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1|2010 PRODUCTS|PRACTICES|PERSPECTIVES 36 Contents KBA Editorial 2 Sheetfed Rapida 106 presses for Zurich 3 Terminic, Germany: calendars for the world 4 A Costa Rican showcase 6 Cheaper kit can prove expensive 8 Flying job changes at Dutch printer Ten Brink 10 Netherlands’ Vis Offset perfects with Rapida 75 12 Rapida 75 at CL Print, Ireland 14 Rapida 105 for Gráfica Biblos in Peru 15 Enhancing productivity with DriveTronic SPC 16 Rapida 142 at Express, France 18 The courage to invest while others waver: delivered, installed, commissioned and started up in January this year – a new Rapida 106 eight-colour Powerful Rapidas in Italy 19 press with two coaters at Bernholz Verpackungen in Bad Salzuflen, Germany, where a Rapida 105 six-colour coater press that came on stream in 2000 has already pumped out 354 million sheets USA: Hanover Packaging’s eco profile… 20 …and 4D Printing’s Rapida 75 21 Enhancing efficiency Economic recovery depends on entrepreneurial courage with VariDryBLUE 22 UV printing on plastic packaging 24 Sustainability at Heider Druck 26 Investment key to innovation Vagner Graphic, France, takes Rapida 75 and 105 28 Web Offset he turbulence in the global fi- sions in the USA, in the UK and prospects, or a lack of entrepre- Brazil: Compacta 618 at nancial and economic market- T many other European economies neurial courage. Editora Abril 29 place has continued unabated for would be a great help, and there are Fortunately, however, there are Compacta duplex at almost eighteen months now, albeit tentative indications that the eco- exceptions. Farsighted printers and Editorial Primavera, Venezuela 30 with regional differences in inten- nomic situation in North America media players are making the most Slim-line Compacta 818 sity. While the number of more pos- may finally be starting to improve. of the current widespread paralysis for Italy’s D’Auria Printing 32 itive prognoses has increased, not When a crisis breaks, politicians in order to reposition themselves in Newspaper even the most revered economic are not the only ones who are readiness for the upturn, whenever experts are willing to prophesy with tempted to sit on their hands and that may occur. In pursuit of this Germany: Commander any degree of confidence whether hope for the best. Many of the de- strategy they are developing new satellites for Parzeller 34 Comet lands at Beijing Daily 35 2010 will bring a perceptible cisions and investments currently business models or enhancing ex- Automated plate logistics change for the better in current being made in the print media in- isting ones, more often than not in with KBA PlateTrans 36 trends or whether GDP figures for dustry and the wider economy conjunction with judicious invest- DB Group, India: the vast majority of national seem to be informed by the belief ment in advanced technology. The Prisma fleet in action 38 economies will fluctuate within a that “if you don’t do anything, you ultimate benefits are enjoyed by all, Comet brings colour to narrow band around zero growth can’t do anything wrong!” While in because in the long run the supply Sudan printer IGPP 40 from one quarter to the next. There some cases there may be little or no industry can only drive innovation is plenty of evidence to support choice, for example if there is a liq- if the customers targeted are will- UV Offset both scenarios. The scattered uidity bottleneck, the bank with- ing to invest. Examples of both can Genius 52UV for Onlineprinters 41 growth centres that do exist, such holds credit lines or business has be found throughout this issue of First Genius 52UV in Switzerland 42 as China, for example, cannot re- collapsed, this sentiment is more Report. Genius cuts emissions at Fishprint, Australia 43 vive the global economy on their often prompted by a persistent loss Klaus Schmidt own. An end to the ongoing reces- of confidence in future growth [email protected] Shorts 44 Editorial

State aid distorts competition and harms the print media industry Bloated structures should not be preserved

Helge Hansen, president and CEO, Koenig & Bauer

The global economic recession precipitated by the turmoil in financial mar- Following a dramatic decline in sales from September 2008 to April kets has persisted for eighteen months now. In the print media and supply 2009, demand for printing presses has been relatively stable since early industries, both of which are heavily exposed to advertising cycles, its with- last summer, albeit at a much lower level than in 2005 or 2006. While ering impact on order volumes and balance sheets has been greater than many countries are experiencing a mild upturn, we believe this will trans- in almost any other business sector. Following decades of outstanding suc- late into no more than a modest lift in market demand, not a sustained re- cess in the international arena, 2009 brought reports from major German covery. press manufacturers of plunging sales, heavy losses, short-time work, im- We are therefore all the more delighted to report that in this volatile pending mergers and the loss of thousands of jobs, overshadowing the en- market environment we posted Group sales last year of €1.1bn and thus tire industry. closely approached the target we had set. In view of the current state of KBA did not escape a painful yet economically imperative adjustment the print media industry the balanced pre-tax result we anticipate is some of the core workforce. In the 2009 business year Group sales plunged by achievement. We were helped by the fact that throughout the crisis we 31 per cent and the Group payroll dropped below 7,000. By the end of have maintained our liquidity with no new bank loans and have not had to the current year it will have fallen by several hundred more. The situation take up the credit lines previously secured as a precaution. While we have at our competitors is much the same: when sales collapse and market responded to market pressures by downsizing over the past two years, KBA prospects are poor, there is simply no viable alternative to a rapid and rad- remains a solidly financed, stable and innovative partner to the print media ical realignment. A merger within the industry would not have mitigated industry. the need to downsize capacity and payrolls in response to a diminished There is absolutely no truth in the rumours currently circulating in the market volume. market that we are planning to withdraw from press technology in order For all those involved, such an adjustment inflicts both personal and fi- to focus on new business lines. What is true is that, 193 years after the nancial pain. It is therefore important to ensure that the conditions under company was founded by the inventor of the printing press, we are ex- which it is implemented are equal for all players. Unfortunately, the mis- panding from our core business into other markets. Industry insiders fore- givings we expressed last summer following the extension of substantial see limited growth prospects for print in today’s media landscape, and state aid to one of our biggest competitors appear to have been justified. exceptions such as packaging merely serve to prove the rule. While KBA According to information we have received, the additional financial scope has a much broader base in the print market than other press manufac- afforded by public credit lines and guarantees is being used to offer ex- turers, it makes sound business sense to establish a firm foothold in a dif- cessive discounts on prices and other conditions of supply in order to ferent sector. With this move we are seeking to counteract cyclical empty overflowing warehouses and create liquidity. Bloated organisational fluctuations in the press market and safeguard our existing plants by ex- structures that are no longer appropriate for today’s markets are thus being ploiting their earnings and development potential in the medium term. preserved, nullifying the impact of successful efforts elsewhere in the in- KBA is fortunate enough to have the necessary room for manoeuvre. This dustry to trim fat and cut costs. is not the case everywhere. This is detrimental both to the print media industry and its suppliers. 2010 will bring fresh challenges for us all. However, a crisis also rep- The decline in prices of new presses is undermining the market value of resents an opportunity to review and realign established structures and existing equipment, which is often offered by printers as security when processes. We wish you and your respective companies every success in seeking a loan for new investments. As if securing funds were not difficult squaring up to these challenges. It is in the nature of economics that a re- enough already, many a printer’s pleasure at obtaining a bargain price for cession is always followed by a recovery. Let us hope that this will arrive a new press is wiped out upon finding that his bank or accountant has val- soon and prove to be a vigorous one for print. ued his assets at bargain prices as well. Yours,

2 Report 36 | 2010 Two views of the press room: on the left the Rapida 106 six-colour press with a perfector after the second printing unit, dedicated plate-cylinder drives and a coater, on the right the consoles for the two presses with the DensiTronic desk in between

Comprinta opens new printing centre in Zurich with two Rapida 106 press lines Focus on quality and sustainability On 1 January a new sheetfed commercial printing plant went live in Zurich-Schwerzenbach at Comprinta, the product of an alliance among three Swiss enterprises: Neidhart + Schön Group, Druckerei Feldegg and Bühler Druck. As part of its avowed commitment to sustainability in commercial print produc- tion the company has installed cutting-edge technology in the form of two high-powered Rapida 106 B1 (41in) press lines. In the marketplace the three alliance partners will continue to act as independent entities.

