlined production workflow: immediately following sheet layout, prior to plate exposure and on the first and last good sheets off the press. At the end of this procedure the customer Press operator Florian Domanski must tap in the sheet format and thickness before initiating the measuring process with DensiTronic PDF 20 Report 37 | 2010 Sheet layout Forme proof Q inspection (forme proof) CTP plate PDF original Converting Press (makeready/proof) Final run Print Cutting, folding or die-cutting, gluing etc. Packing (sampling) Q inspection (end product) Certificate End product How quality assurance is embedded in the production workflow at Mensing Druck & Verpackung Mensing sets milestone in print quality monitoring Automated inline quality control with DensiTronic PDF Mensing Druck & Verpackung in Norderstedt, near Hamburg, is a specialist pharmaceutical and cosmetic packaging printer of more than 50 years’ standing. At the beginning of 2008 it installed the first Rapida sheetfed offset press in northern Germany to feature DriveTronic SPC dedicated drives for simultaneous plate changing. Alongside extensive automation the company’s primary focus was on optional equipment to support integrated quality assurance and control. To this end it specified DensiTronic Professional closed-loop colour measurement and control, and became the first packaging printer in Germany to install DensiTronic PDF software. Time for a first performance update. can request an inspection certificate and a log of the results in one of three levels of sophistication ranging from a simple, single-page statement to a detailed report, and either as a PDF file or as a printout. Pharmaceutical packaging and patient information leaflets are inspected in accordance with sampling directives and cycles specified by the pharmaceuticals industry. DensiTronic PDF’s relevance for The sheet is scanned on the DensiTronic desk this field is clear. For example, if a random speck of dust in the platesetter were to transform the digit 3 in the dosage instructions into an 8, the consequences could easily prove fatal for the patient. What the naked eye may overlook, this new technology can detect with 100% accuracy. While no such spectacular errors have occurred at Mensing, checks in the past have revealed a plate scratch which was visible in the printed image. As a result production was stopped and a new plate made before the complete run was printed. On another occasion a classic pre-press error was detected: the layout cross-hairs had accidentally been exposed onto the plate and would have been printed if DensiTronic PDF had not been in operation. In both cases Mensing avoided having to reprint the entire job. That saved time, capacity, costs Technical manager Klaus Trierweiler explaining how a scanned sheet is compared to the customer’s original PDF file in the DensiTronic PDF computer How DensiTronic PDF works • Operating software for the PDF scanner is embedded in the DensiTronic Professional standard user interface • A scanner beam incorporating a series of individual cameras produces an image every 20mm • Scan resolution is 300ppi • Measuring time is approximately 60 seconds on a 740 x 1060mm sheet • The individual images are collated to provide a total image in the system computer • The total image is forwarded to the inspection program • The reference PDF is uploaded simultaneously (can be automatic or manual) • The inspection parameters (error size threshold, error contrast, maximum fringe dot size, maximum misregistration, colour mode, resolution) are set via simple screen menus • The total image is compared with the PDF file • An inspection certificate, detailed log and evaluation are generated Alongside the new Rapida with simultaneous plate changing (pictured here), the DensiTronic desk and PDF reader are also used to check the prints off a second Rapida press which was installed eight years ago and waste. Our DensiTronic PDF thus indirectly helps to protect the environment. It also boosts efficiency and conserves resources by allowing the company to dispense with forme proofs on paper. While costs associated with returns and complaints have always been modest, since installing DensiTronic PDF Mensing has managed to reduce them by a further 50 per cent. The biggest savings have been made by eliminating errors during the print run. Colour control with DensiTronic Professional and the PDF reader module installed at the DensiTronic desk have enhanced both production reliability and quality awareness within the company. The new electronic quality assurance tools have been accepted wholeheartedly by production staff, boosting their confidence. In addition to furnishing proof of the introduction of a quality management system for the production and sale of pharmaceutical, surgical and industrial packaging, patient information leaflets and commercial work compliant with ISO 9001:2008, combining the two systems has had a huge positive impact both internally and externally. Value added appeals to old and new customers alike Monitor display flagging a scratch in a single blank on a packaging forme Patient information leaflets folded with (on the left) and without the aid of aqua scoring Volker Knoop also perceives a positive marketing impact. While Mensing is a relatively small business compared to the major players in the sector, employing just 45 staff, its order books feature a string of pre-eminent pharmaceutical companies and brand manufacturers including Beiersdorf, Revell and Johnson & Johnson. Some print buyers are in the process of reducing the number of their suppliers, driving a need among packaging printers to develop unique, value-added products. The meticulously proven quality delivered with the aid of DensiTronic PDF is a good example of value enhancement and has proved popular with customers. The prospect of effective error prevention has also attracted new customers, for example manufacturers of agricultural machinery and premium household appliances. As a result Mensing’s order intake is steadily increasing. Mensing highlights the unique possibilities afforded by electronic quality assurance. Its own trademark PRINtector system promises users: • absolute confidence that the product delivered will correspond exactly to the PDF original provided, because the printed sheet is compared with this original and not with a reference sheet (which could itself already contain errors), making this method far superior to inline inspection systems; • a detailed inspection protocol for their own quality management systems; • the certainty that even foreignlanguage texts are checked with absolute accuracy, irrespective of production staff’s linguistic abilities; • efficient, resource-frugal production thanks to early error detection. Cutting-edge technology also used for eight-year-old Rapida Every single job for the pharmaceuticals and cosmetics industries is checked using DensiTronic PDF as a matter of routine, jobs for other branches upon request. Some twothirds of the company’s print out- Mensing managing director Volker Knoop is delighted: “With our PDF-based monitoring we can easily satisfy the demanding quality specs of critical customers in the cosmetics and pharmaceuticals industries.” put is now checked against the original PDF file. Alongside the new Rapida the DensiTronic desk and PDF reader are also used to check the prints off a second Rapida press installed eight years ago. Because the scanner is located at the DensiTronic Professional desk it can be used to carry out density checks on prints off the older press. Since the new Rapida’s DriveTronic SPC system allows all the plates on the press to be changed simultaneously in less than sixty seconds, Mensing can even turn a profit on the ultra-short runs customary in the pharmaceuticals industry. At the other end of the scale the high production outputs of both Rapidas also allow it to print runs of one million boxes or more without exercising its ingenuity. With such premium technology in place Mensing is now busy optimising and streamlining its production processes still further. It has already invested in equipment to enhance its competence in the production of patient information leaflets. This includes aqua scoring, a new option that helps avoid cracking during the folding process by softening the folds with a mixture of softener and water using high pressure water jets. The folded product is thus much flatter (see photo left). Martin Dänhardt [email protected] Report 37 | 2010 21 Sheetfed Offset | France The design of Imprimerie Montligeon’s new, 8,600m² production plant in Saint Hilaire Le Châtel incorporates the most advanced technology in terms of materials flow and environmental conservation the construction of a new 8,600m² (92,600ft²) production plant in Saint Hilaire le Châtel (postal zone 61) whose environmental footprint would comply with rigorous new standards. Productivity leap with DriveTronic SPC and QualiTronic Color Control Second eight-colour Rapida 106 perfector press with DriveTronic SPC and colour control Imprimerie Montligeon boosts productivity with makeready world champion Specialist commercial and packaging printer Imprimerie Montligeon in Normandy is going on the offensive with a gleaming new production plant housing the world makeready champion in B1 (41in) format, the Rapida 106. The eight-colour press, which boasts a four-backing-four perfecting capability, DriveTronic SPC dedicated plate-cylinder drives and an inline QualiTronic Color Control system, is the company’s second new-generation eight-colour perfector and its third Rapida 106 in just two years, the first being a five-colour coater version. he presses are part of an aggressive four-year strategic investment programme initiated in 2006, and the Rapida 106 was brought on stream in June this year. Established 130 years ago in 1880, Imprimerie Montligeon has two production subsidiaries: Orne, T “We boast an impressive level of expertise across a broad range of products.” Frédéric Berthelat, director of marketing and R&D at the Montligeon group Plant director Romuald Sausse (l) firmly believes that the new six-colour Rapida 106 is the most advanced in its class 22 Report 37 | 2010 in Saint Hilaire le Châtel, and Sarthe, formerly Imprimerie La Fertoise, in La Chapelle du Bois. Last year the total group workforce of 214 generated sales worth €28m ($36.4m), €9.5m ($12.3m) of which was attributable to packaging. That is one of the group’s pe- culiarities: in addition to 160 magazine titles it prints folding cartons and point-of-sale displays. In order to create the conditions essential for the organic growth that was to underpin its industrial strategy Imprimerie Montligeon gave the go-ahead in 2006 for The plant’s inauguration in 2008 was accompanied by a refurbishment of the entire press fleet, which at that time comprised a number of different brands. The first new addition was the Rapida 106 five-colour coater press, which is used to print packaging. It was followed by the first Rapida 106 eight-colour perfecting press, which prints commercials. Montligeon plant director Romuald Sausse says: “We chose the first eight-colour Rapida for its cutting-edge technology, which includes automatic plate changing with simultaneous blanket washing, SIS sidelay-free infeed and double-size post-perfecting impression cylinders that are fitted with special non-stick jackets. Compared to the existing eight-colour press from another manufacturer, the eight-colour Rapida 106 installed in 2008 delivered a 43 per cent productivity boost.” His enthusiasm is evident as he continues: “The Rapida 106 installed in June has enabled us to improve our productivity still further and reduce waste by 50 per cent. It runs up to saleable colour in approximately 100 sheets.” The low volume of start-up waste offers additional benefits: “With the new Rapida 106 we can print runs of just 250 copies cost-effectively. Since we regularly have to print multiple language versions, this is a big asset. It is also an enormous advantage when printing magazine titles whose circulations are steadily declining.” At present the average run length for the commercial products printed at Montligeon is around 6,500 copies. Ideal for short runs “In view of the staggering performance of new-generation Rapida 106 QualiTronic Color Control has helped cut waste by almost 50 per cent: the press often runs up to saleable colour in less than 100 sheets presses, with their DriveTronic SPC capabilities, and the professional after-sales service provided by KBA, opting for the same press as our latest acquisition was more or less a no-brainer,” says Romuald Sausse. “Simultaneous plate changing with DriveTronic SPC dedicated drives means that we can change all the plates in the eight printing units in less than one minute. What’s more, the blankets and impression cylinders are all cleaned at the same time.” Another key feature of the press is its QualiTronic Color Control module, with camera-assisted inline colorimetry and dynamic colour adjustment on both sides of the sheet. This ensures total colour stability after just 100 sheets, and from one run to the next. Says Romuald Sausse: “Thanks to these two capabilities, our new-generation Rapidas have shortened job changes by a staggering two-thirds. The first complete job change delivered a time gain of seventeen minutes. This means that we can now print shorter runs more efficiently and therefore more economically.” He cites just one of many examples with the new press: “We recently printed 24 four-colour perfecting jobs, 600 copies per job, in just seven hours. That’s 3.5 jobs per hour. With most types of substrate we can even print at an output of 15,000 sheets per hour in perfecting mode, which is a 20 per cent productivity gain.” The impression cylinders after the perfecting unit are fitted with specially coated jackets to prevent ink set-off from the recto page on the cylinders. Romuald Sausse says: “We print car magazines with a high colour content. That demands a superior reproductive quality in four With DriveTronic SPC, all the plates on the new eight-colour press can be changed in less than 60 seconds backing four, and with the new press we need have no qualms that the sheets will become contaminated.” 50% higher output in packaging printing The company is also pleased with the Rapida 106 five-colour packaging press installed in 2008, which features an aqueous coater and automated pile logistics. “The piles at the feeder and delivery are changed automatically – without stopping the press – and this delivers substantial time gains. The delivery of new pallets is also fully automated, and is completed while the press runs at the maximum production speed of 18,000 sheets per hour. The 106 has enabled us to boost productivity by 50 per cent. In the current market climate, that is more important than ever,” says Mr Sausse. The two eight-colour Rapida 106 press lines – the new one with dedicated plate-cylinder drives for simultaneous plate change is on the right – have turbo-boosted productivity at Montligeon’s commercial operation He continues: “Notwithstanding intense price erosion in the market, with the three KBA presses we have achieved an eight per cent increase in our production volume by enhancing productivity. Sales were stable throughout 2009 and business has remained brisk so far this year too. We operate in three shifts from Monday to Saturday. Since delivery deadlines are getting tighter and now average just five days, our strategy is to keep the presses running continuously and only stop them in an emergency. The aftersales service provided by KBA is tailored perfectly to our needs. Service work is even carried out at weekends.” “Between 2008 and 2010 Imprimerie Montligeon invested a total of eight million euros in new capacity,” explains Frédéric Berthelat, director of marketing and R&D at the Montligeon group. “As well as installing new printing presses we also refurbished the entire prepress division, adding a new Kodak ctp system and JDF/JMF-capable ERP software from Gamsys. The converting department – cutting, folding and gluing – and the bindery were also upgraded.” Montligeon has already attained Imprim’Vert, PEFC (Programme for the Endorsement of Forest Certification Schemes), FSC (Forest Stewardship Council) and ISO 9001/ 2000 accreditation, and is on track for ISO 14001 and ISO 12647-2. Frédéric Berthelat says: “We boast an impressive level of expertise that allows us to combine quality with productivity across a broad range of products spanning commercials, packaging and displays.” Luc Emeriau [email protected] Report 37 | 2010 23 Sheetfed Offset | Energy efficiency Energy measurements were taken on an eight-colour Rapida 106 perfector press with two coaters Energy audit at a sheetfed offset press in shopfloor environment Press kit and order structure have defining impact on energy consumption As energy prices climb and pressure steadily mounts to reduce the volume of the production-specific power consumption of litho presses. But for greater carbon dioxide emitted during industrial production processes