There are many challenges facing offset printers in today’s increasingly competitive and digitized marketplace. These obstacles include economic challenges, raw material challenges, and challenges in sustaining a consistent level of demand for offset work.
Although offset technology is often seen as a stagnant printing process, it is important to shine a spotlight on those manufacturers who are innovating offset machinery with the goal of increasing bottom line profitability for printers. Equipment enhancements and technology advancements in offset equipment (such as inline modules, press speed enhancements and more efficient plate mounting systems) can enable faster makeready and changeovers, thereby increasing the profitability of a given job.
These new technologies are now being adapted to traditional processes and implemented by a number of manufacturers, three of which will be featured today. manroland and Heidelberg’s offset innovations are truly world class.
manroland
manroland’s ROLAND 700 Direct Drive sheetfed offset press enables printers to decrease makeready time by up to 60 percent by allowing a number of different tasks to be completed simultaneously. This 8-colour press with Direct Drive technology can perform three functions at once including blanket and impression cylinder washing, mounting plates and facilitating digital file transfer. All plates can be changed in less than one minute, no matter the press configuration and for up to 12 units. However, because the impression and blanket cylinders must be washed anyway and the plates are being changed simultaneously, it’s as if no time has to be allocated to plate changes at all; enabling “zero time” plate changes. As a result, this press is especially efficient at performing short run jobs (as few as 500 impressions).
In addition to the obvious benefits of performing multiple functions at once, the Direct Drive system also has an electronic print length adjustment, eliminating the need to change plate packing during a changeover, as the press operator can control this from the console. In a press release from manroland, the company makes the announcement that Pittsburgh’s largest independent commercial printer, Knepper Press, has added the ROLAND 700 to their repertoire of machinery and capabilities. “Where makeready issues continue to kill other printers on short-run jobs, with the ROLAND 700 we’ll be better positioned to bring more to our bottom line. It’s an ideal fit between our digital and conventional presses, and meets our expanding client base’s needs nicely,” explains Bill Knepper, chairman of Knepper Press.
Additionally, MetroMail (the UK’s largest direct mail production company) has recently purchased a ROLAND 700. Alan Purvis, managing director of MetroMail, has a very interesting perspective regarding the purchase of offset equipment in an increasingly digital world: “There is a perception in the market that a digital house buying a litho press is going against the grain. However, we believe hardware and software should be the vehicle for achieving strategy and not the drivers of it.” The key word to describe this unique press is “multi-tasker” and one that short-run printers can reap enormous competitive benefits.
manroland’s range of inline modules enable value-added printing for offset printers, including inline coating systems. Process integration allows for innovative production solutions and creates a competitive edge in the over-populated sheetfed offset market. The ROLAND InlineCoater smart applies coating over conventional ink surfaces to create matte or gloss UV effects inline. The system is designed for occasional application of coating, whereby the last printing unit of ROLAND 700 presses can be interchanged between inking and coating. This system is designed for the printer who does not do enough coating work to justify the cost of an extended delivery coating unit. Therefore, this system offers increased flexibility for the printer to offer numerous production options without having to commit to expensive secondary systems. Additionally, manroland’s 700 Ultima flexible inline enhancement is also worth mentioning. The system employs single and double-sided coating modules inline and can also be used to apply opaque white or metallic effects coatings inline.
There are a number of significant benefits to these systems that create greater bottom-line profitability, including reduced job turnaround times and reduced labour costs for combining up to three unique processes into one. Additionally, fewer logistical steps are required to move the job from a digital file to being shipped out the back door. Another important, and not so obvious benefit, is that less space is required for semi-finished goods, as well as for additional production equipment and crews to run the equipment. One last significant benefit to manroland’s inline systems is reducing the risk of problems showing up during a second pass of a second process. Because printing and double-sided coating is all completed inline, all registration is checked at this stage so any issues are addressed immediately on the first pass without excess time and material waste.
Heidelberg
The Heidelberg Speedmaster XL 105 sheetfed offset press made its debut a few years ago, but still proves superiority in speed and efficiency. With production speeds of up to 18,000 sheets per hour this press is able to maintain stable sheet travel, which allows for consistent quality images. Heidelberg’s AirTransfer system guides each sheet from one printing unit to the next on a cushion of air. This technology enables stable sheet transfer throughout the press, even with very thin paper stock.
Heidelberg’s Preset Plus Delivery, as well as DryStar 3000, offers Speedmaster XL 105 users the ability to take their current production performance to the next level. The Preset Plus Delivery is designed for the fast production speeds of this press and enables extremely reliable sheet delivery. Various stocks with varying weights and calipers are all handled expertly. Additionally, the DryStar 3000’s blast air works in conjunction with the Preset Plus Delivery to ensure excellent drying performance at high speeds. Heidelberg states that it is the “best possible drying performance for all applications.” Additional features on this state-of-the-art offset press include the AutoPlate XL plate changer, which mounts all plates simultaneously, thereby reducing makeready time and decreasing associated labour costs. These savings are maximized when working with shorter run jobs.
KBA
KBA’s Cortina newspaper press boasts state-of-the-art technology to decrease makeready time by automating manual tasks wherever possible. Part of this automation happens at the front-end of the printing workflow by automating press presets for startup. KBA’s PressNet automation system encompasses a number of smaller systems that comprise this workflow. Production scheduling and page configuration become a semi-automated task on the Cortina press through KBA EasyPlan. Presets for registration, web tension, dampening and temperature can all be programmed through KBA EasySet. Automated acceleration to production speed (KBA EasyStart), as well as automated deceleration (KBA EasyStop) is achieved at the touch of a single button. Lastly, a detailed summary and statistical report is made available after the job is finished, including information such as waste and speed diagrams (KBA EasyReport). This comprehensive front-end system enables increased productivity and helps printers gain a better understanding of their businesses to remain competitive.
It is clear that there is still a market for offset presses in today’s increasingly digital marketplace. It is also clear that printers must have a competitive advantage to contend. In order to stay competitive in the stagnant market of offset printing, you must learn to innovate using technology, adapt and discover ways not to become stagnant yourself.
