A supplement to
APRIL 2008
Hybrid Production Newspaper Meets Commercial RETOOLING OPERATIONS graphic arts monthly | newspapers & Technology
Hybrid Production 04/08 3 - ranscontinental ranscontinental rancisco.
Adds Brandon Casson, national sales sales national Casson, Brandon Adds Also critical is implementing a digital digital a implementing is critical Also oland’s Colorman XXL, is MAN Roland’s Pictured below will be installed in T three of which nc.’s new U.S. facility near San F Inc.’s prepress workflow, including computer- including workflow, prepress sales of director DeRose, Patrick to-plate. Graphic Kodak’s packaging, & newspaper that estimates Group, Communications operations newspaper of 50% around im very “It’s CTP. to converted have better gain to newspapers all for portant says make,” they product every in quality give readability, with help will “It DeRose. for better is It product. clean nice, a them in newspapers help will it so advertisers them help also will it and sales, own their work.” commercial for compete “All Inc. Lithoplate Southern manager, have who to speak we customers the have who and CTP to move the made been have commercial into diversified to be looking at lowering manufacturing manufacturing lowering at looking be to finishing allow that features at costs, stitching, as such press, on products go to having without folding, and gluing people.” additional with off-line - - - - ve ha “Market trends are pointing towards towards pointing are trends “Market Shane Lancaster, Goss senior VP VP senior Goss Lancaster, Shane “Newspapers are printing new prod new printing are “Newspapers Coldset operations embrace technological upgrades upgrades technological embrace Coldset operations open new markets new clients and to capture venue for other revenue streams, maybe maybe streams, revenue other for venue advertiser their keep them help even stay them help and readers, and base need “They Lapinski. says competitive,” more heatset or UV-cured purchases purchases UV-cured or heatset more the around establishments printing for mar & sales Arlt, Karin agrees world,” Inc. Group, Tensor adminstrator, keting must A must, a are solutions value-added These Ro MAN Lapinski, Vince maintains that is message whole “Our CEO. land’s looking be should printers newspaper looking be should they UV, or heatset at a them give can technology new how at the product and/or demographic they are are they demographic and/or product the publishers other soliciting or after, going Gary says printed,” products need that KBA. sales, newspaper of VP Owen, and simultaneously, happening are “Both newspapers.” for win-win a are both “more that notes U.K., the in GM and (from inquiries our of two-thirds than some for asking now are newspapers) the to solution value-added of kind years Five heatset. or UV either press, case— the been have wouldn’t that back, 20.” in one been have would it Hybrid web production is in full swing. swing. full in is production web Hybrid commercial and newspaper Savvy op market seizing are printers coldset latest the with up gearing portunities, and pressroom, prepress, in innovations much very Still technology. postpress trends compelling two the are play in arena—production web hybrid the in to looking newspapers vs. outsourcing either work, contract with time press fill jobs. commercial or papers other from changing marketplace, own their for ucts Hybrid Model Model Hybrid Heat Generates
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Graphic Arts Monthly Graphic . Joann Whitcher served as Whitcher served . Joann
Newspapers & Technology Newspapers &
Graphic Arts Monthly Graphic Phil Saran, publisher, Phil Saran, Newspapers & Technology Mary L. Van Meter, publisher, Meter, L. Van Mary comprehensive editor for the project. comprehensive & Technology & rial and production efforts and assets of efforts and production rial Arts Monthly Graphic This report represents the combined edito represents report This enlighten readers. enlighten readers. market, groups which provided information information which provided groups market, might insights so that we and invaluable als and to the leading suppliers to the hybrid to the hybrid als and to the leading suppliers We are grateful to these industry profession grateful are We proceeding in full throttle worldwide. worldwide. in full throttle proceeding selves with the tools necessary to succeed with selves a transformation market, in the crossover Inside are stories of newspaper and com stories Inside are them armed who have printers web mercial rial handling systems, and the profitable and the profitable systems, handling rial market. insert including digital printing technology to mate including digital printing supplement looks closely at developments supplement looks closely at developments innovations pressroom on the front-end, technology publications for commercial technology publications for commercial this and newspaper publishers, printers and crossover newspaper and commercial web web newspaper and commercial crossover by Produced printing. This third edition of hybrid production digs production edition of hybrid third This for requirements deep into manufacturing Retooling Operations: Publisher’s Report Publisher’s KBA.W.504.e C p K K C N V p c T a t K p o h d o B h o r r o B e i i m h e o a A m v m A a w n n n n n a o t t s m N e ( i e n g e e l r p g U q o : r a c r e u a a u r K o s e n & s ( t n p a ) w + h d f w d e w d e l 4 B . L e i r u h a A i 9 t t a s s r W t u o - m y d ) e u h C – , t t . h a e e e r 9 , o T u m e e r r a u 3 m i e n u v p t c n d A 1 i n h p e s r a n a d G r q o a l e t 9 i a d I , u m v r p i e i r 0 n t o n a i i W r w 9 c r u d n l e e D i . l - t ü m e e a , s e 0 h i r m r s s t l d u g , z t s e @ e e e w b a h o p i k r d s r k w u e a l b a k e C – e r p w s w e b a g t s 2 s t r n - a e o a s e o o w 0 @ - f F c r r . d p o o a u 0 k e i h F r m k u r r c . e t 8 n i o b b i c n c e r K l o , r a z e h i t o t a e t l b - 2 c . i p o s n y e p u c o u o 9 y u g v o s n n r m K b a e y g . h a M u t . f l n @ i a c o t i l k n a t e B s o o n c , g i k h y l m x d d o e w b T e i a m l A , a n t b a r i w y o r n a w s i - o n l w p t l g i w 1 r w o , r . t C e m k i w 1 c a y i n m b t o . c n o t o a k h J a o l e . d r b d n u - d e m e i p a s m d e m n m ? t . r e p , c e i s a J a t t a n o , w u h u i g c m t o n s p w p e . s i t r t c t n t e . w a e o c h a r e O g . n h n . - e t k u i f u d a a i a b v a t k o r l n t a e s l 1 n s e C e c - t e u 6 p o e n a j t r s B , o n r g n i , t a n b a 4 e d t i t n h s c s 5 c . u a c e a o e o p i l f a r l m e . n r d b K B A N e w s p a p e r T e c h n o l o g y 04/07
successful. It’s not only because of CTP, some newspapers are considering out- dia Group’s Boston Globe is printing but because of all the pieces combined— sourcing production, a trend that seems newspapers for two GateHouse Media adding UV towers, moving up the quality to be on the rise. Outsourcing, which (Fairport, NY) papers at its Dorchester, chain. They are getting incredible results.” mirrors the business model found in MA facility—a contract worth $400 Southern Litho, which had its best book and magazine publishing, lets million. The papers, The (Quincy) single year for CTP system installations newspapers focus on their core compe- Patriot Ledger and The (Brockton) En- in 2007, expects a strong third and fourth tency of disseminating information. terprise, are direct competitors of the