such as print, there transparency, and as a means of identifying energy losses and potential for is a swelling chorus of voices in the marketplace calling for more precise data on improvement, we recommend an energy audit of the entire press. This requires the energy consumed by printing presses. The first step has already been taken knowledge of the energy flows and their chronological sequences during in the form of guidelines agreed among press manufacturers for calculating production. n order to obtain a detailed energy profile for a sheetfed press in actual operation KBA engineers virtually camped out in the press room, taking hundreds of measurements over a period of several months. Records were kept both of the energy input and of the resulting energy flows. They then drew up a comprehensive energy audit for the press. press was switched to energy-saving idling mode. As it accelerated, the energy input correlated with the increase in speed. The power consumption measured at the press connection represented approximately 35.6 per cent of total energy consumption, which included both useful energy and the heat generated through friction and discharged to the press or the ambient air (press room). It is interesting to note the figures for the auxiliary devices. It can clearly be seen that a subassembly such as the cooling unit consumes just as much energy as the air-compression cabinet, which has a much higher power rating. The reason is that the cooling unit is in constant operation, whereas the air-compression cabinet switches off automatically when not required. And despite their comparatively low connected load, the cooling unit and the air-compression cabinet together consume as much energy as the IR/TA dryer. This is because both devices are in operation for prolonged periods of time. I Data capture The press they examined was an eight-colour Rapida 106 incorporating a number of additional features not included in the standard configuration. Specifically these comprised a UV and a hybrid IR/thermal air (TA) dryer, a perfecting unit and two coaters with the appropriate dryers. Studying this press (pictured above) enabled them to capture data on the items of equipment that consume the most energy during any single print job. The data for calculating the electrical and thermal parameters specific to the Rapida 106 were captured during routine print produc- 24 Report 37 | 2010 tion. The information was relayed from clusters of sensors attached to over 120 measuring points. Energy audit The energy audit detailed below for the Rapida 106 examined covers a time frame of one month. It should be noted that energy consumption depends to a great extent on the structure of the jobs printed, and that the values recorded in the measuring period only apply to this specific press and the print jobs produced on it. The focus of this energy audit were the five biggest consumers: the UV dryer, the IR/TA dryer, the press itself, the air-compression cabinet and the multi-purpose cooling unit. A total power consumption of 53.91MWh was recorded for the one-month time frame reviewed here (see figure 1 on opposite page). As was to be expected, readings taken at the power connection to the press revealed that there was a significant difference in energy consumption between standstill and operation. During standstill the The controlled air-compression cabinet is one of the biggest consumers of energy even though it switches off when not required Approximately 13.9 per cent of total energy consumption was attributable to the cooling unit, 28 per cent to the compressors and the remaining 72 per cent to the circulating pump and the metering unit. This energy was utilised to divert 6.84MWh of waste heat out of the press and into the return cooling 16.6 MWh energy from exhaust air Figure 4: 23.82 MWh unspecified energy 19.17 MWh UV dryer IR/TA dryer 15.99 MWh circuit. Additional, unspecified energy consumption comprised useful energy as well as energy losses. The controlled air-compression cabinet consumed roughly 14.4 per cent of the energy input. This was then converted into waste heat and Figure 1: 3.54 MWh discharged via the return cooling circuit (60.5%). Again, additional, unspecified energy consumption (39.5%) included useful energy and energy losses. Energy consumption in the air-compression cabinet is depicted in figure 2. 3.54 MWh (6.6%) 7.47 MWh (13.9%) 7.74 MWh (14.4%) UV dryer 15.99 MWh (29.7%) Cooling unit Air-compression cabinet IR/TA dryer Printing press 19.17 MWh (35.6%) Total energy consumption 53.91 MWh (100%) Biggest consumers of energy Figure 2: 3.06 MWh (39.5%) Unspecified energy consumption Waste heat return cooling circuit 4.68 MWh (60.5%) Total energy consumption 7.74 MWh (100%) Energy consumed in the air-compression cabinet Figure 3: 0.62 MWh (17.5%) 0.95 MWh (26.8%) Heat in exhaust air Unspecified consumption Waste heat return cooling circuit Total energy consumption 3.54 MWh (100%) Energy consumed by the UV dryer 1.97 MWh (55.6%) Air Cooling unit 7.74 MWh 7.47 MWh The biggest consumers of energy were the dryers. Having said that, the UV dryer in the example cited here played a relatively minor role, which is explained by the type of job printed and the level of utilisation of the UV dryer during the period under observation. If the energy consumption of the UV dryer is profiled separately, the following conclusions may be made. Power consumption by the UV dryer depended on the number of modules in operation at any one time. Approximately 6.6 per cent of electrical input during the month’s observation was attributed to the UV dryer. This energy was partly converted into heat, most of which was vented via the exhaust air (17.5%) or the return cooling circuit (55.6%). Here, too, there was an unspecified proportion of energy consumption (26.8%). This encompassed the energy utilised during the drying process, the energy exerted on the paper, the energy input in the press and the energy dissipated in the press room. Energy consumption in the UV dryer is depicted on the left (see figure 3). The energy-efficient IR/TA dryer, unlike the UV dryer, was in regular operation. The substantial fluctuations in the power load measured during the observation period arose from the different types of jobs printed and the coatings applied. The IR/TA dryer accounted for approximately 29.7 per cent of the total electrical input. It was found that the energy generated from the incoming air in the heat registers was much lower than the exhaust air energy discharged from the press. This discrepancy can be explained by the fact that waste air from elsewhere in the 13.49 MWh energy from water cooling press and from the press environment was vented along with the exhaust air from the IR/TA dryer. For anyone engaged in the development of technical processes or concepts for utilising waste air, an audit of the exhaust energy vented via water and via air is of more than passing interest. Such an audit is an essential foundation for quantifying the interaction and mutual impact of these individual processes and concepts. The waste air recycled via the water cooling circuit accounted for 13.49MWh of the energy vented. This is equivalent to around 25 per cent of the total input of electrical energy. The exhaust-air ducts vented 16.6MWh of waste heat. This was roughly 30.8 per cent of the total electrical input. A breakdown of the energy flow within the press is shown in figure 4. The above audit demonstrates that even electrically powered devices with a low connected load can figure prominently in the overall balance. A sustainable concept for cutting power consumption and utilising energy much more effectively could be implemented by optimising press technology, deploying energy recovery systems and installing more energy-efficient dryers, for example KBA’s newly launched VariDryBLUE for large formats. For printers keen on enhancing their energy efficiency KBA offers a service tailored to their specific job structures. Dr Sascha Fälsch (KBA) Benjamin Scheer (Fraunhofer Institut) [email protected] Report 37 | 2010 25 Website: www.climatepartner.com Sheetfed Offset | Environment ClimatePartner A consultancy established in 2006 and based in Munich, with affiliates in Italy, Greece, Austria and the USA. ClimatePartner’s payroll of 30 works on individual climate protection projects for over 400 customers throughout the world, more than 250 of them in the printing and media production industry. Contact: Mario Schilling Tel: +49 89 1222 875-20; E-mail: [email protected] The energy consumed by the press represents a major proportion of the carbon emissions generated by any specific print job. The Rapida 75E pictured here was engineered to minimise emissions, and KBA demonstrated this at Ipex by connecting the press to a green electricity meter (on the right of the red sheet counter at the delivery) so that consumption was clearly visible to all New KBA service in collaboration with ClimatePartner Climate-neutral print production for a modest outlay In alliance with Munich-based consultancy ClimatePartner, KBA has become the first press manufacturer in the www.klimaneutraldrucken.de/kba www.climateneutralprinting.com/kba Koenig & Bauer AG marketplace to offer environmentally minded customers an individual, modestly priced and convenient method of calculating the volume of greenhouse gases emitted during print production. ne of the first members of the industry to team up with ClimatePartner, KBA entered the alliance shortly before Drupa 2008 and also gave the company stand space at the show. Since then a large number of KBA customers have drawn on the expertise and experience of the Munich environmental consultancy in order to reduce their carbon footprint. O New online platform simplifies emissions calculations Printers can use the new online platform created by KBA and ClimatePartner to calculate the volume of carbon emitted during print production. They can then take up the option of offsetting this by participating in certified environmental projects. The online calculation tools provided are practical, easy to learn – and not restricted to KBA sheetfed presses and printing. It is possible to integrate other makes of press along with all upstream and downstream links in the production chain, and to quantify all corporate 26 Report 37 | 2010 emissions associated with any specific print job, including material and labour input. Printers registering at www.climateneutralprinting.com/kba/ and entering their emission-relevant data will receive details of their individual carbon footprint, enabling them to green up their entire production process. This carbon footprint can also furnish the basis for making further improvements in conserving resources. KBA is offer- ing its customers this service in order to sensitise them to the challenges posed by climate change. Contribution to sustainable print production Klaus Schmidt, KBA director of marketing and corporate communications, says: “Climate neutral printing is just one of many services provided by KBA for sustainable print production. Our aim is to support our customers not just with ex- Printers logging onto www.climate-neutralprinting.com/kba/ can not only calculate their production-specific carbon emissions but also, for a modest fee, offset these by taking part in certified environmental projects ceptionally energy-efficient printing presses, and through our commitment to waterless offset as a greener production technology, but also to help them select the most environmentally friendly substrates and finishing processes for their specific production scenarios. Hence our decision to team up with ClimatePartner and create an online platform for climate-neutral printing.” The new service is available in German and English, and has so far been launched in Europe and the USA. ClimatePartner founder and CEO Moritz Lehmkuhl is delighted that collaboration between the two companies has been intensified in this way: “Working with KBA is a major milestone for us.” Klaus Schmidt [email protected] Sheetfed Offset | Superlarge format ooking at the print industry today it is hard to recall the technology of years gone by. Manual labour has largely been replaced by computerised systems, with no end in sight. Computer to plate, CIP3 press preset and automated plate changing are just a few of the advances that have transformed a printer’s working environment. There have also been radical changes in offset sheet formats. Twenty years ago B2 (20.5 x 29in) was the most popular choice, now it is B1 (29 x 41in) and bigger. Whether this shift was driven by printers or press manufacturers is a matter of debate: the fact remains that the number of superlarge-format press installations worldwide is steadily increasing. Computer to plate and a sharp reduction in makeready times have made VLF offset more cost-effective than either inkjet or screen printing for highquality work, whether you’re talking fewer than 200 or more than 500 copies. Quick to exploit this trend, Beyaert Printing installed two 7B (64in) Rapida 162 presses three years ago. Early this year it fired up the five-colour Rapida 205, the first and only press in Belgium for sheets measuring 1,510 x 2,050mm (59.5 x 80.7in). L Folding cartons being printed ready for lamination “I could spend hours watching this fine press in action.” Bernard Ramboux, proud owner of the Rapida 205 Beyaert Printing on growth curve with Rapida 205 Size does matter When it comes to carving out a niche market, (sheet) size does matter. Which is why Beyaert Printing in Waregem became the first printer in Belgium – and the only one within a radius of several hundred kilometres – to install a superlarge-format five-colour Rapida 205. Growing demand for POS displays press is a burgeoning demand for big POS (point of sale; in the US point of purchase) displays printed in the highest quality. Says Bernard Ranboux: “We have noticed local screen and inkjet print providers competing with us for work, but VLF offset is more cost-effective for runs of even just a few hundred sheets, and certainly above. Moreover, printing off an extra 1,000 displays takes only a few minutes longer, which is a big advantage. What makes it all the more interesting is the fact that we are the only printer in a radius of 500 kilometres capable of doing this!” After seven months’ operation Bernard Ramboux’ verdict is nothing less than glowing: “Experience has shown that the Rapida 205 is everything we’d hoped for. It may sound grossly exaggerated, but both our press crew and our customers are full of praise for the quality of the prints it delivers. And with its clean lines and robust design the new press is a real eye-catcher, too. Mind you, the Rapidas’ easy handling and immaculate prints have been impressing us for the past fifteen years.” Another reason for Beyaert’s investment in the superlarge-format Stefan Vermaercke [email protected] Fourth-generation print provider Like many family-run businesses, Beyaert has a long history. Its founder, Leon Beyaert, came from a family of artists. When he started out as a litho printer and bookbinder back in 1882, lithography was widely popular, with both colour and monochrome work a major aspect of the printing trade. Beyaert later switched to book printing and in the late 1950s his company was one of the first in Belgium to make the transition to offset. Today it is a specialist printer and converter of folding cartons for the packaging industry. Its 40strong workforce also prints sheets for laminating onto corrugated packaging and displays. The company is headed by Bernard Ramboux, the fourth generation in the founding family. His right-hand man is Olivier Storme, who is in charge of administration. Despite its huge format the Rapida 205 is compact and has a relatively small footprint Folding cartons steadily growing “As we all know, competition in the retail trade is pretty fierce,” says Bernard Ramboux. “So manufacturers of consumer goods are constantly searching for ways to make their products stand out in the crowd. Adopting more attractive packaging is one method, bigger packaging another. We have noticed that packaging is getting bigger from one year to the next. Just think of the cartons for big, flatscreen televisions: very often the entire surface of the carton is laminated with printed sheets, thus fuelling a demand for larger formats. That is why we purchased the two Rapida 162 presses three years ago. However, no sooner had we brought them on stream than we noticed that demand was shifting towards even bigger sheet sizes. The Rapida 205 was the logical consequence.” Messrs Ramboux and Storme see a similar development among the board converters who supply the company with boxes. They, too, are investing in laminating and die-cutting machinery for much larger formats. “We have always seen ourselves as an industry bellwether, but this development took us by surprise,” admits Mr Ramboux. Report 37 | 2010 27 Sheetfed Offset | Indonesia Jakarta, capital of a country that has become a major market for KBA in the high-growth Asia-Pacific region From the left: Stefan Segger (managing director of KBA Asia Pacific), PT Grafitec factory manager Ooi Teong Huah, Evi Soemardi (KBA agency Intertek Sempana), PT Grafitec director Rudy Ghozali and Ori Santoso Hartono (Intertek Sempana) displaying some of PT Grafitec’s products Sansico Group in Jakarta takes Rapida 105 and Genius 52UV KBA technology invigorates Indonesian packaging sector Within the high-growth Asia-Pacific region Indonesia is fast becoming a key KBA market. In April last year the Sansico Group, a prominent Jakarta-based packaging major, installed a new six-colour Rapida 105 universal coater press at its subsidiary PT Grafitec in Cikarang. In June this year the group’s second Cikarang-based production plant, PT Printec, fired up a Rapida provement. Among many joint initiatives Sansico and Mattel have implemented a lean manufacturing system based on balanced and aligned sequence timing across the Mattel assembly line and Printec’s production flow. In addition Printec has established a state-of-the-art inhouse lab to ensure compliance with international standards for heavy metals and phthalates. 