he focal point of Comprinta’s feed, blanket and impression cylin- waste and thus contribute in no matic ink pumping from 200kg new production plant is the der washing systems, Ergo-Tronic small way to sustainable print pro- (440lb) drums were a crucial part Tpress room, where the two ACR (video magnifier), and auto- duction. The two presses are linked of the package. medium-format Rapida presses matic plate changing, pumping and to DensiTronic Professional spectral were installed and commissioned in cleaning in the coaters. Their new control software. A DensiTronic Successful start December last year. One is an eight- AirTronic deliveries allow them to PDF sheet scanner compares a test LogoTronic Professional’s open sys- colour version with a coater and handle different substrates at high sheet or proof with pre-press data tems architecture allows both perfector for four backing four, the production speeds. and flags deviations in both copy (eg presses to be linked to the alliance other is a six-colour hybrid version in foreign languages) and images. partners’ management information with aqueous and UV coaters plus Closed loop for premium quality Virtually all the tasks normally car- systems. It functions as a master in- perfecting after the second unit. Press specifications also included a ried out by a proof reader can thus terface to all production processes These configurations were chosen comprehensive closed-loop quality be automated. from administration and pre-press to support an extensive range of assurance package based on Quali- to press, finishing and the mail- products and wide choice of coating Tronic Professional, with ColorCon- Targeting greenery room. There are plans to maintain options. trol inline colorimetry and sheet In view of Comprinta’s commit- the plant’s technological and eco- Both presses are highly auto- inspection on both sides of the ment to greener production, the logical edge in the long term, and to mated and incorporate the most ad- sheet. Inline measurement and con- Rapidas’ alcohol-free capability – this end Comprinta has entered a vanced sheetfed technology on the trol not only enhance quality but with the option of converting to wa- collaborative alliance with KBA with market. To minimise job-changing also deliver substantial savings in terless at a later date – and auto- a view to exchanging information times they also incorporate Drive- on process-related technologies and Tronic SPC dedicated plate-cylinder automation, finishing and sustain- drives for simultaneous plate chang- able production. ing, DriveTronic SIS no-sidelay in- The installation and commis- sioning of the Rapidas were com- pleted without a hitch. In the first few weeks the emphasis was on op- timising process sequences, but now the two-high-tech presses can really demonstrate their capabilities Group photo taken after the contract had been inked for the two Rapida 106 press lines (l-r): to the full. Ralf Sammeck (KBA), Peter J Rickenmann (Print Assist), Olivier Neidhart, Christian Neidhart and René Schön (Neidhart + Schön Group), Daniel Schnyder (Comprinta), Erwin Oberhänsli and René Oberhänsli (Druckerei Feldegg), Marco Klaus Schmidt Benovici and Hans Neeracher (Bühler Druck) [email protected]

Report 36 | 2010 3 Sheetfed Offset | Niche markets

Calendar blocks in different colours ready for further processing by one of the automated Terminic enhances flexibility with Rapida 106 world makeready champion finishing lines Wall calendars for the world “We’re not printers, we’re calendar makers who just happen to have a press room as well.” This is how Wolfgang Rolla du Rosey, managing director of Bremen-based terminic, described his company’s line of business. A Rapida 106 with DriveTronic SPC dedicated plate-cylinder drives, a board-printing capability and inline quality control has been in operation at terminic since May last year.

hile most people associate preprinting up to three-quarters of minimum cost-effective run length the word ‘calendar’ with the prior-year quantity on one two- from 500 to 200 – a fact that is Wseasonal business, this does and one five-colour B1 (41in) press. much appreciated, especially by not apply to industrial-scale produc- Sorted by language, public holidays smaller businesses. The biggest tion. Five-and-a-half million calen- and basic colours, the calendars are single contracts are for around dars leave the Bremen company then placed in a high-bay store with 200,000 copies. In between, any- every year. Terminic’s standard 2,500 pallet slots. Production of the thing goes. Complete calendar pro- range comprises twelve different customised backing sheets for the duction begins in April and models, offering from three to six calendars usually starts in March, as continues until the end of the year, months at a glance, in a choice of soon as the first customers have with rush jobs accepted right up to 25 foreign languages. But products okayed their proofs. This is where the last moment. can also be customised, one exam- the new Rapida 106 comes into ple being KBA’s calendar for 2010 play. The five-colour coater press Success with a which shows four months at a with extended delivery is mounted single product glance and was printed in our cor- on a 450mm (17.75in) plinth to ac- B.C. Heye & Co., as the company porate colours. commodate board piles up to 1.5m used to be called, invented the Calendar production for the fol- Terminic MD Wolfgang Rolla du Rosey with (59in) high in the full sheet format. world’s first three-months-to-view lowing year starts in January. The one of the company’s current products, KBA’s The Rapida’s simultaneous plate wall calendar back in 1937. Since it four-months-to-view calendar for 2010 first three to four months are spent changing capability has reduced the was mainly sold to shipping lines

Press operator Andreas Landgraf (in front) and trainee printer Thore Jansen enjoy working Managing director Wolfgang Rolla du Rosey (l) with KBA sales manager Ralf Engelhardt with the new high-performance Rapida 106 at the new Rapida 106 which, like all terminic’s other presses, sports the company name

4 Report 36 | 2010 Website: www.terminic.eu

tomer orders to the second half of the year he was keen to have a high- speed press in place to handle the increased workload. The Rapida was up and running before the end of May. Key criteria for choosing the 106 were its inline finishing capa- bility, simultaneous plate changing and inline quality control. Accord- ing to terminic’s technical staff, KBA was the most convincing in meeting these specifications. Wolf- Terminic gained second place in the awards presented by a German trade magazine for the most attractive production plant gang Rolla du Rosey and plant man- ager Frank Loselein are also delighted with the support and ad- vice provided by KBA following and marine enterprises it was com- Production and calendar design press installation. When Rolla du monly called a nautical calendar. are subjected to a process of con- Rosey discovered that one of his The firm for whom the original tinual improvement and refine- sons was born on the same day of quarterly planner was created in ment. Designing such calendars the year as Friedrich Koenig, the in- 1937 – the Bremen-based Unter- demands the greatest precision to ventor of the mechanical printing weser shipping company – is a cus- ensure that the various countries press, he was sure he had made the tomer to this day, but has switched and regions receive the version with right choice. to terminic’s four-month model. By the appropriate public holidays The coater is used almost ex- the late 1950s other companies marked. Data are gathered by a clusively for water-based protective were also beginning to use this global network of sales bureaux and coatings. Quality management has handy calendar. Its popularity as an dealerships, assisted by embassies. been transformed by QualiTronic organisational and promotional tool To ensure absolute accuracy the and DensiTronic software. The job prompted its inventors to register proofs are checked by the same con- dockets contain a proof plus a copy the name “terminic” as an interna- stellation, which may involve as of the previous order as a guideline. tional trademark in 1967 and to many as five different readers. Colour matching is checked against focus exclusively on this type of Since the calendars must be Prior to being finished the calendar blocks are pre-press data and no longer by rule product. In 2000 terminic was also easy to read from a fair distance, the collated and glue-bound by Pavel Grisko of thumb. With long print runs, es- adopted as the company’s name. typography has also undergone reg- pecially, it is important that inking Today terminic has agencies and ular enhancements. The standard months either side of the current remains stable throughout. Many subsidiaries in many European versions have four basic colours for month, black for the type on work- products contain tonal gradations countries and on other continents, the dates, including one for work- days, and red for public holidays that are affected instantly by fluc- and is one of the few enterprises in days and red for Sundays and public and the date window. These are ter- tuations in ink application. Since Europe which specialise in making holidays. The calendars can also be minic’s logo colours, in evidence users look at the calendars for a these organisational tools. Around customised with additional basic throughout the premises: black whole year – often several times a 75 per cent of all incoming orders and spot colours. The vast majority floors, red partitions and cupboard day – print consistency is crucial. are placed directly by industrial en- of customers ordering three- doors, grey walls and details. A date Absolute precision during produc- terprises, the rest by members of months-to-view calendars still spec- block like those in the calendars en- tion is therefore a must. The new the advertising industry. ify grey for the background of the circles the production hall, there is press controls have reduced the a red date window between the waste rate to just ten per cent of its production hall and administrative former level. offices, and in the individual manu- History facturing rooms a number of details First PSO-accredited calendar 1927 Foundation of book printer B.C. Heye in Bremen are also picked out in the three manufacturer 1937 Development and production of the first three-months-to-view colours. The overall impression is of Some months ago terminic wall calendar a functional, futuristic design cre- achieved ISO12647-2 accreditation 1950 Resumption of calendar production following the Second World War; ated by professionals for this spe- for colour quality management delivery of nautical calendars to shipping companies and marine cific workflow. Last autumn proficiency in offset lithographic enterprises terminic was among the winners in processes, known in Germany as 1958 Expansion of deliveries to include other industries a photographic competition for the the Process Standard for Offset 1967 Registration of the name terminic as an international trademark most attractive production plant. (PSO). While such accreditation is 1968 Relocation to production premises on the outskirts of Bremen now common practice in illustra- 2000 Change in company name to terminic Counter-cyclical investment tion printing, the Bremen-based 2008 Return to Bremen and new, award-winning premises Wolfgang Rolla du Rosey signed up company gained it for cartonboard 2009 Installation of the first KBA printing press for the Rapida 106 shortly before printing. Terminic is thus the first Christmas 2008, when the financial calendar manufacturer in Germany Today: Annual output of 5.5 million calendars and economic crisis was at its to boast PSO certification. It is also height. Anticipating a shift in cus- focussing more on greener produc-