Hybrid Production quarter 2008. Not only does new capital Transcontinental Inc.’s (Ontario, Globe. In a similar vein, The Tribune become available to newspapers after Canada), an outsourcing phenomena, Co. is looking to print Florida and Los the fiscal year end, says Casson, but “we shows no signs of slowing down. In the Angeles editions of The Wall Street expect, with the Congressional Economic last couple of years it signed a 15-year Journal Stimulus Act of 2008, for printers to take contract, valued at $1 billion, to print Greener manufacturing, already a advantage of the opportunity to make the The San Francisco Chronicle; declared trend in commercial production—take move to CTP and take advantage of the its intent to establish a new division note of top insert printer Vertis Com- 04/08 tax benefits for buying equipment.” to pursue the U.S. newspaper market; munications’ FSC ( Forest Stewardship and announced plans for a $60 million Council) chain-of-custody certification upgrade to its Montreal facility. for some of its plants, is making head- More bang for the buck To boost its roster of newspaper way in newspaper operations. 4 Coldset presses are no longer the clients, specifically from the U.S., Trans- The News Corp’s 2007 acquisition stripped down affairs they once were. continental plants will house the latest of Dow Jones & Co. came with a com- To capture new work—be it newspaper technology, for printing higher-quality mand for the paper to become carbon jobs requiring 50%-100% color on every color products and targeted distribution. neutral by 2010, along with the rest of page, or four-color inserts, real estate Southwest Offset Printing (Gardenia, the company. Dow Jones’ first step is to flyers, or grocery shoppers for commer- CA), a production site for daily, weekly calculate its 17 production plants overall cial accounts—coldset presses are now and monthly publications, built its cus- carbon consumption. being sold with quarterfold capability, tomer base by selling “time-shares” on its The News Corp. is not alone in its
nology format versatility, variable web widths, presses. It now has 550 employees, two efforts. The (Detroit) Times Free Press, h some heatset or UV curing, preset con- facilities, and 11 presslines, producing The Washington Post Co. and Cox Enter- ec
T trols, semi- or automatic plate changing, work for such customers as The New York prises Inc. (Atlanta) are all looking to and in-line stitchers and trimmers. Times and The (Torrance) Daily Breeze. go green—and not just because they are All these bells and whistles don’t Yet another option: shared produc- worried about global warming. ers & p come cheap however, which is why tion facilities. The New England Me- It also makes good economic sense. a p
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To enhance prepress operating efficien- Approximately one in three of Kodak’s Trendsetter News CTP device. 6 cies and raise quality levels—necessary MAN Roland’s newspaper customers Kodak’s Preps imposition software, steps to seize revenue opportunities are using some elements of printnet; in which works with Kodak and third-party within the commercial and newspa- Germany, 75% of its customer base uses vendors’ workflows, supplies digital per markets—hybrid web printers are the workflow application. imposition. implementing computer-to-plate and In 2007, The New York Times Co. Scripps Texas Newspapers L.P., digital workflow systems. announced it was implementing print- which prints The San Angelo Stan- Digital workflow management net modules at The Times and the Boston dard-Times, a weekly direct mailer and systems are an integral aspect of an Globe, for ad placement, layout and commercial projects, relies on Prinergy
nology automated, controlled, and ultimately print production, interfacing the system Evo software to drive its Trendsetter h cost-efficient production environment. with SAP’s IS-Media Industry Solution. News 70 CTP device, optimized with ec
T Once such system, MAN Roland’s print- Staccato screening, Kodak Thermal net, automates and networks all print sites News digital plates, and Preps imposi- and production areas, from ad entry to Controlling prepress tion software. ers & p printing, integrating the various processes Kodak’s workflow programs include the “The speed and quality of the a p onto a central database. The printnet Kodak NewsManager Workflow System Trendsetter News platesetter puts us in workflow controls all prepress systems, and Prinergy Evo Software. PDF- the 21st century,” says Robert Aguilar, including the RIP, platesetter and plate based NewsManager controls prepress Scripps Texas Newspapers’ president news | bender. Printing plates are produced on a functions, from edition planning to and publisher. “The Prinergy Evo soft- ly ly priority-driven basis, in the order in which plate production. Prinergy EVO, also ware allows us to catch errors on the fly h they are required by the press. PDF-based, delivers color management, and it doesn’t slow us down in making “printnet starts early in the process, late-stage editing and imposition capa- plates, making our operation run more letting the ad and print salespeople bilities, along with advanced screening smoothly.” follow along the production chain, pro- options, such as Staccato, to optimize At the Scripps Texas Newspapers viding automatic set-up of all produc- Wichita Falls site, the company uses a ic arts mont tion, making sure the right plates are Trendsetter News 70 with ThermalNews ph delivered to the cylinder,” says Markus digital plates to print the Wichita Falls Feldenkirchen, CEO, ppi Media US, Times Record News and other products. gra the unit of MAN Roland that markets printnet. Adds Feldenkirchen, “It helps The differentiator reduce costs, streamline production FM screening is a big differentiator operations, utilizing the presses the in the quest for high-quality coldset most efficiently.” printing. “To do commer- cial work,” says Patrick Kodak’s News thermal DeRose, director of sales, CTP device comes in five newspaper & packaging, Kodak’s Graphic Com- speeds, ranging from 60 munications Group, “you to more than 240 plates have to have the ability to per hour. compete against a heatset web printer. A lot of our coldset customers are able to compete with heatset and Visit Tensor at NEXPO Booth 426 Moving Beyond Conventional Wisdom
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At Southwest Offset Printing’s facility in Gardenia, newspapers. Its roster of clients in- plates, the images jump off the page. 8 CA, five Kodak News Trendsetter CTP units are cludes the Todd County Standard, which We noticed the improved quality on the conveyed to this fully automated Nela VCP Vision it once owned. Its prepress operation very first job. Our biggest client uses punch bending line. The system can produce in is centered on Southern Lithoplate’s gradient type colors, and we saw fine Viper 830 Lithoplates and the Screen dot structures we had never seen before. excess of 360 bent plates per hour. PlateRite News 2000 thermal plate- The images were sharper and cleaner. setter. PolkaDots’ IntroFlo workflow There was less dot gain on press.” get commercial work by using Staccato software automates prepress tasks, Registration has improved as screening.” while OneVision’s Asura preflighting well.“The plates are absolutely right on