105 five-colour coater press. Two of KBA-Metronic’s Genius 52UV presses are already in action at the same location, mainly Shifting market drives realignment printing on plastic and other non-absorbent substrates and materials. These installations followed the commissioning in late PT Grafitec director Rudy Ghozali says: “PT Grafitec and PT Printec used to operate sheetfed offset presses from other manufacturers. But the Indonesian market has undergone far-reaching changes in recent years. Innovative products and continual improvements in customer services have made KBA an attractive alternative. The price, performance, delivery time, makeready and level of automation of our first Rapida 105 universal were pretty compelling, and it was the same with the new five-colour 105. And with top-class KBA reference installations here in Indonesia, staff training was not an issue.” He continues: “As we have known for the past three years, KBA also offers some interesting options for green printing, one of which is the waterless Genius 52UV. We have great confidence in KBA presses. We’ll continue to keep a weather eye on technological advances and when further investments are on the table we’ll be contacting KBA again.” 2008 of two 18,000sph eight-colour Rapida 106 perfectors at publishing market leader PT Gramedia. ansico started out as a local printer but soon evolved into an internationally successful print group for packaging and paper products. Of its five production plants four are in the greater Jakarta area and one in Foshan (Guangdong, China). The manufacturing plants are organised along various printing processes which include offset, flexo and gravure technologies, and are moving towards a fully digital workflow. Each facility also caters to specific customers and sectors, thereby allowing a dedicated focus and high service levels. The group employs more than 2,000 people (with seasonal fluctuations). Alongside quality folding cartons and plastic packaging the broad product spectrum includes greetings cards, wrapping paper, S PT Grafitec director Rudy Ghozali with some of the huge range of quality products his company prints for industrial enterprises and major retail chains 28 Report 37 | 2010 serviettes, giftware (bags, boxes etc) and partyware. Sansico numbers prominent household names such as Mattel, Target, American Greetings, Nestlé, Coca Cola, Costco and Walmart among its customers. Exports account for the majority of group output, and major shipping destinations include the USA and Europe. Focus on Mattel For almost two decades Sansico has built up a close alliance with US toy manufacturer Mattel. Through this partnership Sansico has adopted and assimilated best-in-class manufacturing and management practices in accordance with customer requirements, providing a platform for a culture of continuous im- Gerhard Renn [email protected] Sheetfed Offset | Large format Website: www.hammerpackaging.com ur successful mantra has always been to innovate,” says Jim Hammer, president and CEO. “We lead the industry, not follow. In the past five years, we’ve doubled our sales growth and we’re anticipating that we’ll grow in double-digit figures during the next five years. We chose to partner with KBA because we feel that they are well attuned to the market and our relationship has been very good since we purchased our first largeformat press from them in 2005. Our new KBA Rapida 162 will be assigned to produce cut and stack labels for our high-end national accounts and we anticipate it will be running three shifts right away.” He continues: “Most of our competitors predominantly have six-colour presses, and we’ve found that our customers will design their labels utilising all eight colours. This differentiates us from our competitors. The lightweight paper package is especially important in our market because our customers are trying to shed as much weight as possible on their products to reduce costs. Furthermore, we specified the Densitronic Professional colour control system because it is used on all of our presses; it allows us to easily repeat customer jobs thus allowing us to shorten customer run lengths, while keeping their inventories low and allowing them to change their graphics as often as they wish. Oftentimes, our customers ask for process information in order to map the job for quality control. We need this type of highend technology from KBA to better maintain our own edge as well as provide detailed information for our customers.” O “ More options with film Over the past eight years Hammer’s customers, such as Pepsico and The Coca-Cola Company, have turned to cut-and-stack labels printed on film. Unlike paper labels, film can be clear, giving designers the additional capability to reverse print, as well as surface print. Hammer specified that the new KBA press needed to have a 12-foot extended delivery in order to dry the film substrates run on the press. “We print a fair amount of oriented polypropylene,” says Hammer, “and Jim Hammer, president and CEO of Hammer Packaging, at his new KBA Rapida 162 eight-colour sheetfed press plus coater and reel-to-sheet feeder Hammer Packaging leads industry with eight-colour Rapida 162 Premier packaging printer innovates with increased automation, flexibility Hammer Packaging, a premier package printer in Rochester, New York, has installed a new 7B (64in) Rapida 162 eight-colour press plus coater, reel-to-sheet feeder, Densitronic Professional colour control and lightweight paper package. Hammer is the only packaging printer in North America with this type of press configuration. we need the extended delivery to cure the job at full speed.” Automation an absolute must Another trend is interactive graphics. According to Jim Hammer, “We’re seeing more extensive target marketing focusing on different areas of locale, different groups of people, and different types of activities.” This form of micro-marketing requires a greater variation of graphics on each package, as well as changing label designs from job to job. “Consequently, we’re running shorter run lengths of labels. The key is to be flexible and deliver exactly what customers need in a justin-time environment.” Having highly automated machinery is key at Hammer Packaging, allowing its highly-prized team to focus on quality and productivity. The new Rapida 162’s automated inking system measures the exact ink amount in each unit and captures every cost involved. Hammer replaces its equipment every seven years believing that technology changes enough to warrant new models. When Hammer installed its new KBA press in early 2010 it decommissioned an eight-colour press from another manufacturer to make room. Hammer will continue to use its seven-colour Rapida 162 press purchased in 2005 with a Grafech Engineering sheeter. This was the first installation of a sheeter for a press of this size. Hammer Packaging, established in 1912, is a privately-held highquality package printing company with a focus on labels and product decoration. Core products include cut-and-stack labels, in-mould labels, shrink sleeves, roll-on shrinkon labels, roll-fed labels, pressure- sensitive labels, foam labels and premium packets. Key markets include beverage, food, household products and horticulture. Hammer’s customers also include Nestlé Waters NA, Dr. Pepper Snapple Group and Campbell Soup. The company employs more than 400 associates and occupies over 400,000ft² (37,000m²) of operational space across three facilities. Jim Hammer is a fourth-generation business owner who has been the driving force in growing the $1 million company he took over from his father to the $90 million enterprise it is today. In July 2009 Hammer Packaging was ranked 64 in the Graphic Arts Monthly (GAM) list for top performing printing companies in North America. Eric Frank [email protected] Report 37 | 2010 29 Sheetfed Offset | China n the first seven months alone Chinese printers awarded almost thirty contracts for large-format press lines, every one of which will be shipped before the end of the year. The figures underscore KBA’s pole position in the global market for large-format offset presses, which is now rapidly being paralleled in the high-growth Chinese market. Strikingly, many of the printers signing up for big presses are medium-format specialists and have no prior experience of large format. Here are a few examples. I From medium format to large One of the biggest users of KBA presses in China is packaging printer Beijing Jiazheng, which for the past three years has run five Rapida 105 press lines – one sixcolour, two five-colour (one with a coater) and two four-colour. In autumn this year Beijing Jiazheng will take delivery of its first Rapida 142, a five-colour version with coater. The company is advancing into large format as a means of boosting productivity and honing its competitive edge. At Sichuan Shifang Gongyi in southwest China a seven-colour Rapida 105 universal coater press has been in operation for the past two years. This year it will be joined by a brand-new Rapida 105 and Rapida 142. Here, too, the decision in favour of large format was dictated by the productivity gains it delivers. Integrating the big Rapida in the dedicated production flow will enable the company to print more blanks per sheet. It will also allow it to produce packaging in one pass: at present each item must be assembled from several separately printed pieces. Zhejiang Wuyi Zhangshi in eastern China will be firing up its second large-format Rapida this autumn. The company started making the transition from locally built presses to Rapidas last year with the purchase of a Rapida 105. A few months ago it installed a five-colour Rapida 162a which will now be joined by a four-colour Rapida 142. Again, the choice of large format was driven by technical demands and the wider range of products possible. 30 Report 37 | 2010 In autumn this year Xiamen Jimei will flick the switch on a Rapida 162a – its first KBA press – at a high-tech production plant in Fujian province Soaring demand for big Rapidas Large-format boom in the Middle Kingdom Sales of Rapida presses are booming in China, with our regional sales offices booking as many as thirty orders a month. The total value of contracts signed in the six months to July was higher than for the entire previous year. The most popular choice across the board is our sturdy B1 (40in) workhorse, the Rapida 105, with a few top Chinese players opting for the high-tech Rapida 106. In other words, business as usual. What is surprising is that in a country where large-format presses scarcely registered on the radar, Rapidas for bigger sheet sizes up to 1,120 x 1,620mm (44 x 63.77in) have been selling like hot cakes. LF customers old and new A whole succession of printers who have been operating big Rapidas for some time now have recently been expanding their fleets. One of them is Changzhou Zhengwen, a specialist packaging printer in the eastern province of Jiangsu. The inauguration of a four-colour Rapida 162a in 2006 will be followed in the next few weeks by the delivery of a five-colour Rapida 142 with which the company is aiming to boost its competitiveness still further. Changzhou Zhengwen’s renewed choice of a KBA press was influenced in no small part by the outstanding stability and performance of the Rapida 162a. Foshan Luzhicai, down south in Guangdong province, did exactly the opposite. In 2005 the company The twentieth contract awarded by a China printer this year for a large-format Rapida was signed at the Beijing International Packaging Fair 2010, which took place from 2 to 4 June. Since then the total has risen to almost thirty installed a Rapida 142, which will be joined at the end of this year by a Rapida 162a. Here, the choice of a larger format was dictated by a growing demand for bigger packaging. The excellent reputation enjoyed by the big Rapidas in the marketplace, and the reliable service provided by KBA-China, are what clinched the decision for a second large-format Rapida. Xiamen Jimei in Fujian province and Zhejiang Yixiang were among the first-time buyers of KBA presses – and large-format into the bargain. Both will receive a fivecolour Rapida 162a before the end of the year. While Xiamen Jimei currently operates presses from a different vendor, Zhejiang Yixiang is new to the print business. Both companies, like many others, made a conscious decision to go for the number one brand in large format, and the manufacturer with the most experience. Martin Dänhardt [email protected] Sheetfed Offset | Australia Website: www.percival.net.au utomation modules include DriveTronic SIS no-sidelay infeed, coating plate change and CIPLink software. The washing system for the blanket cylinder, impression cylinder and rollers has a return function to reduce cloth consumption. The two coaters are linked to two pumping and cleaning devices (one for aqueous and one for UV). The press package also includes DensiTronic online colour measurement and control. For Percival managing director David LeRoy and his partner and co-proprietor Rod Jenkins, the 18,000cph high-performance press is a key factor in safeguarding the company’s future. David LeRoy says: “Delivery, installation and commissioning were completed well on schedule. We have been delighted with the execution of the entire project. Apart from the technological competence and the capabilities offered by the Rapida 106, what won our vote was the rapid ROI and the after-sales service provided. Prior to placing the order we were able to inspect a similar press in Paris and realised immediately that the Rapida 106, with its prodigious output, would be a major advance for us. KBA has delivered a press with everything we could possibly need for quality- and servicedriven production.” A A sample of Percival’s sales mix showing the quality of its printed products and customer services Percival Print & Packaging, Perth Rapida 106 double-coater press debuts in Australia At the beginning of March Percival Print & Packaging in Perth fired up the first Rapida 106 doublecoater press in Australia. The high-automation six-colour 106 replaces two litho presses from another German manufacturer and allows Percival to apply top-quality matt, gloss and spot coatings inline for the first time. says LeRoy. “The Rapida’s double coating capability is already in frequent use, and rising. We are confident that inline coating is on the advance in Australia and will prove a big success for us. With the 106 a growth rate of 7.5 to 10 per cent would be realistic for the first year.” Inline coating on the advance According to David LeRoy, inline coating was a key criterion alongside a high output and fast makeready: “Print runs average 4,000 copies, so versatility and precise quality control take precedence over speed. We use substrates weighing between 80 and 400gsm. Previously we could only apply two coats offline, but with the Rapida 106 we can apply a whole range of coatings inline, so there are virtually no limits to the designs we can now handle.” Among its customers Percival Print & Packaging has built up a reputation for first-class quality and service. “We are targeting even higher quality standards in the future while optimising value added,” Percival managing director David LeRoy (right) and his partner and co-proprietor Rod Jenkins are proud of the first Rapida 106 double-coater press in Australia Perth, on the Swan River, is the capital of Western Australia and home to Percival Print & Packaging Supplier of the Year Awards Percival Print & Packaging was established in 1972 by George Percival with a visionary approach to servicing the future needs of the business community in Perth by offering commercial products and packaging with a strong visual appeal. The company’s commitment to quality and service soon enabled it to carve out a sizeable share of the market. Today the 22-employee firm specialises in soft folding cartons, commercial print, posters and trade finishing work. Percival’s select customer base, which