Report 36 | 2010 5 Sheetfed Offset | Niche markets

Grey, black and red – the dominant colours in the calendar blocks were adopted for the interior design of the offices

blocks, die-stamping and applying the date windows, folding the fin- ished calendars and packing them in corrugated sleeves. All at a speed of 1,800 cycles per hour. Maintain- ing and setting such complex machinery demands an intimate tion methods. FSC certification has Fully automated engineered for terminic’s product knowledge of the mechanical work- already been completed, the com- calendar production range and manufactured as a one- ings involved. pressors have been connected to Twice as many staff are engaged in off item. All the production se- Around 98 per cent of ter- the heating circuit and now provide finishing as in the press hall, and quences following cutting, collating minic’s workload is handled in- hot water in summer via heat ex- they include electromechanical en- and glue-binding are handled auto- house, with the application of a changers. gineers and bicycle mechanics. This matically by a single machine: these high-gloss film on luxury title im- is because all the machinery used in include groove-routing the back- ages being the only task out- calendar processing was specifically ing boards, applying the calendar sourced. The number of calendars produced has climbed steadily since the first post-war products came off Typical calendar production sequence the presses in 1950. Prior to ship- • Print date sections • Print backing boards ment throughout the world the cal- • Cut into piles of 12 • Laminate onto corrugated (optional) endars are gently enveloped in the • Collate • Film laminate (optional) enticing aroma of coffee emanating • Glue-bind from the nearby roasting plant – • Groove and trim which, of course, is also a regular Terminic managing director Wolfgang Rolla customer, in this instance for ter- • Glue du Rosey checking one of the trimmed minic’s 4-months-to-view calendars. calendars for which the new Rapida 106 • Die-cut date window and attach (in the background) mainly prints the • Fold backing boards • Pack Martin Dänhardt [email protected]

Grupo Nación: KBA showcase in Central America Rapidas power along in Comet’s wake

For Grupo Nación in San José, 20 No- vember 2008 was a day to remember. Eagerly watched by an audience of customers and suppliers, president Manuel Jiménez had the pleasure of in- augurating three new Rapida 105 five- colour presses simultaneously. It was also the day on which Costa Rica’s lead- ing print provider officially completed the transition to KBA for all its sheetfed technology, following a similar move in web with the start-up of a Comet press in 2004. From the left: Grupo Nación’s executive vice-president for production Mario Hernández with Jürgen Kibler of KBA agency Gevisa Artes Gráficas and Ronald Rojas, managing director of Grupo Nación’s print operation, at one of the three new five-colour Rapida 105s

6 Report 36 | 2010 Website: www.nacion.com Sheetfed Offset | Costa Rica

he trio of 18,000sph, high- powered Rapidas is regarded Tthroughout the region and be- yond as having redefined the bench- mark in sheetfed offset.

Service package plus But the production start-up was by no means the end of the Rapida project for Grupo Nación, whose in- tensive association with KBA will continue under the terms of a “ser- vice package plus” contract that en- tails regular in-depth training for press operators, and preventive Costa Rica’s leading print provider press maintenance. To make the completed the transition to all-KBA sheetfed and web press technology just over a year ago most of the Rapidas’ potential the training courses are also attended by design and pre-press staff. Mario Hernández (executive vice-president for production), by solid evidence gleaned on fact- growing, and we are well equipped Ronald Rojas (managing director of finding tours in Germany, Spain and to handle an emerging demand for Grupo Nación’s print operation) the USA.” heavier stock weights. All three and head of maintenance Mario presses feature dual-purpose chill- Gonzáles are delighted with devel- Expanding the product range ing devices to support low-alcohol opments to date. Says Mr Hernán- “The three Rapida 105 five-colour print production in compliance with dez: “The Comet project was a presses boast just about every pos- Costa Rica’s rigorous environmental huge success, so we knew we could sible whistle and bell,” declares regulations.” rely on KBA to deliver the goods. Ronald Rojas. “They each have a Mario Gonzáles is equally im- When it came to choosing the coater, double extended delivery, a pressed: “The training provided by Grupo Nación’s president Manuel Jiménez (l) sheetfed presses, it wasn’t the price shaftless feeder, no-sidelay SIS in- KBA’s print instructors, and the and KBA sales manager Ulrich Wicke with a plaque commemorating the inauguration of that informed our decision but our feed, automatic plate changing, service provided by Radebeul and the three Rapida press lines confidence in KBA and its cutting- Inkline ink pumping, a cartonboard KBA agency Gevisa Artes Graficas, edge technology. Our four existing package and UV/hybrid capability. have given our staff a detailed un- presses from other manufacturers All three presses had a smooth, derstanding of the presses, enabling had reached the limits of their ca- trouble-free production start. So we them to get the maximum out of pabilities and we realised it was can offer our customers products of them in terms of both performance time to re-engineer our entire the highest quality, with a faster and quality. The Rapidas are ex- sheetfed operation and realign our turnaround than ever before. This tremely reliable and will do us objectives. The quality, perform- is particularly true of jobs requiring proud for many years to come.” ance and productivity of KBA’s UV and hybrid inks and coatings. In- presses gave them an immediate ad- terest among our customers in the Cost savings cushion vantage, and this was underscored new finishing options is steadily impact of crisis The inauguration of the Rapidas at the end of 2008 was accompanied by an extension to the Comet press The controls for the new KBA sheetfed presses line from eight towers to ten. “The include a DensiTronic Professional closed-loop densitometric colour measurement and control Comet is in operation for 16 to 19 system to the left of the ErgoTronic console hours a day, and is well utilised for both coldset and semi-commercial production,” explains Mr Hernán- dez. “The quality it delivers closely and economic crisis. Nevertheless, approaches that of commercial off- we look forward to the future with set. In addition to our three in- confidence and optimism. We have house daily titles, La Nación, La Teja compensated for smaller circula- and Al Día, and a weekly, El Fi- tions and reduced pagination by nanciero, we also contract print trimming production times and dra- around 50 other newspaper titles matically cutting costs. We are not with small circulations.” losing any money and our business He goes on: “The production is as sound as ever.” start of the three Rapidas and the The press operators at Grupo Nación are proud to be working with the most advanced extension to the Comet coincided Gerhard Renn medium-format press in Central America with the breaking of the financial [email protected]

Report 36 | 2010 7 Sheetfed Offset | Cost efficiency

Cheaper kit can prove expensive Productivity – a key cost factor A lot of printers are hoping to survive the current crisis by clinging to outdated kit and economising on maintenance and service. Others are pursuing a policy of counter-cyclical investment to hone their competitiveness in an ever harsher market climate in preparation for an eventual upturn. When investing in a new press, decision-makers often place far too much emphasis on price. As the following calculations taken from large-format packaging printing illustrate, economising in the wrong place can prove expensive: initial capital savings, for example, may later be outweighed by costs further down the line, in production.