nology Brandon Casson, Southern tool provides PDF, EPS and PostScript target,” Finch observes. “Previously, we h Lithoplate’s national sales manager, files processing and correction. experienced film stretch of 1/1,000th to ec
T agrees. “One of the biggest enablers for Owner Mike Finch knew the move 1/3,000th of an inch.” coldset operations moving into higher to CTP was a necessary one if the quality work is FM screening,” says Cas- company was going to grow—he and ers & p son. “Thirty percent of our customers his son Michael were spending 25 hours Revamping the system a p are utilizing FM screening on at least a a week processing film, matching-up In 2004 Southwest Offset Printing weekly, if not daily, basis.” pages, and manually burning plates. (SOP) completely revamped its prepress Its customer use Screen’s AM/FM The cost of the investment held back department, bringing the imaging, news | technology, called Spekta. Southern Litho- the move initially, but as fate would have punching and bending of plates into ly ly plate and Screen are members of the it, Quality Web made some improve- a single area. The new set-up at SOP’s h Southern Lithoplate CtP Alliance, which ments to its web presses, picked up main facility in Gardena, CA, included sells turnkey platemaking programs. some new clients, and the move was on. four Kodak Trendsetter News CTP de- The Bulletin, (Bend, Oregon), uses “We have justified the cost of CTP vices conveyed to a fully automated Nela FM screening on 100% of its jobs, says with the increased number of jobs we have VCP Vision punch bending line. The Casson. “Once you have the control, you been able to attract as a result,” says Finch. system produces plates for The New York ic arts mont start seeing savings in ink consump- In the past five years, gross sales Times, for which SOP prints a local edi- ph tion,” says Casson, which he estimates at have grown from under $200,000 to tion, as well as other daily publications. somewhere between 8%-12%. “You have more than $1 million. Quality Web oper- Soon after the initial upgrade, SOP gra a prettier sheet, as well as the forgiveness ates out of a 9,000-sq.-ft.-facility, staffed determined the need for additional it gives you in registration.” by six full-time and several part-time capacity, and within a year had added a Casson adds, “The sweet spot in employees. Its web printing capabilities fifth Kodak Trendsetter News CTP and cold web printing is a 36-micron spot, have expanded to a total of 13 units. a second Nela VCP vision punch bender although some are going as low as 25. “We output about 1,000 plates each to the existing line. This not only in- FM screening allows you to be consistent, month,” Finch says. “Since installing creased plate throughput, it also created have greater control, and the quality bene- the CTP device, one person can do the back up for the existing bender. fits on the printed sheet are phenomenal.” work of two in prepress. That frees me Once processed, plates are scanned up to perform administrative functions via barcode reader, sent to the appropriate or run the press if necessary.” Nela Vision punch bender and then onto Benefits across the board Print quality also improved. “I custom stacking by the individual press. Shops not running FM screening also really didn’t think we could squeeze The Nela system has the capacity to pro- benefit from a CTP workflow. much more out of the press after the duce in excess of 360 bent plates per hour. Quality Web Printing (Elkton, KY) upgrades, but I was wrong,” notes The Gardenia prepress area feeds runs 28 jobs per month, consisting of Finch. “With the combination of the six coldset presslines and three heat- monthly, twice-monthly and weekly press improvements, CTP and the Viper set presslines. Southwest’s satellite MAN ad hybrid suppl. N&T .pdf 3/13/08 11:39:13 AM - 1 - ( )
“We need a quick way to convert our press from newspaper to money maker.”
We hear you. “There’s nothing so financially depressing as an idle press,” you’ve told us. So we’ve worked with publishers throughout the world to expand their production abilities with coldest/heatset hybrid systems with UV dryers. Now, once their newspapers are printed, their MAN Roland presses can be converted quickly, with advancements like automatic plate loading, to do commercial work with excellent color reproduction values. Exactly the kind of values and capability to reproduce more green. www.manroland.us.com 800-700-2344 04/07
Bear River Publishing upgraded its pressroom with Screen’s PlateRite News 2000, pictured at left, run with Southern Lithoplate’s SLP Viper 830 digital plates. Hybrid Production our quality on press. Having a harder dot, a more refined dot than from the film system, gave us the ability to run UV and a 133-line screen. On our cold web products we can run 110-line screen; we used to run a 85-line screen.” 04/08 facility to the company’s The upgrade allowed the Pioneer in San Fran- annual sales. papers to generate much more color in cisco has two additional Over the last two their publications. “It’s a good sell- presslines and an additional Nela years Bear River has com- ing point for commercial work,” says 10 VCP Vision punch bender. pletely upgraded its prepress Nealy. “Our commercial base has grown area, first purchasing in 2006 a Screen steadily in the last couple of years, PlateRite News 2000 thermal platesetter based on the quality. We get calls from A huge difference which it runs with Southern Lithoplate’s people interested in the work we are A division of Pioneer Newspapers, Inc., SLP Viper 830 digital plates, Nela convey- doing, from Utah and all over Idaho and Bear River Publishing (Prestion, ID) ors and the Presteligence NewsXtreme Wyoming.” prints three daily newspapers and one workflow complete the system. In the summer of 2007, Bear River weekly. These include the Idaho (Pocatel- “It made a huge difference,” says Pat completely automated its platemaking,
nology lo) State Journal, Logan (Utah) Herald Jour- Nealy, GM, Bear River Publishing, refer- installing an auto-bending device. “Every- h nal and Rexburg (Idaho) Standard Journal. ring to the CTP installation. “It improved thing is automatic, from the second you ec
T Magazine, tabloid and broadsheet contract our speed in the prepress department, unwrap the plates to the time the press- work contribute an additional $1.6 million reduced our manpower and improved man takes them to the press,” says Nealy. ers & p a p news | ly ly h ic arts mont ph gra graphic arts monthly | newspapers & Technology