extends far beyond Australia, includes corporates within the pharmaceutical, food services, promotional and retail industries. It also services the medical communication management industry, creative design studios, educational material suppliers and advertising agencies, often fulfilling intricate, multilingual projects. The company is accredited to ISO 9001 standards and its expertise within the pharmaceutical packaging field has won it Supplier of the Year Awards on two occasions, with a placing among the finalists in other years. Gerhard Renn [email protected] Report 37 | 2010 31 Web Offset | New products hile KBA also builds big presses for up to 80 pages, in view of the current trend towards smaller circulations and more specific targeting by magazines, catalogues and upmarket promos, we see a parallel need for innovative 16pp web offset presses. After all, well over 50 per cent of the commercial presses not just in Europe but worldwide are for 16 pages. The C16 is KBA’s technical response to shifting demand in commercial markets. W 55,000 or 65,000cph and extensive automation When designing the innovative new 16pp C16 we made a high net output, high-speed job changes, low levels of start-up waste, enhanced production flexibility and reduced operator, energy and maintenance input our key objectives, along with outstanding value for money. The extensively automated KBA C16 (C stands for commercial) is available in two performance levels: 55,000cph and 65,000cph. Its output falls between the Compacta 215 (max. 50,000cph), of which there are over 150 installations, and the Compacta 217 (max. 70,000cph) launched at Drupa 2004. However, compared to these two models the C16 has several interesting new features and compared to similar models from domestic and foreign competitors it boasts a raft of technical and user benefits. The first to fire up the new press was German commercial print enterprise L.N. Schaffrath in Geldern, North Rhine-Westphalia, which pressed the button on a 65,000cph version in August. New press: KBA’s C16 web offset press boasting a raft of innovations and unique features targets the 16pp sector, still the biggest worldwide New record: the C16’s automatic PlateTronic system can change any number of plates in less than 60 seconds and thus slash changeover times Focus on cutting makeready, waste, handling and maintenance KBA C16: the technical response to shifts in commercial markets With commercial printers still reeling from the impact of the economic meltdown, overcapacity and price erosion, most reports of new investments in the European web offset market tend to focus on high-volume press lines for 64, 72, 80 and even 96 A4 pages on the cylinder. But the proliferation of such presses over the past ten years has in fact contributed to the problem by boosting capacity and driving down prices. On top of this, dwindling ad revenues in the wake of the recession have caused a decline in print runs and pagination, exacerbating the situation. When bidding for contracts, keeping the presses running often takes precedence over profitability. As a result wide, double-circumference presses end up printing jobs for which a modern 16pp press like the C16 would be more cost-effective. C16’s unique winning features The C16’s primary innovations and unique features include: • the fastest plate change in its class (less than 60 seconds irrespective of the number of plates); • Our unique RollerTronic roller locks for a longer service life and reduced maintenance; • a new, automatically convertible P3 folder with just one quarterfold up to 65,000cph and unique automated copy control; 32 Report 37 | 2010 All neat and tidy: the web-guide elements (including optional turner bars), former and slitter in the superstructure are easily accessable, while the modular design with dedicated drives throughout allows extensive customisation • networking technology with high-powered MLC; • dedicated AC drives for each printing couple and other features for enhancing energy efficiency; • flying job change with proven imprinter technology; • optimised EasyTronic software for fast, low-waste start-up and run-down at the touch of a button; • automatic presetting, job management and optional JDF process integration via LogoTronic Professional; New details: the RollerTronic automatic roller locks which have proven their effectiveness a thousand times over on KBA newspaper presses also help reduce roller abrasion, maintenance input and running costs on the C16 • user-friendly handling and optimum access to all subassemblies and feed systems. Efficient reel logistics and energy recovery The C16 is fed with paper by our well-proven Patras reel-logistics Folder innovations: the new high-performance P3 folder can create over 30 different folds, and even at a maximum output of 65,000cph requires just one module for the quarterfold less than two minutes. What is more, RollerTronic reduces roller abrasion, the frequency with which rollers must be changed, recoating costs and maintenance input while enhancing energy efficiency and printing conditions. The C16’s drive system is also the exception in this class: a dedicated AC drive for each couple (ie two per printing unit) allows the circumferential register to be set with no abrasion-prone mechanical parts. And two motors per printing unit generate less braking and accelerating force than does the usual single motor, thus conserving energy. The C16’s inking units are ideal for alcohol-free printing, as are the dampening units which can be converted from direct to indirect operation. The dampening units’ exceptional stability guarantees a rapid ink/water balance and therefore very little start-up waste. Just one quarterfold module, automatic copy control Everything under control: the user-friendly ErgoTronic console incorporates EasyTronic software for fast, automatic press start-up and run-down at the touch of a single button system with custom-configurable automation, and reelstands engineered for the maximum reel diameter and production speed specified (Pastoline, Pastomat C or Pastomat CL for a reel diameter of 1,524mm/ 60in). The C16’s compact form encompasses an infeed unit built into the reelstand and all key elements (such as a web aligner) for a precise web run. Its environmentally friendly technology includes an energy recovery system. New printing-unit design delivers benefits in quality, handling... The robust, bearer-free double printing units in the C16 are designed for a superb print quality, fast job changes and ergonomic operation. They feature the minigaps developed by KBA and subsequently adopted by other vendors, plus blanket plates that can be changed in under three minutes. The printfree margin is less than 6mm (0.25in), which saves on paper and, unlike conventional blankets, requires no adjustment. Another unique feature is the ability to adjust impression pressure via a setting screw when switching to a different type of paper (eg in conjunction with a sheeter). There is a choice of automatic or semi-automatic plate change. Four forme rollers and large roller diameters ensure a swift ink/water balance during start-up and stable colour during long print runs. ...maintenance, cost efficiency and emissions With our RollerTronic roller locks all the inking rollers can be adjusted by push-button from the console in We have also substantially upgraded our P3 pin folder. Already automatically convertible from one type of stock to another, the P3 now features just one quarterfold module and new automatic copy control, but with no loss of speed. This cuts initial investment costs, relieves the press crew of tedious setting tasks, ensures consistent printing conditions and helps reduce waste. A touch screen at the folder delivery shortens walking distances for the operator and can double as a fullscale console. Modular design supports customised configurations The P3 is available in a wide choice of configurations to support over 30 different types of fold in combination with various copy formats. The web guide elements in the superstructure (which can also be configured with turner bars) are easily accessed, as are the former and slitter. Our patented turner bars do not have to be adjusted for different ribbon widths. The superstructure’s modular design, with dedicated drives throughout, means it can be customised freely and subsequently extended with retrofits. The same applies to the entire press line. The C16 is available as a left/ right or right/left floor-mounted Optional equipment • Reel-handling system • Webbing-up unit with chain to former • Flying imprint capability • Automatic plate changers • Desk lighting • Height-adjustable desk • Remoistening unit • Colour-density control • Cross lead for duplex press lines • Steel substructure for stacked configurations • Auxiliary former • Expansion module for 2x8 pages • Cut-off cassette for 4x4 pages • Die-cutter and perforator • Coater, UV coater and remoist gluer • Plough fold • Sheeter • Compressed-air unit • Chilling station • P3 folder with no delta or double parallel fold press with up to eight units, as a two-tier configuration or as a duplex line with cross lead. Predelivery testing of pre-assembled modular components cuts on-site installation and commissioning times. Digital integration with ErgoTronic, EasyTronic and LogoTronic The upgraded, user-oriented ErgoTronic console is the operator’s central work station, where he can initiate fast, automatic press startup and run-down at the touch of a single button. During makeready he can also automatically preset the slitter, turner bars, register rollers and former, or pre-ink the plates. To cut start-up waste we have substantially reduced the C16’s makeready speed. LogoTronic or LogoTronic Professional software for capturing operational data, downloading presetting data and storing job data to accelerate press preset for repeat jobs can be embedded in the customer’s workflow and even supports JDF networking. The C16’s colour measurement and control systems, cut-off register controls, hot-air dryer and other auxiliaries are all sourced from established, proven vendors. Marc Decker [email protected] Report 37 | 2010 33 Web Offset | Saudi Arabia Cutting-edge web press technology for Koran printer King Fahd Complex books Compacta 217 installation Saudi Arabia’s King Fahd Complex for the Printing of the Holy Qur’an has awarded KBA one of the biggest-ever commercial web press contracts in the Middle East. The installation will comprise two 16pp Compacta 217 press lines with a total of four reelstands, twelve double printing units, four dryers and two folders. The deal was finalised during a visit by the Saudi delegation to Ipex. Delivery to Medina is scheduled for autumn this year. rofessor Mohammad Salim AlOufi, general secretary of the King Fahd Complex, is looking forward to a huge capacity boost: “The performance of Compacta 217 press lines at Kunst- und Werbedruck in Bad Oeynhausen and Vogel Druck und Medienservice in Höchberg confirmed our initial impression of premium quality press engineering and print production. The 217 came out top in every one of the challenging print tests we conducted. The dedication and competence of the KBA project team and Graphic Supplies, KBA’s Saudi agency, also played a major role. The two high-automation Compacta press lines will enable us to optimise the quality and cost efficiency of our print production.” P ligious publications, and to produce audio books (CDs and cassettes). It has printed more than 250 million copies, of which 236 million have been distributed worldwide, a large proportion to the many millions of visitors to the holy shrines. The Complex covers around 250,000m² (62 acres) and alongside the printing plant includes a mosque, administration and maintenance buildings, warehouses, accommodation, an entertainment centre, a dispensary, a library and restaurants. Over half the 1,700 employees are engaged in text, quality and final control. Flexibility and output The two identical Compacta 217 press lines, which will have a 630mm (24.8in) cut-off and a max- Pictured at Ipex in Birmingham (l-r): Maher Ghandour, production manager of the King Fahd Complex; Ali Saleh Al-Sanie, general manager of KBA’s Saudi agency Graphic Supplies; Christoph Müller, KBA executive vice-president for web press sales; Talal Al-Rehaili, technical director (Ministry), King Fahd Complex; Helge Hansen, president and CEO of KBA; and Professor Mohammad Salim Al-Oufi, general secretary of the King Fahd Complex for the Printing of the Holy Qur’an imum web width of 1000mm (39.37in), will be engineered to deliver the highest possible quality within a tight production schedule. They will feature cutting-edge control technology, a suite of presetting software to minimise start-up waste, automatic folder conversion and plate-changing to minimise makeready times, and colorimetry and washing systems. Each press will have two KBA Pastomat C reel- stands with Patras M manually assisted reel loading, six printing units, two Megtec dryers and one P3 pin folder to support a wide range of products. Softening and remoistening devices will ensure optimum finishing. Klaus Schmidt [email protected] 13 million copies per year Founded some 25 years ago by King Fahd Bin Abdel Aziz to disseminate religious publications in the Islamic world, the King Fahd Complex is run by the Ministry for Islamic Affairs, Endowments, Da’wah and Guidance, and has established a global reputation for quality. In addition to promoting Islamic studies, printing the Holy Koran and translating it into other languages (50 to date), the King Fahd Complex’s primary function is to print the Holy Koran, the Prophet Mohammed’s (PBUH) Sunna and over 90 other re- 34 Report 37 | 2010 The two KBA Compacta 217 press lines with integrated Gämmerler finishing systems will substantially boost capacity at Saudi Arabia’s King Fahd Complex for the Printing of the Holy Qur’an Web Offset | France The 80pp Compacta 818 has a web 2,060mm (81in) wide and a variable-format V5 folder High-volume commercial web press for the South of France Imprimerie Rockson invests in 80pp Compacta 818 Provence is famous for the outstanding beauty of its countryside and the excellence of its red wine. Only a few industry insiders are aware that in the heart of this popular tourist spot, in Rognac, a number of commercial web presses and one sheetfed offset press from KBA print high-volume runs of value-added products at Imprimerie Rockson. Now Rockson is expanding its fleet with an 80pp Compacta 818 and has taken an option on a second, identical press. ockson’s longstanding business relations with KBA, and the strong position it has established with its KBA fleet in the fiercely competitive French publications market, were major factors influencing the choice of press. Following a recent big order from Saudi Arabia for two Compacta 217 commercial presses (see previous page) this is a further boost for a sector still reeling from the economic crisis. R Successful and profitable Imprimerie Rockson was founded in 1970 and now employs over 100 people. Special-interest magazines and periodicals on fashion, sport and cultural activities account for a large proportion of its output, along with advertising leaflets, supplements and catalogues for the tourist trade. Its customer base includes publishing houses, advertising agencies and other print buyers from all over France, Germany and the UK. Headed by Henri Papazian and Michel Toti, it is one of the most successful and profitable print providers in the country. not only deliver a huge capacity boost but will also enhance productivity and flexibility, enabling Rockson to provide a complete range of services from short-run, low-pagination to high-volume, high-pagination products. “We had been planning a major investment before the fire,” explains Henri Papazian, “and even wanted to establish a new production base, but the economic crisis put paid to that.” However, nothing could quench the company’s dynamism and determination to corner a bigger share of its competitive market. “A major market like France means long print runs and a high page count. Unlike Italy, France is poorly equipped for this. We offer market prices yet still battle against Italian and Spanish competitors who have the benefit of a better production environment. Having said that, being well equipped is no longer adequate. We must also address more sophisticated customer demands with regard to labelling and certification. That’s not always easy, but we are ready.” Performing to order The time and waste savings delivered by EasyTronic during press start-up and stop, and the enormous reduction in maintenance input and roller abrasion achieved with RollerTronic automatic roller locks, will make production with the Compacta 818 exceptionally cost-effective, while a Patras A automated reel-logistics system optimises the materials flow. 2m-plus web width and variable-format folder The Compacta 818 for Rockson is engineered for a web width of 2,060mm (81in) and a cylinder circumference of 1,197mm (47in). It will feature a V5 gripper