PileTronic automated logistics workflow Comparison of makeready times

Job changing program Plate change Blanket washing Coating plate change Roller washing Other makeready Impression cylinder washing First proof Ink duct washing Colour measurement/control Coating change Final proof Corrections Comparable press = 45 minutes

KBA Rapida 142-6+coater = 23 minutes

1 Pile turner with pallet dispenser 4 Park positions for prepared piles 2 Pile conveyor to the relevant feeders 5 Automatic turner for empty pallets 3 Automated DriveTronic feeder with 6 Automated nonstop delivery nonstop facility 7 Park positions for printed piles 5 10 15 20 25 30 35 40 45 Time in minutes

hen printing packaging on fore follows that extensive automa- mated Rapida 142 large-format six- coater (100%) relative to the other an industrial scale two basic tion may well justify the higher cap- colour coater press (Rapida 142- press (85%) was partially attributa- Waims are to maximise out- ital investment cost. 6+coater) with automated pile ble to the automated pile-logistics put while minimising changeover logistics – a constellation commonly system in which it is embedded. times. Where the substrates used Do not compare used to print packaging – and a less are identical, the key parameters in- apples with pears highly automated press from an- Lower hourly rate despite fluencing a press line’s economic ef- In our examples we employed a other German manufacturer in the higher capital cost ficiency and total production costs classic calculation of machine over- same 1020 x 1420mm (40.15 x However, this also (beneficially) in- are net productivity in conjunction heads (see chart on opposite page) 55.9in) format but with no auto- fluences the hourly rate and the with the labour and energy input re- to compare the productivity and mated pile logistics. The higher cap- total payback period. Even though quired for the various jobs. It there- cost efficiency of a highly auto- ital cost of the Rapida 142-6+ the initial capital cost of the com-

Annual production output in jobs Annual production output in sheets

Comparable press KBA Rapida 142-6+coater Gain with Rapida 142 Comparable press KBA Rapida 142-6+coater Gain with Rapida 142 3,597 5,914 2,316 = 64 % 17,985,000 29,568,000 11,583,000 = 64 %

No. of jobs per year Rapida 142, output gain No. of sheets per year Rapida 142, output gain 11,000 95 % 50,000,000 95 % 90 % 90 % 10,000 85 % 45,000,000 85 % 80 % 80 % 9,000 75 % 40,000,000 75 % 70 % 70 % 8,000 35,000,000 65 % 65 % 7,000 60 % 60 % 30,000,000 55 % 55 % 29,568,000 sheets 6,000 50 % 50 % 5,914 jobs 25,000,000 45 % 45 % 5,000 40 % 40 % 20,000,000 17,985,000 sheets 4,000 35 % 35 % 30 % 30 % 3,597 jobs 15,000,000 3,000 25 % 25 % 20 % 10,000,000 20 % 2,000 15 % 15 % 1,000 10 % 5,000,000 10 % 5 % 5 % 0 0 % 0 0 % 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 Ø run length 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 Ø run length (sheets) (sheets)

8 Report 36 | 2010 parable press is 15% lower than for Specifications KBA Rapida 142-6+coater Comparable press the Rapida 142 with peripherals, its Plinth ☑☑ hourly rate is 18% higher. The Rap- Automated nonstop feeder ☑☑ ida’s reduced rate is largely the re- Automated nonstop delivery ☑☑ sult of its higher output in tandem Interlinked pile logistics ☑ PileTronic ☐ Not interlinked ☑ ☐ with a fully automated, interlinked Automatic plate change FAPC Semi-automatic Washing system ☑ Blanket/impression cylinders, rollers ☑ Blanket/impression cylinders, rollers logistics system. Lower labour costs Simultaneous washing ☑ CleanTronic Synchro ☐ Not available and much lower energy consump- Automatic coating plate change ☑☐ Manual tion with KBA’s VariDry dryer also Coating system cleaning ☑ Automatic ☐ Manual helped trim costs (see article on en- Register system ☑ Automatic Camera Register ☐ Not available ergy efficiency, pages 22-23). Energy-efficient dryer ☑ VariDry ☐ Not available When calculating the respective Inline colour measurement/control ☑ QualiTronic CC ☑ output levels of the two presses we Online PDF control ☑ DensiTronic PDF ☐ Not available took as our basis the makeready times and average run length per job. As the top right-hand graph on Machine overheads KBA Rapida 142-6+coater Comparable press page 8 illustrates, a complete job Working days per year 250 250 change on the Rapida 142 takes just Working hours per shift 7.4 7.4 23 minutes – little more than half Number of shifts 3 3 the time on the rival press. A major Gross capacity utilisation rate 300 % 300 % reason for this is the Rapida’s ad- Net capacity utilisation rate 90 % 85 % vanced level of automation and si- Printing as proportion of multaneous washing cycles. Higher production output 90 % 85 % automation is also the reason why Makeready per job 23 minutes 45 minutes changes of coating, printing plates Maximum production speed 15,000 sheets/h 14,000 sheets/h and coating plates are also much Energy-efficient dryer VariDry Not available faster on the Rapida. Average run length 5,000 sheets 5,000 sheets Price of press 100 % 85 % 2,300 more jobs Payback period 37 months 38 months per year Calculated hourly rate 375 euros 443 euros Shorter makeready times mean that the Rapida can print a much larger number of jobs per shift or day. Assuming an average run length of 5,000 sheets per job, the 142 and the comparable press for job costs with the Rapida 142 are times necessarily play a minor role. 15,000sph Rapida 142’s higher average run lengths of between €259.30 lower than with the com- But where short runs dominate the level of automation and modestly 1,000 and 15,000 sheets. They can parable press. production schedule, and this typi- higher production speed enable it be calculated individually for any cally applies to printers of cosmet- to print 2,316 more jobs or printing plant. No false economies ics and pharmaceutical packaging, 11,583,000 more sheets per year The per-job costs for the two While there is some truth in the they can be a key factor – along than the cheaper rival press. presses depend to a large extent on much-repeated argument that a with labour costs, energy consump- The two graphs at the bottom of output. In the graph below it can be highly productive press is only tion and waste rates – in determin- page 8 show the output in jobs and seen that, for an assumed average worth the extra money if it is ing economic viability. In view of sheets respectively on the Rapida run length of 5,000 sheets, the per- utilised to the full, it is wrong to the flexibility demanded today, a conclude that a cheaper, less pro- press that performs well on every ductive press is the right choice measure may therefore prove to be Per-job costs where order volumes leave a lot to the better business option. The be desired. This defensive invest- Rapidas fit the bill. Comparable press KBA Rapida 142-6+coater Gain with Rapida 142 ment philosophy ignores the signif- Printers’ job structures differ €569.03 €309.80 €259.23 icant cost drawback of competing enormously. When contemplating Per-job costs Rapida 142, cost gain with rivals whose equipment is the purchase of new kit, these dif- €1,100 €400 much more productive. ferences can be addressed by con- €1,000 €350 ducting individual productivity and €900 € Pre-investment analysis cost-efficiency analyses. KBA is al- €800 300 € The examples given, based on an av- ways happy to help. 700 €250 €600 erage run length of 5,000 sheets, €200 €500 indicate that even if the initial cap- €400 €150 ital cost is higher, it may still be €300 €100 wiser to go for a highly automated €200 press line with correspondingly €50 €100 shorter makeready times. Where € € 0 0 run lengths are generally long and 10,336 8,724 7,531 6,625 5,914 5,340 4,868 4,473 4,137 3,848 3,596 3,376 3,181 3,007 2,852 Jobs / year Jürgen Veil 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 Ø run length (sh) there are fewer changes, makeready [email protected]

Report 36 | 2010 9 Sheetfed Offset | Innovation

The four Rapida 106 press lines were erected in pairs

Euradius Group pursues ambitious investment strategy in the Netherlands Ramping up book production with four Rapidas and flying job changes The Euradius Group in the Netherlands has squared up to mounting competition with the purchase of four Rapida 106 press lines featuring KBA’s new Flying JobChange automation module. This major capital investment was the final component in an ambitious project that united four printing plants under a single roof in less than four months.

n 2 December 2009 the head- Too many books left on the shelf through the pages,” says Ed van den duction times have been steadily line on the title page of the Ten Brink is a subsidiary of the Eu- Ham, deputy sales director of shrinking.” Which is why, according OMeppeler Courant read “All radius Group. One of the compa- HooibergHaasbeek. “A book stand- to Mr van den Ham, publishers are systems go at Ten Brink printing nies that relocated to Ten Brink is ing on a shelf or lying on a pallet in busy searching for alternative busi- plant!” For Meppel, which was HooibergHaasbeek, a prominent a warehouse is dead. In fact a book ness models. “You can only afford once the graphic arts capital of the printer of literary books. “Books are on a pallet is not just dead – it’s to maintain a large stock of books if Netherlands, this was a major generally impulse buys, and that im- costing money.” you produce a bestseller from time event, safeguarding as it did around pulse is stimulated by seeing the He continues: “Editions have to time.” Publishers today prefer to 260 jobs. Four printing plants were book in the shop and leafing been declining for years, and pro- print short runs rather than incur merged to form one large-scale op- the risk of having a dead weight of eration in the record time of four “For us, flying job changes are key to addressing the growing demand books lying around.” months. According to the newspa- per, the ‘icing on the cake’ was the for shorter print runs and faster turnaround.” René de Heij fact that this new entity had in- vested heavily in new press tech- Flying JobChange nology: four identical Rapida 106 With Flying JobChange, the plates on four-colour perfectors for two-back- the printing units not required for the ing-two, with DriveTronic SPC current production run can be changed dedicated plate-cylinder drives, ‘on the fly’ and the press made ready DriveTronic Plate-Ident pre-registra- for the next job rapidly and more or less automatically, with virtually no tion and a software package for down time. This substantially enhances switching flying plate changes to net press productivity. printing units 1 and 3 while a monochrome perfecting job is printed on units 2 and 4, then vice versa for the next job. The presses The Rapida 106 with Flying JobChange is a are the first in the country to fea- Formula 1 machine that demands a similar level of performance on the part of the press ture this capability, which is a world crew first.