Hybrid Production 04/08 11 - - Also fully fully Also operational are the the are operational , the Ferag mailroom, and the the and mailroom, Ferag the , ´ “The print quality of the magazine magazine the of quality print “The The compact FPS, which stands stands which FPS, compact The com outsourced had which INM, Goss Automatic Web Lead (GAWL) (GAWL) Lead Web Automatic Goss mercial work prior to its FPS instal FPS its to prior work mercial copies million 4 generate will lation, brought is everything when annually cph, 87,000 at runs FPS The in-house. full-color 177 to up produce can and a printing of option an with pages, tab coldset pages 96 to up of combination heatset. pages 80 and commercial full to compared been has Lancaster, Shane says work,” magazine and semi-automatic plate loading loading plate semi-automatic and system. 12.8 at 90-degree a at located reelstands, press’ Goss floor. single a on housed are angle, interest increased is there that reports the of side the at pasters the setting in it as below, directly than rather unit, a in function to operation the enables conventional a as such building, lower built, specially a than rather warehouse, faciltiy. complex A’s ultra-compact ultra-compact A’s consists of three three of consists 15-tower, 15-tower, d a e ah pressline pressline m m a Daily News A configuration of A configuration the NY side of the press line. triple-width version of KB triple-width version press, viewed from the gear from Commander CT press, viewed ull ste ull for heatset, running 58´´ and 73´´ webs, webs, 73´´ and 58´´ running heatset, for J2:5:5 two into feed These respectively. quarter-folders with equipped folders capability. stitching in-line and preparation and on-demand reel loading loading reel on-demand and preparation equipment related and inserting and Goss. and Ferag from F (INM) Media and News Independent At the of phases both Ireland, Newry, in complete. now are installation FPS Goss September since production full In the 2007, coldset running towers printing 4x2 Goss with towers printing 5x2 two and rolls chills integrated and dryers Ecocool than $100 million, includes a Patras A Patras a includes million, $100 than with system reel-logistics automated splice vehicles, retrieval and storage Latest technologies generate high level of activity in high level generate Latest technologies operations commercial newspaper and ’ - can can Daily News Daily film-type inking inking film-type , which signed a signed which , quarter 2009, the pressline pressline the 2009, quarter
rd
Daily News Daily The new press will be housed in in housed be will press new The KBA introduced the 90,000-copy- the introduced KBA
The latest news comes from New New from comes news latest The
Continued Expansion Expansion Continued Pressroom Crossovers’ Crossovers’ Pressroom Jersey City, NJ, production site. The The site. production NJ, City, Jersey more at estimated investment, entire an expanded facility at the the at facility expanded an heatset and UV. and heatset units with three form rollers that rollers form three with units including inks, of variety wide a handle for quick access, and and access, quick for The press, a compact 12´ 9´´ high, fea high, 9´´ 12´ compact a press, The apart split can that towers oil-free tures specifically for operations that produce produce that operations for specifically work. semi-commercial and newspapers an-hour Commander CT in 2006, 2006, in CT Commander an-hour and one KF 7 jaw folder. folder. jaw 7 KF one and will have three sections, each with five five with each sections, three have will towers five reelstands, Pastomat KBA newspaper with that ability, Scheduled Scheduled ability, that with newspaper 3 live go to giving the tabloid the ability to run color color run to ability the tabloid the giving market major first the page, every on of its ultra-compact Commander CT, CT, Commander ultra-compact its of contract earlier this year with KBA to to KBA with year this earlier contract version triple-width 15-tower, a install York’s York’s to stay competitive. stay to commercial concerns look to boost color color boost to look concerns commercial versatility product increase and capacity production continues to to continues production and newspaper as headlines, make Crossover web web Crossover 04/07
are configured with three towers, each housing eight printing couples, for a total of 24 per press. Fed by four MAN Roland CD–15 XXL reelstands, and operated from two PECOM control con- soles, each shaftless press is capable of producing 36 broadsheet pages in full
Hybrid Production process color or 48 broadsheet pages with 24 of them in full color. All three presses can be equipped for heatset production in the future. An array of MAN Roland produc- tion automation joins the PECOM system: AutoLoad 2.1, for automatic reel 04/08 loading; WebSys, for automatic webbing up; and TecoSys automatic tension con- trol system for optimizing web flow. Ferag and Goss materials handling 12 systems will include three UTR convey- ors, five DiscPool buffering systems, five MultiSertDrum inserting drums with RollStream, 40 JetFeeder, two 30:2 Magnapack inserting systems, 10 MultiStack stackers and 20 SmartStrap strapping machines. One of MAN Roland’s newest of-
nology ferings for the pressroom is not a press, h but the robotic APL system. Developed ec
T by robotics specialist Kuka, APL uses a robotic arm to deliver plates and lock them into position. The entire plate ers & p loading process is completed without a p human labor, reducing plate changing to 2.5 minutes for an entire pressline. In 2006 The Rockford Register Star news | went live with its variable-width KBA ly ly Colora, equipped with five towers and h 40 printing couples. The pressline is Independent News and Media’s FPS compact press from Goss, now fully operational, consists of five printing configured with six Pastostar reelstands, towers—two capable of running heatset/coldset and three running straight coldset. one folder superstructure with five formers, a 2:3:3 jaw folder, in-line stitch- ers, gluers and trimmers. Variable-web- ic arts mont width allows printing on webs from ph GM for Goss International in the U.K. and assembled in the mailroom, where 24´´ to 36´´ in width. “The register is very good, the fold qual- they are stitched and trimmed. It could The configuration of the Rockford gra ity is very good—our customers are very take as much as four days. The FPS Register’s Colora’s ribbon superstruc- pleased.” produces magazines in a total run time, ture, the number of formers and the Also, the press works fast, the result from paper loading to finished product, pre- fold and post-fold product capabili- of such features as DigiRail for digital in around 10 hours.” ties, have given the Rockford Register un- inking and slide apart towers for easy Additional FPS installations are limited commercial product flexibility. access. “Ink changeover is fully auto- currently underway in The Netherlands, The 75,000-copy-per-hour Colora matic,” says Lancaster. “You can make and in Fredericksburg, VA. print up to 80 four-color pages in one changes in the folder very quick. You pass. It is replacing a 37-year-old let- can changeover everything in 35 to 40 terpress. minutes, from heatset to coldset web, First blanket-to-blankets Rockford Register had anticipated including switching from newsprint to Transcontinental Printing’s three about $350,000 annually in commer- coated.” MAN Roland Colorman XXL presses, cial revenue by 2010, but by the end of Adds Lancaster, “In conventional destined for its first U.S. plant, are 2007, it closed in on $3 million. systems, magazine signatures are scheduled to go on edition in 2009. Variable-web-width capability printed in 32-page sections then col- The first 6x2 blanket-to-blanket gives the Register the ability to run lected and stored as works in progress, newspaper presses in North America, newspapers with non-standard web PRACTICAL TECHNOLOGY EFFECTIVE SOLUTIONS