folder which is unique in its ability to deliver both short- and long-grain products. For even greater versatility the press incorporates a gluing and softening device and a section stitcher. LogoTronic Professional allows job and presetting data to be transferred directly to the press. This well-proven system converts press, production and administrative data into meaningful statistics, promoting transparency throughout the enterprise. Market-focused investment strategy The Compacta 818 replaces a 48pp Compacta 618 destroyed in a fire, and joins two 16pp Compacta 215s and a 24pp Compacta 318. It will Pictured after signing the contract for the Compacta 818 in Würzburg: Imprimerie Rockson president Henri Papazian and general manager Michel Toti (centre) flanked by KBA sales manager Reiner Dluschek (l) and executive vice-president for web press sales Christoph Müller Marc Decker [email protected] Report 37 | 2010 35 Book Printing | France s the European market leader in book printing we owe it to our customers to innovate on an ongoing basis. Our investment in this extensively customised and highly productive web press represents a major technological advance and sharpens our competitiveness,” declared CPI group president Pierre-François Catté. The CPI group has production plants (printing and binding) in France, the Netherlands, the UK, Germany and the Czech Republic. The new Commander CT will go live in spring 2011 at group subsidiary Brodard & Taupin in La Flêche (Département La Sarthe) some 250km (156 miles) southwest of Paris. A “ Raft of unique features Custom-configured for printing paperback books, the Commander CT for CPI will be fed by a Pastomat CL reelstand embedded in a Patras A automated reel logistics system. It will have a maximum web width of 1,480mm and a maximum rated output of 35,000 sections per hour in both straight and collect mode. The maximum page count in a wide range of common formats represents a radical innovation over the present options. The Commander CT’s printing towers, which are only half as high as those of conventional newspaper presses, will comprise four couples with an imprinting capability for flying job changes in 1/1 production. Compared to conventional bookprinting presses makeready time will be virtually zero and there will be much less waste. A PlateTronic automatic plate-changing system will allow the plates for the next job to be mounted while the first job is still being printed. CleanTronic blanket washing, automatic colour and cut-off register controls and other automation modules will enhance not only productivity but quality as well. In response to an emerging demand from CPI’s publishing customers for books – particularly thick books – that lie flat more easily when open, the new Commander CT press will even support long-grain production, where the paper fibres run parallel to the spine. Another unusual feature is its 36 Report 37 | 2010 The Commander CT with infra-red dryer incorporates commercial technology Productivity boost for market leader in mono book printing CPI group in France opts for innovative Commander CT French print group CPI, the European market leader in monochrome book printing, is boosting productivity with a specially modified Commander CT press line incorporating an infra-red dryer, an imprinter and a KBA book folder. KBA sales director Kai Trapp (left) and CPI group technology & supply chain manager Bernard Kieffer signing the contract in Würzburg at the end of February attended by (l-r) KBA project manager Albrecht Szeitszam, corporate lawyer Stefan Ganz and sales manager Bernd Hillebrand, plus Frederic Duquenne of KBA-France infra-red dryer, whose capacity can be adjusted to production specifics such as a narrower web so as to improve energy efficiency. In the superstructure, which was adapted from publication gravure, the ribbons are turned 90° over individual bars before entering the KBA book folder where they are stitched via the quarterfold (chopper fold) to create two-up copies. The press will be controlled from an ErgoTronic console with a LogoTronic presetting system. Alliance between two market leaders The CPI group was founded in 1996. In 2009 the European market leader generated sales of €480m ($647.5m) on an output of some 500 million monochrome books. The group employs around 4,000 staff at production plants in five countries (France, UK, Germany, Netherlands and the Czech Republic). CPI co-operates with over 2,000 publishers, among them the top European names. It runs 17 printing plants, including FirminDidot and Aubin Imprimeur in France, Clausen & Bosse in Germany, Koninklijke Wohrmann in the Netherlands and Mackays in England. The order for the Commander CT is the first in what both CPI and KBA hope will be a long-term alliance. After signing the contract in Würzburg KBA sales director Kai Trapp said: “The CPI group’s decision to opt for this new combination of innovative newspaper and commercial press technology is confirmation of our superior competence in addressing customers’ individual requirements. We are confident that our close co-operation in this project can create a classic win-win situation for both our companies.” Rene Sieber [email protected] Newspaper Production | Jordan Jordan Press Foundation (JPF) director general Nader Horani (centre) and KBA executive vicepresident for web press sales Christoph Müller (l) signing the contract for the KBA Commander in Amman at the end of April attended by JPF vice chairman Mohammad Al Amad (seated, right), Ramzi N Kteily of KBA agency Giffin Graphics, JPF chairman Fahed Fanek and JPF technical committee chairman and commercial press manager Amjad Ayesh (standing, l-r) Jordan Press Foundation in Amman High-performance Commander hybrid press for Jordan The Jordan Press Foundation (JPF) in Amman is planning to boost production capacity and flexibility with a conventional double-width Commander tower press for printing newspapers, semi-commercials and hybrid products. The Commander will be installed at a new production complex near Amman airport. he €25m ($32.3m) project, which will include a new mailroom and central store, is scheduled for completion by the end of next year. T Market leader in newspaper publishing The Jordan Press Foundation publishes a national Arabic daily newspaper, Al Rai, which has the biggest circulation and advertising section in the country. Other titles include the Jordan Times, an English publication launched in 1975, and Hatem, a monthly magazine for children and youngsters. The project is the biggest investment to date by a Jordanian media company in newspaper technology. According to JPF chairman Fahed Fanek it will enable the company to consolidate its pole position in the market and sustain profitable growth in the future: “With the high-powered KBA Commander we can offer our readers, advertisers and print customers full-colour newspapers, supplements and other print products with still greater visual appeal and immediacy.” Amjad Ayesh, JPF technical committee chairman and commercial press manager, adds: “The Commander’s heatset capability will allow us to print semi-commercial and hybrid copies on newsprint and improved paper. While we’ll be exploiting these options and the new press line’s productivity for our own titles, we’ll also be accepting contract work to shorten the payback time.” Flexible press with an array of extras The Commander will be engineered for a 578mm (22.75in) cut-off on a maximum web width of 1,520mm (59.8in) and a maximum rated output in straight production of 80,000 copies per hour. In heatset mode there will be a choice of web widths from 1.260 to 1,520mm (49.6 59.8in). The maximum page count in full-colour production will be 96 broadsheet or 192 tabloid pages, with 16 broadsheet or 32 tabloid pages running through the heatset dryer. The configuration of the substructure press will include: • 8 Pastomat reelstands with Patras A automatic reel logistics and two stripping stations; • 6 four-high towers for 4/4 or 2 x 2/2 production with semiautomatic plate changers and RollerTronic automatic roller bearings; • single turner bars, turner decks and bay-window rollers; • 2 folder superstructures with two formers; • 1 hot-air dryer with chill roller stand etc; • 2 KF 5 jaw folders with length/cross perforation and quarter fold; • automatic ink pumping, colourand cut-off register controls and fan-out compensation; • automatic blanket and inkingunit washing systems. The Commander installation will be controlled from five EAE consoles with Print software for job scheduling and press preset, a RIP interface and a diagnostics PC. Press operators will be given in-depth training. Klaus Schmidt [email protected] The Commander hybrid press line for the Jordan Press Foundation in Amman Report 37 | 2010 37 Newspaper Production | Investment Big newspaper press contract from Express Newspapers in UK West Ferry Printers orders 22-tower Commander CT West Ferry Printers, a subsidiary of Express Newspapers Group, is to move from its printed newspapers within the multimedia environment. For KBA, it is the biggest London Docklands home of the past 24 years to a new, as yet unnamed site, pos- single contract of 2010, and a striking contrast to the widespread reluctance sibly to the north of London and close to the M1/M25 corridor. This follows the among members of the print media industry to invest in new kit. The decision by announcement of a £100 million ($145.5m) spend on new hybrid coldset and what was formerly one of the biggest newspaper printing plants in Europe to heatset presses and ancillary equipment over the next five years by owner Richard install a Commander CT is evidence that KBA’s innovative compact platform, with Desmond. As debate wages on the iPad and the current crisis in the print media its focus on future versatility, is steadily gaining converts in a media market this major investment is a powerful declaration of confidence in the future of wrestling with far-reaching changes. est Ferry and Broughton Printers’ chief executive David Broadhurst said the huge contract with KBA followed an exhaustive investigation of all the newspaper press designs and printing methods available. mander CT presses will also print contract work, including the Daily Sport, and in time will be used for semi-commercial work which will also enable the group’s magazines to be printed in-house. With many publishers and printers reluctant to commit funds W Heatset a possible option The company has initially ordered four compact high-performance Commander CT press lines totalling 22 towers along with mailroom and publishing equipment from Ferag. And the plans are for additional printing towers, reelstands and heatset dryers at a later stage. The first coldset phase is expected to be up and running in early 2012. Alongside Express Newspapers Group titles – the Daily Express and Sunday Express, and the Daily Star and Daily Star Sunday – the Com- to new equipment, this major investment is all the more significant and shows huge faith in the future of printed newspapers within a Two Commander CT press lines totalling 22 four-high towers for West Ferry Printers 38 Report 37 | 2010 multi-platform industry. This massive investment signals that the future for news is not just about iPads, electronic publishing and digital presses. Dramatic reduction in operation and maintenance times The four highly automated, doublewide Commander CT presses comprising 22 Pastomat reelstands, 22 compact four-high towers and four heavy-duty KF 7 jaw folders will be embedded in an automated paper logistics system. David Broadhurst, who has Commander press lines in the north west of England at Broughton Printers in Preston, said: “The high level of automation will extend throughout the press line, dramatically reducing the time input required for operation and maintenance. PlateTronic automatic plate changers, RollerTronic automatically ad- A Commander CT with 15 towers and three folders went live last year at the Daily News in New York just-able roller locks and NipTronic bearing units for automatic adjustment of printing pressure are further examples of the Commander CT’s innovative technology.” 3 4 2 1 5 4 13 4 11 14 12 6 5 8 7 9 10 The quick-response inking units with three forme rollers and precision spray dampeners in the Commander CT support a high print quality in both coldset and heatset operation The 4/2 presses will have a maximum output of 90,000 copies per hour, a 578mm (22.75in) cutoff on a 1,156mm (45.5in) cylinder circumference and a maximum web width of 1,460mm (57.5in). They will come complete with ErgoTronic consoles featuring EAE’s Print production scheduling and press presetting software. There is also a significant amount of Baldwin technology included with the KBA press, following a successful installation at Broughton Printers. This includes web cleaning equipment, ink train cleaning systems and Maxima spray bars. Broadhurst added: “The £100m investment is split between the north and south print centres. We have a stage two option with KBA for the supply of a further twelve units and two folders of the same CT for Preston together with an additional unit for the existing Commander.” 1 Blanket cylinder 2 Plate cylinderr 3 PlateTronic automatic plate changer (optional) 4 Ink forme roller 5 Ink drum (oscillating) 6 Ink transfer roller 7 Film roller 8 Ink-duct roller 9 Ink duct 10 Spray bar 11 Dampening distributor roller 12 Dampening roller 13 Dampener forme roller 14 Blanket washing unit The Commander CT’s high level of automation and compact design, with towers that split down the centre at the touch of a button, make for easy handling and fast edition changes Major milestone in KBA’s long history KBA executive vice-president for web press sales Christoph Müller commented: “The fact that we are West Ferry Printers’ vendor of choice is both an honour and a responsibility. The commissioning of this big KBA Commander CT installation in our 194th year represents a major milestone in a history dating back to the invention of the mechanical printing press by our company founders in early nineteenth century London.” Commitment to print Northern and Shell owner Richard Desmond added: “I am delighted to announce this investment in our print products. The Daily Express and Sunday Express will benefit massively from expanded editions, full colour for readers and advertisers, and later deadlines meaning even fuller coverage of breaking news. This move will also allow us to accommodate the rising circulation of the Daily Star. A few years ago I made a pledge that we would remain committed to our print products and would invest whatever it took to keep control of our printing in our own hands. This upgrade puts our group at the cutting edge of print technology and will give us a vital edge on our rivals in these competitive times.” Gary Cullum/Klaus Schmidt [email protected] Report 37 | 2010 39 Newspaper Production | Innovation German media house Der neue Tag in Weiden has signed up for the first triple-wide Commander CT in Europe he 48pp, twin-tower press line will be installed in a new printing plant on an industrial estate in west Weiden, and is scheduled to go live in summer 2011, replacing a 1995-vintage Express. In addition to the press hall the 16,000m² (172,000ft²) site will also accommodate a warehouse, a new mailroom complete with loading hall, and a pre-press department integrated in the printing centre. T “Voice of the region” Founded on 31 May 1946 by Anton Döhler and Victor von Gostomski, Der neue Tag looks back on a close and longstanding association with KBA. Speaking at the groundbreaking ceremony for the new print centre, publisher and board member German Vogelsang explained that the purpose of this, the biggest investment in the company’s history to date, was to strengthen newspapers as the “voice of the region”. He said: “This ambitious project is a vote of confidence in the region and, naturally, in our core business. This high-tech press from Koenig & Bauer will enable us to print our newspapers, freesheets, supplements and magazines with even greater timeliness, flexibility, efficiency and economy, and in superb full-colour quality.” Now owned by the Döhler, Shanahan, Vogelsang and Panzer Der neue Tag in Weiden, Germany, invests in compact newspaper press technology First triple-width Commander CT in Europe German newspaper and media house Der neue Tag in Weiden, Northern Bavaria, is gearing up for future success with a €25m ($32.3m) investment package aimed at substantially expanding its production and publishing activities. It will become the first user in Europe to install the triple-width version of our compact and highly automated Commander CT. families, the media house employs more than 400 staff. Alongside Der neue Tag, which is the biggest-selling daily in the region, it publishes two other regional titles, the Sulzbach-Rosenberger Zeitung and Amberger Zeitung, plus five local editions. The total daily circulation of its titles is around 84,000 copies. The company also publishes and prints a number of weekly freesheets which, like the newspaper