10 Report 36 | 2010 Internationally active The Euradius Group is active in many sec- tors of the graphic arts market. Ten Brink and HooibergHaasbeek print books, maga- zines and business stationery under a single roof in Meppel, while Printforce in Alphen aan den Rijn delivers a range of other printed products. Euradius also has opera- tions outside the Netherlands, for example Cross Media Solutions and Stürtz in Ger- many and Eurasia in the Middle East.

Managing director René de Heij: Operations manager Hans Kleijn: HooibergHaasbeek deputy sales director “Down times on our presses are virtually zero.” “If you’re printing on an industrial scale, the Ed van den Ham: “You can only afford to individual links in the production chain must maintain a large stock of books if you produce be 100 per cent co-ordinated.” a bestseller from time to time.”

Move towards books on demand shorter print runs and faster turn- routine be kept at a minimum? The ing on an integrated production So just what is required to produce around. Thanks to the new flying solutions were eventually found chain that starts at order reception short runs of books in a minimum job change capability we can match after some long and strenuous and ends when the contract has of time and at a profit? Euradius output to demand. Down times on working days. been completed and the goods de- opted for automation of the pro- our presses are virtually zero.” The pre-press department has livered. If you’re printing on an in- duction chain and the installation of In the months preceding the four 70/100 ctp platesetters. These dustrial scale, the individual links in four KBA presses with an unrivalled press installation De Heij and his are needed to maintain an uninter- the production chain must be 100 level of output. Managing director team had to resolve a number of rupted supply of plates to the fleet per cent co-ordinated, and this de- René de Heij says: “Our press fleet knotty issues. How do you integrate of nine KBA presses, which have a mands highly sophisticated systems. has enabled us to corner some four disparate companies, each with total of 45 units. With so many We connected KBA’s LogoTronic twenty per cent of the market. The its own culture, into one healthy plates being changed at such fre- Professional software directly to our Rapidas’ cutting-edge technology is enterprise? How should the new lo- quent intervals, mistakes can easily management information system. a major advantage, since it allows us gistics system be organised? How occur. To eliminate this risk each So on my computer I can view all to address a market shift towards can disruption to the production plate is automatically furnished the relevant management, produc- with its own individual data matrix tion, purchasing and logistics data code prior to leaving pre-press. in real time. We have automated With the aid of this code – KBA calls wherever possible.” the module it has developed inter- nally Plate-Ident – the system recog- Three minders for two presses nises whether the plate is new or Ink feed to the KBA presses, for ex- used and to which printing unit it ample, is via a central pumping sys- has been assigned. The module also tem. The Rapidas were erected in checks whether the correct lan- pairs, side by side, with a raised guage version is being loaded. platform in between so that the op- erators can move to and fro. This Continuous printing enables three minders to operate Operations manager Hans Kleijn two presses. had his hands full while the presses The press crews in Meppel were being installed. “We are work- work in three shifts, and there are Ten Brink in Meppel is the product of a merger by four printing plants to form one big operation plans to expand this to continuous production. At present Ten Brink is training 23 press operators to han- dle the new presses. Says René de Heij: “In our line of business, job losses are inevitable. For those af- fected this is a bitter pill to swallow, but at the same time everyone is well aware that, however tough this may be, we simply have no other choice. The only way to maintain profitability is to streamline opera- tions and invest in the most ad- vanced equipment and processes on the market. This is what we have done in Meppel.” During a flying job change the plates are changed in one pair of printing units (1 plus 3 or 2 plus 4) Print production in 2010: while mono perfecting takes place in the other pair multiple short-run jobs Leon van Velzen [email protected]

Report 36 | 2010 11 Sheetfed Offset | Netherlands

Vis Offset’s Rapida 75 four-colour press with automatically convertible perfecting after the second unit

Dutch printer Vis Offset installs its first Rapida 75 perfector press “With our new Rapida we are more flexible than we previously were with two presses” What audacity! Purchasing a new Rapida 75 perfector press in the midst of a set in Alphen aan de Rijn has taken the place of two others. “It has increased our recession. Not only that – this single press line at Dutch print enterprise Vis Off- flexibility enormously,” says founder Arie Vis.

ll over the world the graphic 40,555 registered employees cov- printers and the outdoor advertising Rational decision arts industry is in the throes ered by collective wage agreements. industry. Vis Offset is a typical example. The Aof a radical transformation, On 31 August last year, the most re- This year employment in this company has been supplying and the Netherlands is no excep- cent date for which figures are avail- sector is expected to be approxi- printed products to the retail trade tion. According to statistics released able, there were 3,687 fewer – a mately 20 per cent below the 2008 since 1949, along with magazines. by the Grafische Bedrijfsfondsen 9.1 per cent decline in just eight level. However, a closer look reveals Founder Arie Vis started off doing (GBF, the agency which administers months. Which means that at pres- something else behind these fig- duplicating work for his father’s ad- pension schemes for the Dutch ent there are still 36,868 people ures: while employment is dwin- ministrative office. He was joined graphics/media industry), at the end employed by trade printers, screen dling, productivity continues to soon after by his brother Jan. In of 2008 the sector had a total of printers, newspaper publishers and climb rapidly. 1954 the two siblings decided to expand into small-format offset, and were among the first to do so. Nowadays the company is run by two of the brothers’ sons: Arjan has followed his father into the techni- cal side of the business, while Daniel – also like his father – is in charge of sales and administration. In August 2009 Mijdrecht- based Wifac, KBA’s sheetfed and commercial web press agent in the Netherlands, installed the first Rap-