WIFAG evolution 371, La Vanguardia, Barcelona
Productivity, Flexibility, Quality and Dependability
Broad product range: - plate cylinder sizes: 4/2, 6/2, and 4/1 - printing units: blanket-to-blanket, 9-cylinder satellite - jaw folders: 2:5:5, 2:7:7, quarterfolder - autopaster: up to 1’500mm Ø roll
Automated production: - automated plate change - optimized start-up and production changeover sequences - closed-loop color register and cut-off control
Workflow-integration according to PRIME: - data networking with prepress, roll logistics, and postpress
Format variability and semi-commercial printing: - variable web width - UV, heatset
Upgradable by new technologies: - closed-loop ink density control - on-press imaging CtPress
Contact: Mr Thomas S.Stuart 1901 St. Ives Drive, AL 35242 Birmingham Please visit us at booth 2524 Tel. 205.980.0748, Fax 205.980.0645 [email protected] www.wifag.com
NewsandTech Hybrid.indd 1 07.03.2008 11:32:44 04/07
sizes. The Colora’s double-out folder, enabled by its shaftless drive, also provides great flexibility, allowing two different products to run simul- taneously to different deliveries, or a single product to run on both sides, effectively doubling output. Hybrid Production
Staying coldset with UV Coldset shops with single-wide presses are increasingly turning to UV curing to up quality levels and print on coated glossy paper. Prime UV reports it has 04/08 equipped over 80 4-highs with its processors. With an eye on expansion that included a move into new facilities in 14 October 2006, Coastal Web Press (Sur- Plate changing with MAN Roland’s fully automated robotics APL system is reduced to 2.5 minutes for the entire rey, British Columbia) installed a Tensor newspaper or commercial web pressline. T-400BE four-high tower with a Prime UV drying system and a Tensor H-50 HD folder. A Goss HV nine-unit web press runs strictly coldset. A single-wide, one-around press, the Tensor T-400BE prints at speeds up
nology to 40,000 iph. Coastal runs coldset on h one side of the H-50 jaw folder, which ec
T can handle as many as 14 webs into one folder, and heatset on the other. The shaft-driven version of the T- ers & p 400BE uses clutches to enable running a p of either the coldset side or the heatset side, or both, as needed. “With UV, we can run coated stock, news | such as a cover wrap for our ethnic ly ly papers, which we couldn’t do before,” h says Doug Candy, GM and co-owner of the 17-employee company. Coastal also prints magazines in runs up to 25,000 on glossy stock, in three passes through the Tensor, and then saddlestitches the ic arts mont signatures together. ph “The quality is far superior to just running cold,” says Candy. “With cold- gra set printing, ink is all over everything. Now, running the UV we don’t have any delivery issues—the outside web is dry. Coldset never dries.” For its customers, the upgrade in quality realized with the Tensor/UV combination has given them a market advantage, says Candy. “Our customers weren’t asking for the better quality, but they are happy to get it. It is a quite a competitive market, and this gives our customers a competi- Eagle Web installed its first Prime UV curing system on a Goss Community SSC press in 2006; a second Prime UV tive edge,” reports Candy. system was added to its WPC 4-high this past January. In fact, now that Coastal Web has hit the market with its coated covers, other community newspapers are graphic arts monthly | newspapers & Technology
Hybrid Production 04/08 15 GVcYn
“The two UV units sit between two experience and capabilities in emis- 42 pages, and El Siglio, a tabloid averag- folders with the ability to take two webs sions control provide specialized ing 56 pages, are both projected to grow, to either folder, or one web to each, expertise and unique collaborative once the upgraded press line is up and allowing us to run two different jobs at opportunities. One result is our Dual running, La Estrella to 80 pages, and El the same time,” says Connor. Dryer technology with integrated Siglio to 96. oxidizer, which effectively addresses The plant also prints an English emission issues, too. It is the most edition of USA Today, as well as shop-
Hybrid Production Some prefer the heat advanced system available today.” pers and inserts for supermarkets and “As more organizations look to grow Newspaper and commercial printer retail outlets. “The new vertical dryer their business beyond traditional areas El Siglio-La Estrella in Panama City runs and Goss press will let us do hi-brite — especially in today’s tight economic its two dailies, as well as a host of com- newsprint and 80-gram supercalen- climate — their choice of drying mercial work, on a 3-tower Goss Com- dered paper,” says Juan Luis Correa E., systems can make a critical difference,” munity press, soon to be replaced with Gerente General, Grupo Editoria. says Mohit Uberoi, Megtec Systems a 7-tower Community with two jaw fold- “With the new machine we can ev- 04/08 president. “Hot air is the most com- ers and equipped with a Megtec Coanda ery page in color. We run color now but monly used drying technology, for sev- 155 vertical dryer and chill assembly for it is very difficult,” says Correa E. “The eral good reasons: It enables users to heatset, seven Megtec 134050SE zero first thing I did when I came here last print on all paper grades with improved speed splicers for splicing of pre-printed year was to make sure the owner and 16 ink gloss, and without marking. It is rolls in register and a Megtec ETI-40 main partner realized that the company also the most cost effective.” Infeed for providing stable web tension needed capital investment to improve Uberoi adds, “Regarding envi- over wide operating ranges. the quality of printing and news content ronmental issues, Megtec’s extensive La Estrella, a broadsheet averaging and to enhance production.” nology