titles, serve a good two-thirds of the Upper Palatinate region. To maintain a high level of production capacity Der neue Tag also contract prints freesheets and other newspaper-related products. Trailblazing press technology Our practice-proven PlateTronic automatic plate changers support high-speed job changes 40 Report 37 | 2010 The Commander CT 6/2 press line for Der neue Tag will be configured with a substructure and engineered for a maximum web width of 1,890mm (74.4in). Its maximum rated output will be 90,000 fullcolour copies per hour in straight production. The two compact triplewidth towers will feature PlateTronic automatic plate changers, RollerTronic automatic roller locks, NipTronic cylinder bearings, FanoTronic fan-out compensation, automatic colour register control, CleanTronic blanket washing and central ink pumping. The two Pastomat CL reelstands will be embedded in a Patras A automated reel-logistics system with integrated stripping station and daily store. Other features will include two double turner decks, a folder superstructure with three formers, a KF 5 jaw folder, a section stitcher, a skip slitter and a variable perforation unit for tear-out ads (“Zip’n’Buy”). Options also include half-covers and flying pages. A combination of reel alignment units, cut-off register controls and web guidance systems will ensure that start-up waste is reduced to a minimum. The Commander CT 6/2 will be controlled from two ErgoTronic consoles incorporating KBA production scheduling and press presetting functions along with KBA EasyStart and EasyStop modules. Publishing house manager Reinhold Pöll says: “Tours of Commander CT installations in Würzburg and New York compellingly demonstrated the benefits delivered by the various automation modules in terms of makeready times, waste reduction and print quality, plus ease of operation and maintenance. The compact design reduces walking distances for the press crew and facilitates handling.” Klaus Schmidt [email protected] NN publisher Hans Wilhelm Baur says: “The technology used to print our newspaper titles at our production plant in Neureut, a suburb of Karlsruhe, has always been of the highest standard. Continuing our policy of choosing cutting-edge technology, next year we’ll be replacing a 1995vintage Commander satellite press and 2001-vintage ten-cylinder satellite press line with a new, compact 6/2 Commander CT. Since the CT can be made ready much faster and its output is much higher, it will dramatically cut production times for all our titles. This will give us much greater flexibility while enhancing productivity. It will also deliver an even better print quality and, for our press operators, be even easier to handle than its predecessors.” BNN publisher Hans William Baur (third right), managing director Joachim Ernst (right) and head of technology Georg Siepmann (2nd left) pictured with (from left) KBA head of printing unit engineering Bernhard Harant, executive vice-president of web press sales Christoph Müller and sales manager Matthias Horn after signing the contract B Major daily title in the Karlsruhe area Under the guidance of Wilhelm Baur, who co-founded the company in 1946 and later became sole publisher, and his successor Hans Wilhelm Baur, the newspaper publishing house has evolved into a leading media enterprise both in the Karlsruhe area and in the region between the Black Forest and the Rhine valley. The Badische Neueste Nachrichten, which has a total daily circulation of some 150,000 copies and over 400,000 readers, is one of the best-selling newspapers in Baden-Württemberg. Headline news sections – politics, sport and business – are covered by 90 fulltime editors at the Karlsruhe headquarters plus a network of stringers in Europe and the rest of the world. Local news, which has steadily gained in significance in recent A further Commander CT 6/2 for Germany Badische Neueste Nachrichten snaps up 6/2 Commander CT Badische Neueste Nachrichten (BNN) in Karlsruhe is the latest in a line of prominent German newspaper publishing houses to succumb to the attractions of our 6/2 Commander CT. On 1 July the contract was inked for a 96pp press comprising four reelstands, four printing towers and two folders. Commissioning is slated for the end of next year. years, is handled by ten local editorial offices throughout the paper’s distribution zone. Alongside the BNN, which is published in separate editions for Karlsruhe, Hardt, Rastatt, Baden-Baden and Ettlingen, there are nine local titles of which the Pforzheimer Kurier, Bruchsaler Rundschau, Brettener Nachrichten and Acher- und Bühler Bote are but a few. BNN editor-in-chief and co-publisher Klaus Michael Baur says: “We are squaring up to the challenges posed by the transformation of the media marketplace in the twentyfirst century by enhancing our flexibility, in terms of what and how we publish, while maintaining the intellectual gravity and quality of our daily titles. This blend of tradition and innovation will enable us to safeguard the success of our regional titles.” 2,100mm web width for greater flexibility Engineered for the Rhine format, the new triple-wide Commander CT will have a 510mm (20in) cutoff and a maximum web width of 2,100mm (82.67in). BNN head of technology Georg Siepmann explains: “The CT’s short makeready times and high level of automation will give output an enormous boost. In future we’ll be able to print up to 45,000 copies per hour, each with as many as 96 full-colour pages. Pagination changes for the many different titles can be initiated automatically from the console. In addition we’ll have the option of using 5/12, 7/12 and 11/12 web widths to produce innovative ad forms such as spadias.” The Pastomat reelstands will be located beneath the press and fed with paper via a Patras A automated reel-logistics system complete with a stripping station. The printing towers will incorporate PlateTronic automatic plate changers, RollerTronic automatic roller locks, NipTronic bearings, FanoTronic fan-out compensation, automatic colourregister controls, CleanTronic blanket washing, inking-unit washing systems and central ink pumping. Extras will include four double turner bars, two folder superstructures with three formers apiece, two KF 5 jaw folders, cut-off register controls, variable perforating devices for tear-out (“Zip’n’Buy”) perforations, gluing units and a four-page centre spread capability. Ink-density controls, a skip slitter, section and ribbon stitchers can be retrofitted if required. The 6/2 Commander CT will be controlled from three ErgoTronic consoles featuring EasyStart and EasyStop automation modules to reduce waste and manual intervention during press start-up and edition changes. The press will be embedded in an upgraded EAE Print production scheduling and press presetting software suite. Klaus Schmidt [email protected] A compact newspaper press line for the Badische Neueste Nachrichten: the 96pp, triple-width Commander CT for a web 2,100mm wide Report 37 | 2010 41 Newspaper Production | Sweden The modular, waterless Cortina for MittMedia Print in Sundsvall, northwest Sweden, is the eighteenth press of this type to leave KBA’s production line MittMedia Print greens up with waterless offset Heatset Cortina for Sweden MittMedia Print, a subsidiary of Sweden’s fourth-largest media group MittMedia Förvaltnings in Gävle, is gearing up for sustained growth and expanding its product spectrum with a compact waterless Cortina whose hybrid coldset/heatset capabilities will enable it to print semi-commercials (supplements and magazines) alongside newspapers. ince there is no fan-out in waterless offset it is possible to produce high-quality hybrid copies containing both heatset and coldset sections. The press line for MittMedia Print will be the eighteenth Cortina to leave the KBA production line, but the first such installation in Sweden. The investment package includes new finishing kit and an extension to MittMedia’s production plant in Sundsvall, where the Cortina is scheduled to come on stream in spring 2011. A city with around 95,000 inhabitants some 400km (250 miles) north of Stockholm on the Baltic coast, Sundsvall was previously dominated by paper and pulp production but has since evolved into a centre for celluloseand aluminium-processing industries, IT and telecommunications. S Ideal press for a burgeoning hybrid market “Our strategic investment in the titles printed in Sundsvall – the Sundsvalls Tidning and Dagbladet – furnishes the technology to address a brisk demand for tabloid products on coated stock,” says MittMedia Print managing director Jan Andersson. “We want to gain a foothold in the heatset and hybrid market with all possible speed. So the Cortina, 42 Report 37 | 2010 with its outstanding image quality, fast makeready and unique, rapid conversion between coldset and heatset with no change of ink, is the perfect press for this purpose. Its impressive green credentials, with minimum waste and a total absence of fount solution, also appeal to environmentally sensitive print buyers.” Unique features The double-wide press line with a 560mm (22in) cut-off and a maximum rated output of 75,000cph will initially comprise two Pastomat reelstands, two compact four-high towers and a KF3 folder, but provision has been made for future extensions. It will be capable of printing 64pp tabloid copies in full colour. PlateTronic automatic plate changers and automatic conversion from the maximum web width of 1,590mm (62.5in) to another width, eg 1,260mm (49.5in) for magazines, support high-speed job changes. The Cortina’s unique NipTronic bearing technology, which guarantees optimum impression pressure and can be adjusted quickly and easily for different stock types, is another winning feature, while our innovative ribbon-splitting device cuts the conversion times for different tabloid formats. MittMedia Förvaltnings managing director Jan Cahling, KBA sales director Jochen Schwab and MittMedia Print managing director Jan Andersson (l-r) signing the contract in Gävle at the end of February watched by KBA sales manager Ulf Funke, Svein Grødum of GCON Consulting, Anders Skäär of KBA Nordic sales, MittMedia Print production manager in Gävle Kenneth Jansson and MittMedia quality coordinator Monica Dahlström The webs run unturned through the two formers, after which the slit ribbons are assigned to the relevant stitchers. This makes it much easier to produce tabloid sections with different page counts. The customised superstructure has four turner bars, two bay-window rollers and two formers above the folder to support a wide choice of products. Copies can be delivered glued, stitched, perforated and/or with a quarterfold. The Cortina will be controlled from an ErgoTronic console with presetting software. Automatic colour and cutoff register controls, CleanTronic blanket washing and a raft of other features will enable the press to deliver a superb image and fold quality with minimum waste. Says Jan Andersson: “This highly advanced compact press can print and inline finish premiumquality newspapers and semi-commercials fast and cost-effectively, in runs ranging from ultra-short to 300,000 copies. Our upgraded finishing department can create tabloid copies with up to 128 pages. The new technology package af- fords opportunities that were previously unknown in Sweden, and we are exploiting its unique capabilities to expand still further in the regional market.” Major milestone MittMedia’s production plant in Gävle already operates a Journal web press. In 2004 its Östersund facility fired up an eight-tower Continent. The MittMedia Förvaltnings media group owns 17 regional newspaper titles in central and northern Sweden with circulations totalling 280,000 copies per day. In addition to newspaper publishing and digital media the group’s activities include distribution, commercial radio and commercial printing. Following rapid growth through acquisitions in 2005 and 2008, last year the group’s workforce of 1,700 generated sales of €160m ($207m). Subsidiary MittMedia, which operates seven printing plants and has a total of 115 employees, posts annual sales of around €30m ($39m). Klaus Schmidt [email protected] Newspaper Production | Finland otnia Print’s enthusiastic production staff ensured that commissioning and acceptance went without a hitch in just a few weeks. The printing plant’s official inauguration in September will be followed by a KBA user meeting at which press demos will be given for the benefit of other Scandinavian newspaper printers. For KPK chairman Juhani Hautamäki and the management team, HSS Media CEO Hans Boije and KPK CEO Antti Porko, the Cortina’s impressive performance since launching into operation is confirmation that they made the right decision in opting for innovative waterless technology. The press crews soon became accustomed to their new press and are delighted with its ease of handling, short makereadies, superior print quality and low maintenance. Says Mr Porko: “Our objective in installing the Cortina was to consolidate our technological edge. We have not only achieved this objective but have reaped economic and quality benefits into the bargain.” B Botnia Print’s brand-new production plant in Kokkola houses the first Cortina in Finland and the first 4/1 Cortina worldwide Checking the first prints off the press Waterless newspaper production at Botnia Print Finland’s first 4/1 Cortina goes live in Kokkola In May this year the world’s first double-width, single-circumference Cortina rolled into action at a brand-new production plant inaugurated by Botnia Print, a joint venture by Finnish media houses HSS Media and KeskiPohjanmaan Kirjapaino (KPK). This milestone event in the port of Kokkola was followed a few months later by the start-up of a multi-unit 4/1 Cortina press with four heatset dryers at the Gulf News in Dubai. Waterless newspaper production now widespread The Cortina in Kokkola was the sixteenth to come on stream. So far 68 of the 84 4/2, 6/2 and 4/1 towers sold, or 16 out of 18 press lines, are now in daily operation. Waterless, keyless newspaper production with the Cortina has thus long since become a matter of routine in many places. A 4/1 Cortina with a hybrid coldset/heatset capability is currently awaiting shipment to a desert location in Dubai. It will be the first of its kind outside Europe and one of the biggest installations to date. Users appreciate the Cortina’s many benefits Along with high-speed edition changes supported by extensive automation, an outstanding print quality, environmentally friendly technology and the exceptionally low level of start-up waste typical of waterless, keyless offset, users of heatset Cortinas cite the fast, easy changeover between coldset and heatset production – using the same inks – as one of the press’s biggest virtues. The Cortina’s ability to handle different web widths In addition to three daily and more than thirty weekly titles the Cortina prints a raft of products in different formats for greater format flexibility when printing supplements and special publications is also a huge asset compared to conventional presses with ink keys. The 4/1 Cortina in Kokkola, which is configured with four fourhigh towers and two KF 3 jaw folders, has a 560m (22in) cut-off and a maximum web width of 1,600mm (63in). It can pump out 150,000 full-colour tabloid copies per hour, each with a maximum of 32 pages. The press’s high level of automation encompasses colour and cut-off reg- ister control, blanket washing and central ink pumping. The Patras A paper logistics system to which the Cortina is connected is also fully automated. Depending on specifications, the printed copies can be stitched, glued, perforated or scored, and delivered after the quarterfold. Originally established as a newspaper publishing house in 1917, Keski-Pohjanmaan Kirjapaino has since evolved into a modern multimedia group. Among the many products printed on the Cortina are Waterless, compact, user-friendly and easy to maintain: the Cortina’s many virtues are fully appreciated by the press crew in Kokkola three regional dailies, Keskipohjanmaa, Österbottens Tidning and Vasabladet, plus over thirty weekly titles. Klaus Schmidt [email protected] Report 37 | 2010 43 Newspaper Production | Italy o one tower can print 12 broadsheet or 24 tabloid pages per impression, while the entire press line can deliver 36 broadsheet or 72 tabloid pages. The Colora is scheduled to come on stream at a contract printing plant in Medicina, approximately 30km (19m) east of Bologna, at the end of the year. S Respected newspaper specialist Qualiprinters, Colasanto’s contract production plant in Medicina, prints some 40 international, national and local newspaper titles plus diverse weeklies and monthlies. In addition to Bologna the Colasanto Group operates printing plants near Milan, Rome and Naples (Benevento). It thus has facilities at convenient transport hubs affording quick and inexpensive access to domestic publishers’ distribution areas throughout Italy. For greater customer proximity in central Europe Colasanto also has three production plants in