A touch-screen (right) at sheet delivery allows rapid intervention

12 Report 36 | 2010 Cutting-edge control technology makes life much easier for the press crew The Rapida 75’s compact footprint and low energy consumption make it the press of choice for an increasing number of printers, both in western Europe and beyond ida 75 perfector press in the town. “The Rapida prints up to 15,000 saleable colour means there is very the Rapida printed its first job – Says Arjan Vis: “We signed the con- sheets per hour. But even more im- little waste, so we can insert rush without a single hitch. Right from tract with Wifac in November portant than its maximum speed is jobs more easily into the production the start we had complete confi- 2008, when the crisis had already the time required to prepare the schedule. Press operators don’t like dence that everything would run broken. If we had to make a deci- next job, and the speed with which having to stop in the middle of one smoothly. As a small-format offset sion today it would be no different.” it runs up to colour. This is where job in order to do another, but with operation we were already well ac- At that time Vis Offset employed we save both time and waste. One the Rapida that’s no longer an quainted with Wifac, and they have twelve staff, but this has since been of our customers has his letterheads issue.” never disappointed us.” reduced to ten. printed with four PMS colours, Arjan Vis agrees: “Don’t forget “Initially our press foreman Daniel Vis explains: “A press op- which means the press must be this press has twice the output of found that the Rapida 75 took some erator and a print finisher both cleaned as thoroughly yet as rapidly the previous two combined. While getting used to – as soon as the ma- reached retirement age. We had as possible prior to impression. This our sales figures have not yet dou- chine was up and running he had been printing on a mono press that is one of the Rapida’s main bled, we have gained enormous virtually nothing more to do,” de- was almost twenty years old and on strengths, alongside extensive au- time savings. One press operator is clares Arjan Vis. “At times the press a two-colour press that had served tomation with a CIP3 interface.” now doing the work of two.” crew still find this hard to believe, us well for ten years or more. When But when a company replaces but they are delighted with the Rap- we came to take a closer look at our two older presses with one single Holiday installation ida’s print quality. Regardless of order structure, we found that a new one, isn’t it taking a consider- Wifac and KBA’s specialist installa- whether it is handling lightweight large proportion entailed two able risk, like skating on thin ice? tion team erected the Rapida during paper or heavier grades, the results passes, for recto and verso produc- Not unnaturally, the two cousins the company’s summer break. “We are immaculate. On top of this its tion. Armed with this information devoted a great deal of thought to always close down for three weeks ease of operation and practical level we set to work and came to the this issue. “If a really serious prob- in the summer. That may sound like of automation, with semi-automatic conclusion that a four-colour press lem were to arise, we could always a luxury, but it means our staff can plate changing and washing, save with a perfecting capability would turn to Wifac,” explains Daniel Vis. take the number of days off that our operators a lot of work. They be the best choice. In the end we “Much more important for us is the they are legally entitled to, and we also reduce our consumption of opted for the Rapida 75, largely be- enormous flexibility we have today, have found that business is nor- fount solution and cleaning cloths.” cause what struck us particularly which allows us to take on much mally slack at that time of year. The Vis is a dedicated offset printer about this press is that it can per- bigger contracts. An added advan- old presses were dismantled and re- and has no intention of changing. fect at maximum speed. Another tage is that the fast run-up to moved on 17 July, and on 13 August “We print jobs for customers from point in its favour is that job all over the country. I cannot be- changeovers are remarkably short lieve that a market with annual sales because the impression cylinders worth 7.5 billion euros is in danger and blankets can be washed simul- of vanishing at a stroke. While we taneously.” are obviously aware of a shift to- wards the internet and digital print Enhanced flexibility production, we certainly do not see Vis Offset generally runs just a day ourselves as the last of the Mohi- shift, and management would like cans. Our investment in the Rapida to keep it that way. Says Arjan Vis: 75 is an investment in our future.”

Even though the print media are experiencing a period of wrenching change, Vis Offset management is confident that offset printing Leon van Velzen has a promising future [email protected]

Report 36 | 2010 13 Sheetfed Offset | Ireland

e identified the fully-specified B2 KBA as “the perfect re- Hplacement” for a Heidelberg as CL’s frontline press and says: “The results speak for themselves – being able to offer high-quality short-run colour print competitively has been essential to our survival in the current economic climate. We would have gone under without the Rapida 75. “Now we are completing 50% more colour book work. Customers want shorter runs completed faster and we never would have been able to do that before in such a price- sensitive way. Also with the quicker makereadies we are able to change jobs over faster, allowing us to get more small runs out of the door to meet the tighter turnaround times. Some former customers who had moved away because we weren’t competitive enough have started coming back.” The new press investment was Micheál Ó Conghaile, owner of CL Print, is happy to have the Rapida 75 on side in today’s challenging market environment part of the Connemara printer’s strategy to drive up quality, improve efficiency and increase capacity in order to boost competitiveness for CL Print: Rapida 75 makes the difference new business as well as existing ac- counts – these include Aer Arann’s prestigious in-flight magazine, ex- Quality and productivity press-it, and the annual order of 120,000 handbooks for the Central Applications Office attached to the sharpen competitive edge Department of Education. CL Print also has a strong tradi- A “company-saving investment” is how Micheál Ó Conghaile, owner of Clódóirí Lurgan Teo (CL tional customer base within the Print Ltd) in Inverin, County Galway, has described the addition of a six-unit B2 (29in) Rapida 75 region and beyond, a mix of inde- pendent publishers, authors and to his pressroom firepower. “We would not still be in business if it wasn’t for the KBA,” said Ó Con- government bodies as well as key ghaile, who was the first printer in the UK and Ireland to install the new Rapida 75 following its commercial clients. world launch at Drupa 2008. All-rounder in Irish and English As its dual name suggests, the west tures from its larger presses into coast printer works in both the Eng- this machine – like the automated lish and Irish languages. Its lan- sidelays, the self-adjusting grippers guage advantage in the Gaeltacht and the cocking system,” says Mr Ó (Irish speaking) regions has created Conghaile. “It also has a strong con- a sound base historically, although struction but a small footprint and, as more than 40% of output is now most important for us, it is very en- in English the ability to compete as ergy-efficient. That has given us a a commercial print house at every key operational advantage and re- level is essential. duced our carbon footprint. This is Before investing in the Rapida an increasingly important factor 75 all the major manufacturers when tendering for government were considered, with print quality and blue-chip contracts.” and productivity key concerns. Then it came down to operational Vic Fletcher benefits and value for money. “KBA [email protected] has incorporated a lot of the fea- CL Print’s premises on the Emerald Isle

14 Report 36 | 2010 Sheetfed Offset | Peru

Gráfica Biblos’s Willy (l) and Alfredo Yoshimoto with their press crew at the new Rapida 105 universal

in Peru – an Agfa-Galileo UV with ApogeeX workflow. The result: a re- duction of around 80 per cent in pre-press preparation time, a much sharper image and a surge in orders for hardback anthologies and coffee table books. The sheer volume of new orders created the need to expand pressroom capacity once again. So in 2004 Biblos signed up for a Rap- ida 72 with six printing units and a coater. This established the com- pany as the country’s showcase for modern printing technology. A good year ago the Yoshimotos installed their first medium-format press – a five-colour Rapida 105 universal, Healthy expansion from half- to medium format also with a coater. Alongside its big- ger format and an output of 15,000 sheets per hour, the new Rapida’s Gráfica Biblos shines with automatic plate changing, Ergo- Tronic ACR (video register) and DensiTronic measuring and control “Río Amazonas” and Rapidas system delivered a further huge productivity boost. Automatic wash- In 2007 Lima-based Peruvian print enterprise Gráfica Biblos won the much coveted Benny Award, the highest ing systems for the impression accolade bestowed by the PIA (Printing Industries of America) for various printed products in 100 different cylinders, blanket cylinders and ink- ing rollers have vastly improved the categories. In the category “hard cover trade books, journals and other books” Biblos’s entry, a book entitled “Río working environment for the press Amazonas River – 7,000 km” scooped the award against some 5,000 competitors from all over the world. At the end crew by reducing both labour input of 2008 the company’s first B1 (41in) press, a Rapida 105 universal, launched into action alongside its two existing and emissions. With the CIP3 work- flow, initial ink-key presetting val- B2 (29in) Rapida 72 presses. ues are a 90 per cent match with the proof.

iblos has been in the market second four-colour press, this time which delivered a big boost in print New premises provide for twenty years. Its founda- a B2 (29in). There followed exten- quality and productivity. Repeated greater capacity Btion in 1989 by two brothers, sive investment in pre-press and difficulty in maintaining a ready Early last year Gráfica Biblos moved Alfredo and Willy Yoshimoto, coin- finishing kit as the company’s cus- supply of imaged plates prompted into new company premises which cided with the fall of the Berlin Wall tomer base and order volume grew them to install the first ctp system are just a few minutes from Peru’s in Germany. Initially they offered along with its capabilities. financial centre, giving it 3,200m² print services which they out- (34,500ft²) of floor space for pre- sourced to other firms, but in 1991 From a Rapida 72 to a Rapida 105 press, press and post-press produc- they installed their first press, a universal in ten years tion. 106 employees work two four-colour SRA2 (25in) model. In 1998 the two brothers pur- twelve-hour shifts producing cata- Three years later it was joined by a chased a four-colour Rapida 72 logues, non-fiction and school books, diaries, travel guides and a lot more besides. The plant con- sumes up to 1,000 tonnes (1,100 US tons) of paper per year. At pres- ent Biblos is busy expanding its publishing arm with the aim of pro- moting its own products not only Alfredo Yoshimoto proudly displaying the on the domestic market but also in Benny Award the company won in 2007 for a Central America and on the West book entitled “Río Amazonas River – 7,000 km” Coast of the United States.