h Kodak Takes Lead in Newspaper Digital Production ec T Kodak is spearheading the drive in digital newspaper a commercial printer will gang together several newspa- production. per titles and print them at their shop,” says Christopher ers & p In February, MAN Roland and Kodak’s Graphic Com- Klepacz, inkjet printing solutions’ product manager. a p munications Group signed a letter-of-intent to introduce a “Newspapers are looking for ways to leverage their high-speed on-press digital inkjet printing. content, and digital printing is another source for them,” Based on Kodak’s Versamark DS6240 ink-jet head adds Donald Allred, inkjet systems’ director of business news | (pictured), the system can run at speeds of up to 3,000 fpm. development. ly ly It is being field-tested on Colorman XXL presses in an un- h disclosed location in Europe, says Ron Sams, VP, newspaper sales at MAN Roland. The system will allow newspapers to Triblocal a success produce a variety of localized advertisements, text and im- In April 2007, The Chicago Tribune became the first news- ages, including barcodes and Upcodes. paper to implement Kodak’s Microzone Publishing System, Designed to work with MAN which lets the Tribune reach ic arts mont Roland’s PECOM control system highly localized groups of readers ph via a proprietary interface, it will and advertisers. Basically, it gives be available for new presses as well people in local communities a way gra as retrofits on PECOM systems to share their experiences and sto- installed after 2000. ries, while giving local businesses Kodak’s Versamark VX5000 a cost-effective way of reaching printing system with in-line finish- local residents, Citizens submit ing from Hunkeler AG lets news- content to community web portals; papers print short runs in local The Tribune publishes community markets for distribution in remote papers and is generating website locations. The VX5000 can pro- content using the contributor’s duce 100% variable data in black, submissions. spot color or CMYK process color, Triblocal is expanding to 21 depending on the configuration. microzone community websites, “If a newspaper like The New with growth during 2008 expected to York Times wants to print a few reach a total of 35 microzone websites hundred or thousand copies at and eight printed newspapers, for a a vacation spot, they can either combined circulation of 120,000. set up their own shop, or maybe graphic arts monthly | newspapers & Technology
Hybrid Production 04/08 17 - 6150. - 332 - Co.’s Chicopee, MA facility, views the benefits of tension measurement equipment to newspapers as three different tools: “a production tool to identify problem spots during press runs, giving the press operator a start ing point to make adjustments that reduce total web tension; a training tool for press operators that shows how different press adjustments affect web tension; and as a maintenance tool, because it points out wear-items on the press that need to be changed The Tension Control Specialists , a dead-shaft pipe roller with tension , a dead-shaft pipe roller with tension displays the roller’s output as total total as output roller’s the displays DOVER DOVER FLEXO FLEXO ELECTRONICSELECTRONICS www.dfe.com/newspapers.html Dover Roller™ Dover TI15 indicator paper tension. The readings Out-of-spec edge. web either at tension or tension equalize to adjustments make to operator press the alert break web For tension. total optimize and tension side-to-side alarm. an activate to set be can limits max and min prevention, Visit Or phone 603 to download more info. Web tension monitoring helps reduce waste by signaling tension Web they get out of hand. potential problems to operators before The quickly and easily at any sensors built into each end, installs robust and simple way to measure running A point in a press. 841 DFE customer Darin LeFave, a Some of DFE’s newspaper customers customers newspaper DFE’s of Some are finding that web tension right before before right tension web that finding are higher is press the of section folder the making so be, would it thought they than tension running the lower to adjustments web of occurrence the reduced has there that finding are customers Other breaks. too is cylinders blanket their on tension or them change to need they and high blankets. different use production manager at Dow Jones created a tension-critical process.” process.” tension-critical a created ------
reness , NJHG’a only contract job job contract only NJHG’a , a w
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“For the newspaper industry this this industry newspaper the “For The machine, engineered with a with engineered machine, The NJMG’s Evolution 371 is also also is 371 Evolution NJMG’s The press’ processing system deliv system processing press’ The “The Evolution gives us a lot North Jersey Media Group (Rocka Group Media Jersey North
ension ension Greater ink saturation on both sides of of sides both on saturation ink Greater has stock paper thin increasingly the such as tension-related web breaks. breaks. web tension-related as such the print towers and folders on a large large a on folders and towers print the problems print in reduction a and press tive correlation between reducing the the reducing between correlation tive throughout paper the on tension total Electronics. “There seems to be a posi a be to seems “There Electronics. thinner newsprint stock,” says Mark Mark says stock,” newsprint thinner Flexo Dover manager, marketing Breen, more recently with the advent of a of advent the with recently more and product 4-color in jump significant ‘tension’ awareness has developed developed has awareness ‘tension’ color registration. registration. color though reducing web tension through tension web reducing though color-to- improve helps press the out ing consistent zone-to-zone running running zone-to-zone consistent ing even concept, unfamiliar an is tension T maintain shops, coldset many For or collect. or divide the Evolution 371 into two sepa two into 371 Evolution the divide straight run either can that presses rate ers variable web capability. NJMG can can NJMG capability. web variable ers 21´´ cutoff and a 50´´ web width, deliv width, web 50´´ a and cutoff 21´´ left in the printing couple to include an an include to couple printing the in left bar. imaging laser imaging units, for imaging the the imaging for units, imaging laser was Space cylinder. the on right plates designed for eventual use of WIFAG’s WIFAG’s of use eventual for designed sity since NJMG runs color on every page. page. every on color runs NJMG since sity 4-over-4 webs. Closed-loop ink density density ink Closed-loop webs. 4-over-4 neces a control, under color keep controls circumferential register for all full-color full-color all for register circumferential ers image-based controls for cut-off and and cut-off for controls image-based ers for integrating press controls and pre- setting capability.” lets us make fast zoning or edition changes. Also, it has a good platform without stopping the press, which tremendous amount of automation. can do plate-changingWe on the fly, of says versatility,” Robert J. Konig, manufacturing VP, NJMG. “It has a following its decision to leave the com the leave to decision its following arena. mercial a slew of weeklies, and an edition of of edition an and weeklies, of slew a Today USA press with two independent 2:5:5 folders folders 2:5:5 independent two with press newspapers, daily two prints folders jaw 2006. The six-tower, 4x2 double-wide double-wide 4x2 six-tower, The 2006. way, NJ) went on-line with its WIFAG WIFAG its with on-line went NJ) way, of summer the in press Evolution 371 04/07
Bear River Publishing runs its mail- A complete makeover room operation with little automation. Seacoast Media Group (Portsmouth, “We have a STI stacker, that’s as auto- NH) houses a Goss Magnum two- mated as it gets,” says Nealy. “Products around press with 32 printing couples— are manually loaded into our Schur A the first U.S. installation—as well as a 855 inserter. We don’t palletize anything Goss NP632TM inserting system with going to the paper.”