Belgium – one to the north and two to the south of Brussels. Well geared for the future Michele Colasanto, head of the Medicina plant, says: “We are delighted with the KBA Continent that came on stream in 2005 at our plant in Oricola-Carsoli, near Rome. Of the twenty-odd presses we operate within the Group, most of which are two-across and onearound, the KBA is by the far the best in terms of print quality, output and production flexibility. This, and our highly successful relationship with Koenig & Bauer, are what prompted us to invest in a second KBA newspaper press, especially since the new one is custom-engineered.” The 3/2 Colora for Editorial underscores KBA’s pole position in the Italian newspaper market 44 Report 37 | 2010 The first 3/2 Colora press line worldwide will go into operation near Bologna at the end of the year Italian printer orders further KBA newspaper press Colasanto targets growth with customised Colora Italy may be experiencing a prolonged post-crisis recession that has impacted severely on investment in the print media industry, but there are a few cheering exceptions. Rome-based Editorial, part of the Colasanto Group, recently signed up for a customised Colora tower press that will give it much greater flexibility in printing its many titles. Instead of the usual four plates across the cylinder width the two-around press has just three, ie six per plate cylinder. The floor-mounted 3/2 Colora will primarily print tabloid copies and is engineered for the 620mm (24.4in) cut-off which is currently so popular in Italy. It has a maximum web width of 1,350mm (53in) and a maximum rated output of 75,000 copies per hour. It will comprise three Pastomat reelstands embedded in a Patras M reel-handling system, three four-high towers, a KF 3 jaw folder and a superstructure with two formers. The press line will be controlled from EAE consoles with provision for online remote maintenance. Says Michele Colasanto: “This configuration will afford much greater flexibility in meeting the needs of our print customers. As well as six single plates it can accept two full-width plates.” Klaus Schmidt [email protected] UV Offset | Germany As the saying goes, “Good things come to those who wait”, and that is certainly true of print enterprise Druckerei Gerhard Bohm in Zehlendorf, a suburb of Berlin. Although keen to invest in new kit, this dynamic company in the south of the German capital took its time in deciding precisely which press to choose. But the effort invested in a painstaking screening process since Drupa 2008 has paid dividends. The press of choice and the key to future success is a Genius 52UV, whose ability to print unusual products will support a much bigger portfolio. KBA-Metronic’s Genius 52UV now in the capital Berlin printer gets in gear for specialist production ntil then Bohm was just one print enterprise among many. Founded 132 years ago, it has been headed for the past eighteen years by Mariana Weihe, whose enthusiasm for the press is evident: “With the Genius 52UV we can now expand our product range with substrates we were previously unable to print. These include mousepads and table mats, waterproof labels and plastic point-of-sale signs, 3-D postcards and lenticulars – the list is as endless as the possibilities the press offers.” match that in A3-plus format,” says Ms Weihe. Another big asset for a family-run business whose core strengths lie in its agility and flexibility is that using UV inks allows it to print non-absorbent substrates. Which doesn’t mean the Genius 52UV is limited to printing plastic sheets – Bohm can continue to print conventional substrates such as paper and board because the Genius can handle these with ease as well. Greater flexibility in meeting customer specs Asked what the biggest difference is in the Genius 52UV, Mariana Weihe responds instantly: “KBAMetronic’s waterless inking system, which virtually redefines offset.” She goes on: “We no longer have to set the ink keys, which saves a lot of time. Tedious colour matching and the inevitable colour fluctua- U Mariana Weihe and her team are delighted not just with the new options now open to them, but also with the brilliant technology. The Genius 52UV can print substrates up to 0.8mm (0.032in) thick. “No other press manufacturer can Benefits count in day-to-day business tions are a thing of the past. And of course water can no longer have a detrimental impact on the ink. Achieving the correct balance between ink and water is one of the major challenges in conventional offset. The Genius 52UV dispenses with all that hassle: ink application in its five keyless inking units requires no intervention whatsoever by the minder. Also, the sheets dry much faster, which shortens turnaround time substantially. Makeready is generally much quicker than with conventional offset presses. And the fact that start-up waste is just a few sheets delivers sizeable savings in material costs. The inks cure instantaneously, so the sheets can be finished with no interim storage – and there are no lengthy delays arising from poorly dried sheets.” Druckerei Bohm is well equipped for the Genius 52UV, Delighted with the Genius 52UV’s many virtues and the wide-ranging options it offers in everyday production: Babett Prokop (front), Mariana Weihe and Mario Weihe with computer-to-plate systems in pre-press. The only item that KBAMetronic had to supply was a developing device for the waterless offset plates. In the finishing department there is a collating machine and a glue-binder for producing brochures and catalogues, plus a folding machine, a hand-operated die-cutter, a scoring device and a drill. On 25 and 26 March this year Bohm held an open house at its premises in Berlin-Zehlendorf. Attendance was high, with existing and potential customers seizing the opportunity to watch the Genius 52UV in action and to discuss the new dimension it represented in offset printing at Bohm. Klaus Schmidt [email protected] Report 37 | 2010 45 Shorts ollowing a string of installations in various parts of the world, the B2 (29in) Rapida 75 launched at Drupa 2008 made its successful Thailand debut early this year at Thammasat Printing House, a production facility attached to Bangkok’s Thammasat University. For Thammasat Printing House’s production head Pitsanu Napakorn it was the fulfilment of a longstanding ambition. Thammasat University was founded in 1934 as the University of Moral and Political Sciences, and is often called the “University of the People” because of its efforts to make higher education accessible to all classes of society. Thammasat Printing House, which was established in 1940 by the university founder, Pridi Banomyong, started off printing textbooks and exam papers. While the number of presses steadily increased, colour capacity remained unchanged and colour print jobs had to be contracted out. When the F The Rapida 75 represents a big improvement for the press crew Thammasat Printing House’s production head Pitsanu Napakorn has found that production is much more efficient with the new Rapida 75 Rapida 75 makes successful debut in Thailand funding was finally approved in 2009, things moved fast. Pitsanu Napakorn recalls: “We scrutinised offers from several vendors, but in the end we were unanimous in choosing the Rapida 75. KBA has an outstanding image among Thai printers, and there are any number of reference installations. The new Rapida 75 is com- pact, fast and economical. Its practical level of automation and short makeready times have enabled us to expand production substantially and streamline the workflow. Also, KBA agency Intergraphics provides an excellent service.” The Rapida 75 was custom-configured to meet the demands of a university printing plant. A digital press handles ultra-short print runs of up to 100 sheets, while the new 15,000cph Rapida is reserved for runs of 500 to 2,000 copies and prints up to ten jobs per day in oneshift operation. Products range from brochures, pamphlets, magazines and catalogues to degree certificates and admission tickets for the Royal Palace. Chili Padi open house in Kuala Lumpur At the open house the compact Rapida 75 compellingly demonstrated its fast makeready, simple handling and superb print quality Stefan Segger (centre, back), his team from Malaysia and Singapore and staff from KBA-Grafitec expressing their delight at the success and popularity of the open house t the end of April KBA Asia Pacific held an inaugural open house at its new company premises on the outskirts of the Malaysian capital, Kuala Lumpur. More than 160 commercial and packaging printers nationwide answered the call to “come & taste KBA’s chili padi”, a reference to Malaysia’s popular national dish containing small but fiery chilli peppers. The focus of the event was an equally fiery Rapida 75 six-colour coater press that demonstrated print pro- In his opening address, KBA Asia Pacific managing director Stefan Segger interpreted the exceptionally high level of attendance as a reflection of the Rapidas’ outstanding reputation in the high-growth Malaysian market. The turnout was equally high at KBA’s road shows in Kuala Lumpur and Jakarta in November 2009. Malaysia has long been a major export market for KBA presses. Alongside brisk growth in the sales of new Rapida presses, in recent A 46 Report 37 | 2010 duction on a wide range of substrates. The print pros present were visibly impressed by the Rapida’s fast plate changes and makeready. Hosting the demonstrations, KBA sales manager Rex Teng highlighted the press’s easy handling, flexibility and economy. The Rapida 75 is not only the most compact B2 (29in) press on the market, but also the most energy-efficient. This was demonstrated with the aid of an electricity meter at Ipex in Birmingham. years sales of second-hand equipment have also taken off. Throughout the region there are perceptible signs of a sustained upswing in investment, in Indonesia as well as Malaysia. By the end of April this year KBA Asia Pacific had already surpassed its total sales figures for 2009. Shortly after the open house the Rapida 75 six-colour coater press demonstrated went live at Dragon Hitech Printing in Kuala Lumpur. Shorts Left: Central Printing production manager Tan Wee Chan (l), pictured here with KBA Asia Pacific sales manager Rex Teng, is delighted with the company’s second-hand Rapida 72 Right: The ten-year-old Rapida 105 made a fine start at Easy Print Studio in Kuala Lumpur, as executive director Fok Boon Leong, production manager Lim Tiam Seng and KBA Asia Pacific sales manager Rex Teng (l-r) can attest Far right: At Eastsun Superior Print in Kuala Lumpur a Rapida 104 six-colour coater press built in the 1990s has joined four Planeta Variants Burgeoning demand for secondhand kit in Asia he outstanding reputation Rapida sheetfed offset presses enjoy in the growth markets of Southeast Asia is not confined to the latest generation. KBA Asia Pacific is also doing a brisk trade in second-hand kit, particularly in and around Kuala Lumpur. The most popular models are the B2 (29in) Rapida 72 and 74 and B1 (40in) Rapida 104 and 105 universal. The surge in interest is driven by a widespread conviction in the market that the Rapidas are more rugged, last longer and deliver a better performance than some other makes of press. So when times are hard and budgets are tight T printers often opt for a good second-hand press in preference to a costly new one. Both in Malaysia and throughout the region KBA Asia Pacific has steadily expanded its service network over the past few years in order to improve both customer proximity and quality. Central Printing in Kuala Lumpur recently installed a fivecolour Rapida 72. Established in 2000, the fifteen-employee company prints packaging, books and promos. Managing director Loh Chee Boon says: “The Rapida made a fine start and in the first year will deliver a 50 per cent increase in turnover. We are equally satisfied with the project support and service provided by KBA Asia Pacific.” Another Kuala Lumpur enterprise, Easy Print Studio founded in the 1990s, opted for a secondhand Rapida 105 four-colour coater press. Directors Fok Boon Leong and Vincent Wong Chung Mun are pursuing ambitious growth objectives: “Here in Malaysia our MOOF and AEIOU brands are market leaders in gift packaging, bags, wrapping paper and other creative print products. We are confident that with the KBA press we can materially enhance our quality and portfolio, and anticipate a rise in annual sales from 2.5 to 4 million ringgit.” A six-colour coater version of the 105’s predecessor, the Rapida 104, was the press of choice for Eastsun Superior Print, which is also based in Kuala Lumpur. Since being launched by Tang Yen Fe in 1987 the company has built up a reputation throughout Malaysia and beyond for upmarket displays, labels and packaging. Management has relied on the quality of presses from KBA Radebeul for many years. The six-colour Rapida 104 is the company’s fifth KBA press to date, joining a medium-format Planeta Variant and three more in large format. Gopsons Papers in India orders brace of Rapida 130a presses opsons Papers, a major Indian book printer, sealed a deal on the KBA stand at Ipex for two 5B (51in) Rapida 130a four-colour litho presses. Delivery is slated for the end of the year to Sivakasi, in southern India, where a new production plant for quality books for Englishspeaking export markets is currently under construction. Gopsons’ headquarters in New Delhi already boasts eight KBA litho presses, among them a five-colour Rapida 74 and two four-colour plus one five-colour Rapida 105 during the past eight years alone. All are equipped with UV dryers and are G Delighted at signing a major contract from India at Ipex (l-r): Aditya Surana of KBA sales agency Indo Polygraph, Vasant and Sunil Goel, proprietors of Gopsons Papers, KBA sales director Dietmar Heyduck and Bhupinder Sethi, also of KBA sales networked with pre-press via CIP3. In future the plant in New Delhi will focus on production for the domestic market. The two Rapida 130a presses, whose raft of features includes automatic plate changing, will be the first large-format presses of this type to ship to India in some time. Established in 1950, Gopsons Papers has built up a global network of sales outlets. The company has been ISO 9001 accredited for many years now and has carried off a string of coveted prizes, among them accolades at the Printer of the Year Awards. Report 37 | 2010 47 Shorts Henan Daily orders third Comet press arlier this year Henan Daily Newspaper Group in Zhengzhou, the capital of China’s most densely populated province, Henan, reaffirmed its successful association with KBA by signing a contract for a third Comet press line. The order follows the installation in 2001 and 2005 of two Comet press lines with a total of eight towers and four folders. Henan Daily plant manager Chen Guo Sheng says: “The two single-width Comet presses demonstrate their high output, reliability and superior print quality day in and day out. Thanks to their flexibility and ease of operation, we can switch from one of our many inhouse and contract titles to another in a minimum of time.” Henan Daily general manager Zhang Jian is equally impressed. “We have always been 100 per cent satisfied with the support KBA has provided, from the initial concept right through to after-sales service. So it’s a pleasure to be working with KBA and the Comet once again as part of our expansion project.” Following a recent order for a Comet from Beijing Daily Group E Henan Daily general manager Zhang Jian (seated, centre) and vice general manager of the import company Qian Tong Cun (on his left) pictured with KBA sales director Stefan Segger after signing the contract in Zhengzhou at the beginning of February. Looking on (l-r) are Han Shao Sheng (KBA China sales), Mr Lu (Henan Daily administration), Chen Guo Sheng (Henan Daily plant manager), Andreas Friedrich (KBA sales manager), Mr Wang (Henan Daily finances), Liu Shan Jun (Henan Daily deputy plant manager) and Wang Hong Feng (KBA China sales) KBA sales director Stefan Segger was delighted to receive a second order from China for this popular press type within just a few months. “The new press line will make Henan Daily the biggest Comet user to date in China. This latest contract reflects the esteem in which our newspaper press technology is held among Chinese media houses.” The new 75,000cph Comet press for Zhengzhou will come on stream this autumn. In addition to high-circulation titles such as the Henan Daily, Dahe Daily and Henan Commercial Daily the Zhengzhou plant contract prints a large number of other publications. These include several in English – China Daily, China Youth Daily, Workers Daily and Peoples Daily. The four-high press with a cylinder circumference of 1092mm (43in) and a web width variable between 630 and 870mm (24.85 34.25in) will comprise four Pastoline reelstands, three towers with fan-out compensation and colour register controls, and a KF3 jaw folder. The contract includes three KBA consoles with colour preset and diagnostics PC. Comet with dryer for