Alongside the B1 Rapida 105 the company Martin Dänhardt operates a Rapida 72 six-colour coater press [email protected]

Report 36 | 2010 15 Sheetfed Offset | France

onservation is a major focus in the town of La Rochelle, whose Ccommitment to the environ- ment is widely known. Pascal Sabourin and Dominique Boucard, president and managing director re- spectively of Imprimerie Rochelaise, have a similar philosophy. The com- pany was awarded the “Imprim’ Vert” certificate for green print pro- duction in 2003, has also gained PEFC and FSC accreditation and is currently preparing for ISO 9001 (quality management) and ISO 14001 (environmental manage- ment) compliance. It has even cre- ated its own QSE (quality, safety, environment) unit, hiring a skilled engineer to fill the post, and has drawn up its own carbon emissions balance sheet. Dominique Boucard says: “Our aim is to reduce emis- sions of greenhouse gases by ten Imprimerie Rochelaise president Pascal Sabourin (left) and managing director Dominique Boucard are delighted with their first KBA press per cent within the next three years.” Printing inks based on veg- etable oils, zero per cent IPA, waste minimisation, air humidifiers, os- Imprimerie Rochelaise on growth trajectory with Rapida 106 mosis systems for fount solutions – the two partners are working to- wards environmental production DriveTronic SPC using every tool at their disposal. Since 2008 they have invested heavily in finishing equipment (fold- enhances productivity ing machines, gang stitchers, foil laminators) with the aim of reduc- Following ten years of uninhibited growth, a few months ago 55-year-old French printing enterprise Imprimerie ing the number of suppliers and Rochelaise in La Rochelle ushered in a new period of rapid expansion when it pressed the button on a high-per- also the number of lorries making deliveries to the plant. This year a formance Rapida 106 eight-colour perfector with DriveTronic SPC dedicated plate-cylinder drives. The competitive 300m² (3,230ft²) photovoltaic sys- gains delivered by the world makeready champion are most evident for run lengths of up to 3,000 copies. tem will be installed on the roof.

Printing plant with a social conscience of its workforce qualified through sports clubs and other associations, clares Pascal Sabourin, “and that in- Imprimerie Rochelaise, which sees youth or sandwich (intern) training and nurtures a social working cli- cludes investment.” Total invest- itself as a “socially oriented” print- schemes. The firm is also closely mate with profit sharing by employ- ment in 2009 and 2010 will top ing plant, devotes a lot energy to aligned with the town training cen- ees. “For us, sustainability is key in €4 million ($5.7m). The biggest helping young people. One quarter tre, supports youth work via diverse every aspect of the business,” de- item on the agenda was the new eight-colour Rapida perfector for four backing four. Two new ctp sys- tems and a new gang stitcher will follow later this year. The Rapida 106, which is the company’s first KBA press, joined a four-colour coater press for a slightly smaller sheet size (740 x 1040mm or 29.31 x 41.15in) and a five-colour B2 (29in) press.

Unparalleled productivity “Our Rapida 106 is a real work- horse, with unparalleled productiv- Imprimerie Rochelaise derives its name from its location in the beautiful town of La Rochelle on the Atlantic coast ity,” says Sabourin. “It has enabled us to hone our competitiveness, cut

16 Report 36 | 2010 The KBA LogoTronic production management system supports data transfer from pre-press to press and also the creation of a detailed environmental balance sheet by furnishing production and consumption data

delivery time-frames and enhance in 2000. Thanks to Pascal Sa- was brought back on course again. tion, reactivation and return to prof- our customer service.” In 2009 the bourin’s pugnacity and his young “The new logo, ‘R’, stands for ren- itability,” the president explains. 50-employee company posted sales team’s fighting spirit, the company aissance, reinvestment, reorganisa- Corporate philosophy and culture of €7.7m ($11m). Annual profit for also played a role in the choice of the past two years has averaged 3%. press manufacturer. Says Sabourin: “This proves that sustainability and “Imprimerie Rochelaise shares profitability are not mutually exclu- many values with KBA. The found- sive,” he says. ing family still plays a significant Productivity and fast turn- role and, like us, KBA operates ac- around were key criteria in the cording to the maxim ‘we say what choice of press. The LogoTronic we do and we do what we say.’” software not only allows ink and paper consumption to be calculated Tests prove the Rapida 106 is but in conjunction with the high the most productive of all level of automation also boosts net “The decision in favour of KBA was output and cost efficiency. Drive- a no-brainer: tests conducted on a Tronic SPC supports fast, simulta- number of eight-colour presses neous changes of all eight plates using our own data and paper while the blankets and cylinders are proved that the Rapida 106’s per- being washed, which saves a lot of A video system (upper screen) monitors sheet travel through the perfecting unit formance was way ahead of the time. in the Rapida 106 rest,” declares Dominique Boucard. “When we gradually increased Shared values stock weight, the other presses Imprimerie Rochelaise’s focus on were already producing deep sustainability and craftsmanship scratches and buckling while the may be attributed to its family tra- KBA press had barely started leaving dition. It was founded by René fine streaks.” Says Sabourin: “What Chevalier, grandfather of the cur- most impressed me was the per- rent president Pascal Sabourin, who fecting unit.” Boucard agrees, took over in 1989. René Chevalier adding: “We were also pleasantly was a charismatic man with strong surprised to find that the Rapida humanistic principles. However, a consumes less ink and is much qui- printing plant is no “long quiet eter.” river”, and in the 1980s and 1990s Luc Emeriau Imprimerie Rochelaise experienced [email protected] two structural crises, resulting in All the inks consumed at Impression Rochelaise are based on vegetable oils, and the quick response the closure of its web offset division inking units are connected to a central pumping system

Report 36 | 2010 17 Sheetfed Offset | Packaging printing

Express Packaging managing director Henry Breban (l) and production manager Régis Coffin: The KBA Rapida 142 stands on a 420mm plinth “Our new Rapida 142 is a high-powered production tool.”

Rapida 142 UV coater press at Express Packaging in France Growth through skill and versatility French print enterprise Express Packaging, formerly part of the glass manufacturing group Arc International, has installed a six-colour Rapida with an aqueous and UV coating capability plus automated pile logistics to support a superior print quality on an extensive range of substrates.

xpress Packaging and its sister others). It was given its present machine to the other. Also, the test company Express Découpe, a name following its acquisition by results from the KBA press were by Etrimming and print finishing Breban at the end of 2006. Today far the best.” operation established in 1997 by Express Packaging employs 110 Henry Breban, are located within staff. It still has an exclusive con- Automated, sophisticated and flexible easy reach of each other in Arques tract to supply Arc International The new Rapida 142, which stands and Saint Omer (northern France) with packaging, and enjoys the ben- on a 420mm (16.5in) plinth, has a respectively. Express Découpe spe- efit of diverse specialist services triple delivery extension, automatic cialises in trimming and finishing provided by the Arc International plate changing, ACR Control au- paper products as well as cutting group, which include a photo- toregistration, automated colour and converting board. Its customer graphic studio, graphic design and density control and UV dryers. An- An automated pallet preparation system base includes some of the world’s packaging engineering. other unusual feature is the fully (pictured) and automated pallet logistics allow the Rapida 142’s nonstop capabilities leading paper manufacturers (eg In- The highly automated Rapida automated pallet logistics system in to be exploited to the full ternational Paper, Arjowiggins) plus 142 six-colour coater press with UV which it is embedded. In conjunc- packaging merchants in Europe, the capability represented another key tion with nonstop facilities at the USA and South America. component in Breban’s investment feeder and delivery this saves the strategy. This was no coincidence. press crew a lot of hard physical ef- cluding drip-off. “Thanks to our Outsourcing broadens options Under the aegis of Arc International fort. new Rapida 142 and the ongoing The current 27,000m² (290,630ft²) Express Packaging had acquired a Since all the jobs printed on the exchange of know-how with KBA of warehouse space will be in- wealth and depth of know-how that Rapida 142 are coated, Express we have enormous potential for creased this year by a further has made it one of the most profi- Packaging also invested in a cutting growth,” declares Coffin. 12,000m² (129,000ft²). “Our aim is cient cartonboard printing outfits in table for making coating plates. A “The Rapida 142 offers an addi- to offer our customers a one-stop Europe. A Rapida 142 five-colour Kodak Magnus large-format ctp tional benefit: its versatility,” ex- service, complete with logistics,” coater press has been strutting its platesetter was installed in pre- plains Henry Breban. “Although we says Henry Breban. For the past stuff there for some years now. press, and the converting depart- are specialists of exceptional skill, three years Express Découpe has Production manager Régis Cof- ment is similarly well equipped. we also have much broader capabil- been pursuing a policy of ongoing fin says: “In 2001 we were the first “Ninety per cent of all the jobs ities: alongside millions of folding service enhancement supported printing plant in France to install a printed on the new Rapida 142 are cartons we can print short runs of by an extensive investment pro- KBA press with a dual conventional packaging made of 130 or 700 gram posters on all types of substrate. We gramme. Express Packaging – a and UV capability. Since then we substrates, while seventy-five per are keen to expand our customer major plank in this strategy – was have gained a lot of experience. The cent are printed in six colours and base beyond Arc International and originally a captive printing plant choice of new press was more or coated,” says Régis Coffin. “The are thinking about food packaging, owned by Arc International, the less a foregone conclusion: we print quality and stability are fan- for example.” global leader in domestic glassware wanted to make sure that our oper- tastic.” The press configuration Luc Emeriau (Cristal d’Arques, Luminarc and ators could switch easily from one even supports matt/gloss effects in- [email protected]