Hybrid Production 22 hoppers in its 70,000-sq. ft. produc- Bear River’s Schur A 855 inserter tion facility. Seacoast uses the systems with 10 insert stations has improved to produce the newspapers it owns in the flexibility and capacity of its mail- southern New Hampshire and Maine, room. The 35,000 cph A 855 inserter, along with several other products and which is equipped with a modern commercial print publications. It also feeder system, permits feeding of al- manages distribution of several other ready stacked inserts into the machine 04/08 newspapers. without a lot of labor. The need for expanded color, pag- In 2007, Bear River purchased ing and sectioning capacity on the press a 14 into 1 Schur inserter, which it and through the mailroom prompted retrofitted as an 855 with grip- 18 the installation, says Paul Briand, per delivery, giving the company Seacoast’s operations director. increased inserting capability and Its Goss Magnum press has three speed and its newspapers improved 4-high towers, two 2-high towers and a capability Goss Universal 2:3:3 jaw folder with two Dan Kemper, Schur Packaging formers. The configuration prints up to Systems’ president, comments, “We 48-broadsheet pages with 24 full-color offer production production equip- pages and 16 spot-color pages in collect ment solutions that can handle
nology production. conventional newspaper dimensions
h Coastal Web Press quality levels received a boost from The Goss NP632TM inserter cycles and smaller formats within the same
ec its single-wide Tensor T-400BE with Prime UV curing T up to 25,000 papers per hour and is machine. The two major components and Tensor H-50 SD folder. equipped for zoned inserting with Goss from our standpoint are our inserting/ Omnicon controls. Goss also supplied collating machines and our palletizing ers & p Goss NP125TM Inserter gripper convey- systems.” a p in order for target tension to be ors to feed products from the inserter to achieved.” two stacker tie lines. When a web break occurs in a run- In Preston, ID, Bear River Publish- Stacking with ease news | ning press, explains Breen, it means ing equipped its coldset web with a The Daily Hampshire Gazette ly ly productivity loss, hours of costly down Technotrans spray bar. The main coldset (Northampton, MA) recent purchase h time as the press is re-webbed, and web line consists of 16 printing units, of a double-wide press will print extra print scrap. “The major benefit of configured with an in-line jaw folder. two dailies, for a total circulation of installing tension transducers and indi- A four-high UV tower with its own jaw 32,000, giving them press time for cation electronics—as another customer folder produces four-color work on commercial jobs. pointed out—is that ‘paying attention stock ranging from 45-lb. to 60-lb. A Rima-System lapped stream ic arts mont to web tension and tension balance “We installed the Technotrans spray conveyor was also installed, to de- ph reduces their incidence of unexplained bar to get rid of the brush dampening liver products from the press folder running breaks,’ ” says Breen. system,” explains Pat Nealy, GM, Bear overhead to an RS-36 compensating gra “While press operators may be good River Publishing. “It is much more ef- counter stacker. The RS 36’s servo at making educated guesses about the ficient than brush dampening—it gives functionality completely eliminates limits of speed and tension on a press us much better control of ink/water any product drop in the stacker cham- without measuring them exactly, the balance and the press is not nearly as ber, enabling it to easily stack lighter first step toward run-to-run consistency, sloppy. As far as the water goes, it is a weight, lower page count, commer- tension stability and balance from zone- closed loop system.” cial-type products (typically difficult to-zone is to monitor tension directly, Tom Carberry, Technotrans VP to handle on conventional newspaper in real time,” points out Barry Villiers, of sales, states “Spray bars are a great stacking equipment). Already the production control systems analyst, at choice when dealing with ink, especially Daily Hampshire Gazette has con- The Toronto Star. “Once accurate pro- more expensive ink such as UV ink. Our tracted to print an outside 24-48 page cess-tension indication is implemented, spray dampening systems let printing tabloid, 150,000 copies, five days per operators and support staff have a operations optimize ink mileage, provid- week. quantitative basis for making tension ing homogenous and finely adjustable The Gazette is adding a stitcher/ adjustments at key points throughout distribution of the dampening solution. trimmer, outfitted with a Rima-System the press. This aids in your efforts to You can really control the water, unlike stacker, which doubles as a backup to reduce print quality problems.” with conventional systems.” the RS-36.
04/07
Handling Masses of Material
Hybrid Production with Automated Ease
Automated materials handling systems keep paper
04/08 rolls moving in and finished products moving out
Material handling within hybrid shops an all-day circulation of 220,000 and IMC America will also furnish New 20 run the gamut—from complex af- a Sunday circulation of 305,000. En- York’s Daily News with an automated, in- fairs with automatic guided vehicles, hanced color capability has enabled new tegrated newsprint roll-handling system automatic storage and retrieval systems, commercial opportunities with advertis- from vR systems. The system will feed production planning and monitoring ers, such as targeted special sections. the new KBA Commander CT presses. software, conveyors and automatic strap- “The Daily News’ material handling ping—to manual loading of paper rolls system includes a full roll-prepara- onto reelstands, pallets, or into inserters. ASRS roll handling tion line with an automated EcoPrep In terms of material handling, the The pressroom also contains a vR splice-pattern preparation system,” says
nology larger operations tend to invest in auto- Systems (formerly Metso/vonRoll) Mayle. The system will parallel the KBA h mated systems,” says Curt Miller, VP of newsprint roll system, supplied by IMC pressline, and will store hundreds of ec
T design and development for newspaper America, the exclusive North American newsprint rolls. projects, The Austin Company. “They agent of vR Systems GA, Delemont, have higher labor rates, so they would Switzerland; conveyors; a quiet room at ers & p get the ROI from the investment. “ the second press level; observation decks moving finished product a p The Austin Co. offers design and and building-support equipment. Once newspapers take on commercial work, they have to consider what they are going to do with those finished news | products. ly ly “The signatures will have to go to a h At the Buffalo News, two lanes of secondary operation, such as a bindery, rolls sit between the two parallel KBA says IMC’s Mayle. IMC also distributes presses; the v/R ASRS robot picks up Recmi for stacking and palletizing for the specific roll needed and brings it commercial operatons. to the reelstand, which then feeds it to “They will need either a brick, log ic arts mont the press. or compensatory stacker,” says Mayle. ph “The speed of the presses is so fast today they will need something to keep gra up with them.” construction services for the printing “The presses are each approximately Automatic palletizers are already and publishing industries, also special- 110 feet long with the v/R systems ASRS a part of many newspaper operations. izing in business consulting services running along the length of the press- As part of its multimillion dollar including production process planning, es,” explains Rick Mayle, vp of sales and production upgrade, The Denver News equipment evaluation and selection, marketing, IMC America.” Two lanes of Agency installed 11 Winrob II palletiz- and distribution network design. rolls sit between the two parallel presses; ing systems, configured as five double When The Buffalo News decided to the ASRS robot picks up the specific roll cells that include 10 palletizers and five upgrade its pressroom from letterpress needed and brings it to the reelstand, PSW stretch wrappers, plus one single with KBA Colora offset presses, it called which then feeds it to the press.” cell containing one palletizer and one on The Austin Company to re-design The ASRS also generates operations wrapper, all from Schur Packaging and re-construct its pressroom support data used to track newsprint consump- Systems Inc. facilities and implement a major facility tion and performance. The ASRS soft- The Schur systems are giving DNA renovation in downtown Buffalo. ware lets The Buffalo News select paper better bundle tracking and support The presses handle The News’ entire by mill and by brand, communicated via for finer zoning, says Katie McManus, printing requirements, which include a barcode. DNA’s packaging director.