cost-effective book production few months ago Compañía Editorial Ultra fired up a Comet at its production plant in Mexico City. The new press, which features a four-high tower for 4/4 and a heatset capability and is used to print books, follows a Compacta 215 delivered in 2004. A longstanding KBA customer, Editorial Ultra is a family enterprise which was established in 1983 and is headed today by three brothers. Over the years it has built up a reputation throughout Mexico and beyond for high-quality books, periodicals, brochures and flyers. Since the 1980s these have been printed on Compacta commercial web presses. Alongside their fast-growing domestic market Mexican printers have long since expanded into the A 48 Report 37 | 2010 high-volume US market. Mexico is one of the biggest printing hubs in Latin America, alongside Brazil. So flexible, cost-effective press lines like the Comet, which is operation the world over, are in brisk demand among Mexican printers. General manager Enrique Espinosa says: “The single-width heatset Comet, with its high output, reliable operation, fine print quality and production flexibility, was custom-configured to our specifications. Its performance has surpassed all our expectations. It has enabled us to produce books much more cost-effectively and to drive growth in the market with much more competitive prices.” The Comet has a 578mm (22.75in) cut-off and a web width variable from 630 to 1,000mm (24.85 - 39.37in). For book production full-circumference plates are used. The maximum rated output is 75,000 copies in straight-run production. The floor-mounted press is fed with paper from a Pastoline reelstand embedded in a Patras M reelloading system. Special features include a chill roller stand, a folder superstructure with one former and a heatset-compatible KF 3 SC jaw folder. Auxiliary features such as a second cross fold, a quarter fold, gluing and perforating devices support a wide choice of inline finishing options. The control system for colour and cut-off register incorporates mRC cameras supplied by QI. The press is controlled from two KBA consoles. From the left: Herbert Schmidt of KBA agency Offset KBA Mexico, Enrique Espinosa of Editorial Ultra and sales director Kai Trapp of KBA captured by the camera at the new Comet Shorts Commander CT demonstrates cutting-edge newspaper printing t the end of May, veteran KBA user Heraldo de Aragón held an open day at its production plant, Impresa Norte in Villanueva de Gállego, drawing representatives from just about every major newspaper printer in Spain. It was the perfect opportunity to demonstrate the capabilities of the company’s new compact Commander CT press. Those present were particularly impressed by the CT’s performance and ease of operation, and by the superb quality of the full-colour prints delivered. After welcoming the assembled guests, José Manuel Lozano Orus, managing director of the Heraldo Group, focused attention on the A high-tech printing centre with its Comet press (installed in 2005) and new Commander CT. He emphasised that the company’s investment in the highly automated CT would enable it to unlock crucial production and cost benefits in a shifting market environment. KBA sales manager Christian Klein outlined the numerous advances in newspaper press technology that KBA has achieved in recent years. The compact Commander CT and its waterless counterpart, the Cortina, are two outstanding example, encompassing a whole host of unique features. A representative from 3TControl, a Heraldo Group start-up, gave Impresa Norte production director Miguel Angel Pérez (right) explaining the finer points of his compact and highly automated Commander CT press a briefing on the company’s closedloop automation system for measuring and controlling the presses’ colour and cut-off register and ink density. The event concluded with a tour of the facility and a print demonstration on the Commander CT. Premiere for Genius 52UV and Universys in Romania L-r: Gabriel Petcu (Prosystem), M-F Osiac, A Cracium, N Viorel, O A Bila and C Ududoiu (all from Moniorul Oficial) pictured at the Genius 52UV in KBA-Metronic’s training centre with instructors Jürgen Leib (print) and M Klafke (pre-press) Prospective Universys technicians and operators were able to familiarise themselves with the new kit during a week-long training course at KBAMetronic’s experimental printshop in Veitshöchheim, Germany omania’s pre-eminent printing house, Bucharest-based Monitorul Oficial, is boosting production capacity with a B3 (20in) Genius 52UV litho press and a Universys card personalisation system from KBA-Metronic. The company is planning to expand its product R Alongside books, business stationery and commercial jobs Monitorul Oficial prints Romania’s biggest daily newspaper by circulation, The Official Journal portfolio in the long term by adding plastic films and special substrates. Alongside book covers the Genius will mainly print multi-up products which will then be personalised on the Universys. Head of technology Christian Ududoiu is fascinated by the Genius: “What caught our eye was its ability to switch from one job to the next in just a few minutes, and deliver saleable products after just ten start-up sheets. Unlike our large-format machines the Genius 52UV requires no alcohol or powder. The inks dry immediately. There are no delays when printing work and turn, for example, or prior to finishing. UV inks not only allow us to print on sensitive, non-absorbent materials, they also speed up production processes.” He continues: “Our customers will benefit from our ability to print substrates with metallised or extremely smooth or shiny surfaces, and even plastic films such as PVC, polycarbonate, polystyrene, polyethylene, PET and ABS. The coater supports both protective and spot coatings, matt and glossy effects. We can print cost-effectively even in short runs because waste is minimal.” The module-based Universys system is designed for the 85.5 x 54mm (3.4 x 2.1in) ISO card format. Monitorul Oficial will use it to personalise cards printed in multiup production on the Genius 52UV and these will then be laminated and die-cut in the finishing department. The Universys will mark the individual cards, eg with PIN num- bers, character fields or barcodes, via two inkjet printing heads. With the Universys it is even possible to hot stamp a label onto the cards, for example to prevent the pin codes on telephone cards from being seen by third parties. The Universys also features a magnetic strip encoder, making it possible to both write on and read the magnetic strips on the lower part of the card. The cards can be inline printed in either landscape or portrait format. A control camera monitors the printed data and compares it with the database. The Universys can personalise paper and plastic cards between 0.25 and 0.8mm (0.01 - 003in) thick. Website: www.monitoruloficial.ro Report 37 | 2010 49 Shorts KBA users carry off awards from International Newspaper Color Quality Club Some of the 36 winning titles printed by users of KBA newspaper presses, who submitted one-third of the 109 titles accepted by WAN-IFRA’s International Newspaper Color Quality Club 2010-2012 his year 162 newspaper titles from 43 countries worldwide competed for membership of WANIFRA’s exclusive International Newspaper Color Quality Club 2010-2012. Alongside coldset titles the jury assessed heatset products for the first time. Once a month, from January to April, applicants had to submit print samples featuring a prespecified test element. Two copies of each title from actual production runs were also scrutinised for quality by a panel of experts. At this, the ninth selection trials since the Club was founded, 109 titles fulfilled the rigorous criteria for outstanding quality in colour newspaper production and were granted much coveted mem- T bership for two years. The awards ceremony is scheduled for October at the IFRA Expo newspaper trade fair in Hamburg. 36 titles – one third of the winners – were printed on KBA web presses. Users of our compact Commander CT (New York Daily News) and KBA Cortina (Freiburger Druck und Rheinpfalz) were among the topmost rankings. The award-winning KBA newspaper customers are: • Allgäuer Zeitungsverlag, Kempten, Germany (Allgäuer Zeitung); • Dar Alyaum for Press, Printing and Publishing, Dammam, SaudiArabia (Alyaum Newspaper); • Freiburger Druck, Freiburg, Germany (Badische Zeitung, Der Sonntag); • National Zeitung und Basler Nachrichten, Basel, Switzerland (Basler Zeitung); • Büchler-Grafino AG Druckzentrum, Bern, Switzerland (Berner Zeitung); • DB Corp Ltd., Jaipur and Ahmedabad, India (Dainik Bhaskar, Divya Bhaskar); • Diligent Media Corporation Ltd., Bangalore, India (DNA); • Wegener Nieuwsdruk Twente, Enschede, Netherlands (De Twentsche Courant Tubantia, Hengelo’s Weekblad); • The Printers (Mysore) Pvt. Ltd., Bangalore, India (Deccan Herald); • Rheinpfalz Verlag und Druckerei, Oggersheim, Germany (Die Rheinpfalz); • Göttinger Tageblatt, Göttingen, Germany (Foto Presse); • FAZ – Frankfurter Allgemeine Zeitung, Mörfelden and Potsdam, Germany (Frankfurter Allgemeine Sonntagszeitung, Frankfurter Allgemeine Zeitung); • Druck- und Verlagshaus Frankfurt am Main, Neu-Isenburg, Germany (Frankfurter Rundschau); • Concentra Uitgeversmaatschappij, Hasselt, Belgium (Gazet van Antwerpen); • Wegener Nieuwsdruk Gelderland, Apeldoorn, Netherlands (Havenloods Noord); • Feza Gazetecilik, Istanbul, Turkey (Zaman); • Ungeheuer + Ulmer, Ludwigsburg, Germany (Ludwigsburger Kreiszeitung); • Verlag Lensing-Wolff, Münster, Germany (Münstersche Zeitung); • New York Daily News, USA (New York Daily News); • Nordost-Druck, Neubrandenburg, Germany (Nordkurier); • OÖN Druckzentrum, Pasching, Austria (Oberösterreichische Nachrichten); • Rheinisch-Bergische Druckerei, Düsseldorf, Germany (Rheinische Post); • West Australian Newspaper Ltd, Perth, Australia (Seven Days Magazine, The West Australian, West Weekend Magazine); • Tamedia, Zurich, Switzerland (Tages-Anzeiger); • Singapore Press Holdings Ltd (The Straits Times); • Mediacorp Press Ltd in Singapore (Today); • V-TAB, Västerås, Sweden (VLT); • Wetzlardruck, Wetzlar, Germany (Wetzlarer Neue Zeitung); • Brune-Mettcker Druck- und Verlags-GmbH, Wilhelmshaven, Germany (Wilhelmshavener Zeitung); and • Heilbronner Stimme, Heilbronn, Germany (Heilbronner Stimme). Congratulations to the new Club members on this outstanding achievement. A further Rapida 106 for Fischer in Switzerland ollowing the installation of a Rapida 106 five-colour B1 (41in) coater press with extended delivery in 2008 Swiss enterprise Fischer AG für Data und Print has ordered a second, identical press line for installation in a joint media, prepress and print production plant which Fischer is building at the new Grünau business park in Wabern in alliance with Ast & Jakob, Vetsch. The two companies’ product offerings are a perfect fit: Ast & Jakob, Vetsch prints promos and boasts a broad customer base among advertising agencies and service providers, while Fischer’s strengths F 50 Report 37 | 2010 Fischer AG für Data und Print will soon take delivery of its second Rapida 106 five-colour coater press lie in marketing and publishing services for the magazine sector. According to head of technology Daniel Troxler, the two presses will afford much greater flexibility in multiple shift production. He says: “What persuaded us to go for a second Rapida 106 was the enor- mous productivity, and more specifically the absolute reliability, of the first 106 installed in 2008: two identical high-powered presses form the centrepiece of a fleet that enables us to fulfil every customer demand in terms of both quality and performance.” Fischer purchased a five-colour Rapida 105 coater press in 2005 and followed this up with a fourcolour coater version in 2006. Shorts Straubinger Tagblatt celebrates 150-year jubilee with Commander CT n 3 May celebrations were the order of the day for publisher Martin Balle and all his staff at the Straubinger Tagblatt/Landshuter Zeitung media group in Germany. Attended by a host of luminaries from politics and business, Professor Balle pushed the button on a highly automated 64pp Commander CT press line at a new production plant in Lower Bavaria. On the same day the Straubinger Tagblatt also celebrated its 150-year jubilee. The Straubinger Tagblatt/Landshuter Zeitung media group employs over 500 permanent and around 1,500 freelance staff, plus a 1,500-strong delivery force. It publishes 15 newspaper titles with a total daily circulation of some 140,000 copies. In addition to the Straubinger Tagblatt, which first appeared in 1860, and the Landshuter Zeitung, which dates back even further, to 1849, the group publishes twelve local editions for southwest Bavaria and Rhineland-Palatinate, covering a corridor extending from Cham in the north to Freising in the south, via Bogen, Dingolfing and Vilsbiburg. It also has an active internet presence, a number of online titles and interests in local radio and television stations. The Straubinger Tagblatt and its sister publication, the Landshuter Zeitung, have cornered a sizeable share of the media market around Landshut and Straubing. One reason for their high standing is their extensive local news coverage. This O emphasis on local events and culture is something the group has consciously nurtured, and with considerable success. In the commemorative issue of the Straubinger Tagblatt printed on the Commander CT at the inauguration Professor Balle wrote: “This is the biggest investment in our history. It was the logical move because there is still a strong demand for print: the internet cannot compete with books and newspapers in providing intellectual nourishment for the spirit and the soul. In our immediate environment our newspaper titles remain a true documentary record of local events. We preserve the memory of the people in our local region.” Thanks to the new, high-output Commander CT, editorial close for all the group’s newspaper titles has been extended substantially, enhancing their immediacy. Their colour content has been expanded and print quality improved. The press also prints a broad palette of freesheets and supplements. The company has exploited its new capabilities and the Commander’s compelling performance to win a succession of external contracts that previously went to other printers. Production manager Wolfgang Heitzer says: “On top of the many benefits the Commander CT’s ergonomic design offers our press crew, the automation modules KBA has introduced over the past ten years ago or more, such as PlateTronic automatic plate changers, have progressively reduced makeready time, waste and maintenance input to a minimum. The press’s innovative yet conventional offset technology has enabled us to meet all our goals in terms of product immediacy, targetability, quality excellence and cost-effective production.” The 45,000cph press is configured with four extensively automated compact four-high towers for printing full-colour broadsheet copies (Berlin format) with a maximum of 64 pages or tabloid copies with up to 128 pages. It is fed with paper by four Pastomat C reelstands and incorporates two KF 5 jaw folders with two formers apiece. It is controlled from three ErgoTronic consoles. The Commander CT for Straubing was the second 4/2 version of this press type in Bavaria following a pilot installation at the Main-Post media group in Würzburg. Next year Der neue Tag, a newspaper publishing house in Weiden (Rhineland-Palatinate) will flick the switch on the third Commander CT in Bavaria and the first 6/2 version in Europe (see page 40). So don’t let anyone tell you the Bavarians are arch-conservatives. When it comes to technology that label certainly doesn’t apply. Publisher Martin Balle greeting guests at the inauguration of the new press and the Straubinger Tagblatt’s 150-year jubilee celebrations Report is the corporate magazine issued by the Koenig & Bauer Group (KBA): Koenig & Bauer AG, Würzburg Friedrich-Koenig-Strasse 4 97080 Würzburg Germany Tel: (+49) 931 909-4336 Fax: (+49) 931 909-4101 Web: www.kba.com E-mail: [email protected] Koenig & Bauer AG, Radebeul Friedrich-List-Strasse 47 01445 Radebeul Germany Tel: (+49) 351 833-2580 Fax: (+49) 351 833-1001 Web: www.kba.com E-mail: [email protected] KBA-Metronic AG Benzstrasse 11 97209 Veitshöchheim Germany Tel: (+49) 931 9085-0 Fax: (+49) 931 9085-100 Web: www.kba-metronic.com E-mail: [email protected] KBA-Grafitec s.r.o. ˇ Opocenská 83 51819 Dobruška Czech Republic Tel: (+420) 494 672-111 Fax: (+420) 494 623-675 Web: www.kba-grafitec.cz E-mail: [email protected] Publisher: Koenig & Bauer Group Editor in chief: Klaus Schmidt, KBA director of communications, Würzburg Layout: Pia Vogel, VOGELSOLUTIONS.COM Translation: Christina Degens-Kupp, KBA Production manager Wolfgang Heitzer expounding the benefits delivered by the highly automated, ultra-compact press line Checking the commemorative colour publication printed on the Commander CT at the official inauguration, under the Church’s eagle eye Printed in the Federal Republic of Germany Report 37 | 2010 51