04/07
Inserts:
Hybrid Production Bring in the Bucks
Showing no signs of slowing down, FSIs and local
04/08 shoppers deliver great opportunity for coldset plants
U.S. Post Office. According says Brandon Casson of Southern Litho- 22 to the Newspaper Associa- plate. “This will give them a big boost in tion of America, newspa- revenue. They already have the distribu- pers distribute more than 87 tion network set up; they are already billion inserts annually, just delivering to thousands, if not millions, A schemiatic of The Austin American-Statesman’s automated packaging fa- in the U.S. In 2006, the of people in their area. They already cility, slated to go on-line later this year, with its two shaftless Goss Magnapaks, Chicago Tribune delivered have the overhead included in produc- nearly 30 million advertis- ing their daily news product. Inserts are Ferag UTR press grippers and direct-to-pocket MultiDisc storage systems. ing inserts were delivered in a natural fit for newspapers.”
nology Insert marketing is big business. TNS the Sunday edition. Bradford Publishing (Bradford, h Media Intelligence (2007) estimates that The surging FSI and grocery insert PA,) owns three dailies: The Bradford ec
T advertising expenditures for local shoppers market bodes well for coldset commer- Era, Olean Times Herald, and Salamenca in 2007 was $11.1 billion, while advertising cial and newspaper web printers look- Press. It also prints grocery inserts, expenditures for FSIs were $1.6 billion. ing to expand their customer base. weekly newspaper and other commer- ers & p “Marketers continue to leverage FSIs Western Oregon Web Press (Al- cial work on its eight-unit Harris (now a p as a cost-effective advertising medium to bany, OR), operates three shifts a day owned by Goss) V-15D coldset. deliver consumer impressions and to cre- producing newspapers, inserts, maga- It doesn’t run UV, and in fact, still ate purchase intent for their brands,” says zines, and catalogs. does hand-inserting. Yet its insert busi- news | Mark Nesbitt, COO, Marx Promotion “Inserts have been a part of our mix ness, now in its 25th year—is on the up- ly ly Intelligence, a TNS Media Intelligence since day one,” says Randy Leopard, co- swing; Bradford currently prints 30 differ- h company. “Additionally, many retailers owner and production manager. ent weekly inserts, drawing accounts from align quality merchandising support with Western Oregon has experienced a radius within 250 miles of the plant. these FSI promotions to improve overall growth across the board, a fact Leopard “People see what we print and then promotion effectiveness and to increase attributes to its Web Press Corp. Quad- call us,” says Linda Cardamone, produc- incremental sales. FSIs continue to be a Stack outfitted with two UV towers. tion manager, Bradford Publishing. “We ic arts mont source of news about product categories “We’ve had a considerable amount of are in a very small market; we take jobs ph to the consumer and to be a driver of growth,” says Leopard, “and all of it is that larger printers don’t want to sched- category trips for the retailer.” attributable to UV. It’s been a huge step- ule. We take care of the little guy.” gra Vertis Communications, a leading ping stone for us.” Bradford doesn’t invest in new provider of print advertising and direct In 2007 the company’s revenues equipment easily, but in 2006 it did marketing solutions, reports in its Cus- grew 15-20%; for 2008 sales are pro- migrate to a CTP workflow, installing tomer Focus 2008 retail study that the jected to grow 15%. a Screen PlateRite News 2000 with a number of insert readers who use inserts Five years ago, that grocery store Trueflow PDF workflow, run with South- and circulars to help them in purchasing circular was nearly always coming in from ern Lithoplate Viper 830 digital plates. decisions rose from 52% to 59% over the a commercial web printer, delivered to the Insert growth is also having a dra- past four years. The data also shows that newspaper for insertion before distribution. matic impact in the packaging depart- inserts and circulars have overcome tele- ment, as more traditional mailroom vision advertising as the medium most operations struggle to keep up with able to elicit consumer attention. A Natural Fit insert volume increases and advertisers’ “With conversion to CTP, with modi- demands for more zoned distribution. fied UV, newspaper printers can now In fact, U.S. newspapers ordered more Second Largest compete, at least locally, for these type than 20 Goss Magnapak packaging sys- Newspapers are the second largest of printed products, so they are not only tems throughout 2006 and 2007, reports distribution channel, second only to the inserting them, but also printing them,” Doug Gibson, Goss International VP. Everything 2/19/08 11:41 AM Page 1
Everything that goes into your Press
Dampening Circulators
Ink Temp Control
Combination Units
Multi-zone Temp Control
Fountain Solution Recycling
Blanket Washer
Blanket Wash Recycling
Ink Leveling
Ink Pumps
Ink Agitators
Ink Metering
Ink Cartridge Dispensing
Coating Circulators
Spray Bars Except Paper & Power
technology and services
Phone: (847) 227-9200 • 800 255-6658 • e-mail: [email protected] • www.technotrans.com What is print? It’s how we communicate. How enterprises are enabled and individuals influenced. Here, there, and everywhere. Kodak provides answers for a dynamic, diverse marketplace. See for yourself at NEXPO. Kodak solutions are here. Print is powerful.
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