18 Report 36 | 2010 Sheetfed Offset | Italy

Rotolito Lombarda’s press room in Pioltello, with an older large- format Rapida in the foreground

Counter-cyclical investment: as well as installing new presses Rotolito Lombarda is building a new production hall

World makeready champion now at Rotolito Lombarda Piling on the power in Pioltello with Rapida 106 and 162a Rotolito Lombarda is one of the biggest and oldest users of KBA sheetfed and web offset technology in Italy. Rapidas constitute virtually the entire press fleet at its sheetfed production plant in Pioltello, while three Compacta web presses are in operation at its Cernusco facility. Rotolito Lombarda recently placed an order for two more Rapidas.

B1 (41in) eight-colour Rapida ing printing units are fitted with global market leader in this sector. tomatic plate changing, which is vir- 106 for four backing four was jackets to eliminate set-off, and an In February the Pioltello produc- tually obligatory in large format, job Adelivered in January. As befits alcohol-free package enhances press tion plant took delivery of a 7B changeover times are minimised by the reigning makeready champion ecology by cutting emissions. (63.75in) Rapida 162a five-colour the insertion of a second washing of the world, the press is equipped In large format, too, Rotolito press capable of printing books bar for simultaneously washing the with just about every automation Lombarda continues to rely on the at a maximum rated output of blanket and impression cylinders. option going. superior experience of KBA, the 13,000sph. In addition to fully au- The press also boasts an optional capability for printing lightweight Total automation stock. with the Rapida 106 Rotolito Lombarda’s extensive Alongside DriveTronic SPC dedi- fleet of presses also includes web cated plate-cylinder drives for si- offset and gravure equipment from multaneous plate changes in just other manufacturers. In addition it sixty seconds, these options include has a bindery and a fully automated CleanTronic Syncro high-speed si- paper store. Since being established multaneous washing of the inking in 1976 the company has made a units, blankets and impression number of farsighted decisions that cylinders during plate change. No- bucked established traditions. Its in- sidelay DriveTronic SIS infeed – a vestment in the two new sheetfed feature unique to KBA – supports a presses in the midst of an economic fast and convenient change of sub- meltdown is a typical example. Ro- strate, while DriveTronic Plate-Ident tolito Lombarda’s avowed aim is to ensures precise plate pre-registra- emerge from the crisis stronger and tion and allocation, thus ensuring more productive than ever. that wrongly positioned plates are a The existing large-format press at Rotolito Lombarda has been joined Manuela Pedrani thing of the past. The post-perfect- by a B1 Rapida 106 [email protected]

Report 36 | 2010 19 Sheetfed Offset | USA

President Rhonda and chairman/CEO Larry Chatzkel are delighted with the performance of their new Rapida 106

Makeready Champion Rapida 106 at Hanover Packaging Delivering that environmental edge Rhonda and Larry Chatzkel, president and chairman/CEO respectively of Hanover Packaging, have implemented strong environmental initiatives at their nearly 85-year-old family-owned packaging and printing business in central Pennsylvania where they cater to the world’s market leaders in the cosmetics, gourmet food, health and beauty, publishing and consumer products industries. These initiatives have resulted in Hanover being designated as one of only 284 companies in the US as an EPA Climate Leader. When they decided to purchase a new printing press, it, too, had to fulfil those same requirements. The firm’s new KBA Rapida 106 B1 (41in) six-colour sheetfed press with conventional aqueous and UV capabilities installed during the summer of 2009 delivers their mandate.

anover’s environmental initia- mart’s online packaging scorecard. The new Rapida is equipped both high and low gloss coatings, tives were implemented for “This helps our customers increase with KBA DriveTronic dedicated strike-throughs and even a reticu- Htwo reasons. “We need to their sales to Walmart and when our drives for simultaneous plate chang- lated texture for a cosmetic cus- preserve our resources as a legacy customers sell more, so do we,” ing, and the GATF InterTech award- tomer. The firm is also working for our children,” says Rhonda says Rhonda Chatzkel. winning sidelay-free infeed, Drive- with a coatings company to develop Chatzkel. “Plus, these initiatives The Chatzkels were first at- Tronic SIS. In order to make quick a new proprietary metal foil tech- make good business sense. When tracted to the emissions-tested makereadies between conventional nique to be called HanoFoil. our customers can play up the fact Rapida at Drupa 2008. Hanover and UV, Hanover had the press “This press allows us to run that their products are packaged in Packaging is at the forefront of sus- equipped with CleanTronic multi multiple short runs with extraordi- environmentally-friendly packaging, tainable packaging production, in- wash-up systems and the ability to narily low waste, and therefore this helps to differentiate the prod- cluding the use of materials with a print 155gsm (40lb) paper to more cost effectively,” says Larry uct and build consumer loyalty at very high recycled composition. 1.2mm (48pt) board and E-flute. Chatzkel. “Many of our customers, the retail level.” Since the Rapida 106 emits zero “Within a week and a half, the press this year in particular, are asking for Packages can be printed with VOCs when printing UV, it has be- was up and running and producing just-in-time deliveries and this press Hanover’s renewable choice logo come key to the firm’s environ- a variety of very difficult and beau- enables us to be even more respon- showing that it was manufactured mental commitment, as have its tiful jobs,” says Larry Chatzkel. sive to this need. For long runs, the using 100% renewable energy. Con- quick makeready and minimal Since its installation, the press press has a maximum speed of sumers who see this logo know that waste. Plus, the new press can has become a manufacturing work- 18,000 sheets per hour, which efforts have been taken to be apply an inline metallic coating horse in producing high-quality makes it an industry leader and a “green”. Many of Hanover’s cus- that can simulate foil, mylar or packaging jobs on all substrates, es- cost-effective solution.” tomers sell to Walmart, where an stamping with much less expense pecially board and plastic, as well as environmentally-friendly package but maintain its environmental both aqueous and UV coatings. The Eric Frank helps them score higher on Wal- friendliness. press allows the firm to produce [email protected]

20 Report 36 | 2010 Sheetfed Offset | USA

“ e wanted to be one of the first to operate the new WKBA Rapida 75 23 x 29-inch press when it came on the market,” says Doug Silsbee, vice-president of 4D Printing. “We’re staying busy but we wanted to position ourselves for the print market when it re- bounds after the recession. Having the new half-size press along with our two-year-old KBA Rapida 105 41-inch six-colour one-over-five per- fector press with aqueous coating capability allows us to produce whatever jobs our clients give us.” Silsbee has kept his word. The firm quickly took delivery and began production on its Rapida 75 five-colour plus coater press after it made its North American debut on Donna Silsbee and her husband Doug at their new Rapida 75 five-colour plus coater press the KBA stand at the Print 09 trade fair in Chicago last September. The press fitted perfectly into 4D’s en- Rapida 75 follows Rapida 105 vironmental mantra by bringing a high level of automation to its pro- duction output and decreasing 4D Printing grows with Rapida 75 waste significantly while using much less power than any other 4D Printing, a general commercial printer located in Conyers, Georgia, outside Atlanta, has always been ahead printing press. of new market trends. Before environmentally friendly and the term “green” became popular, 4D Printing had The six-up Rapida 75, a 605 x 750mm (23.75 x 29.5in) press, of- already been certified environmentally safe. Early on, the firm paid close attention to delivering its clients’ needs fers a 15,000sph output, is config- and providing a safe work environment for its employees. And today, 4D Printing is ready to take advantage of urable with two to eight colours the upturn in sales as the recession ends. plus coater and four-over-four per- fector, and incorporates some 30 new features. These include non- stop facilities for the feeder and delivery, the DensiTronic density Now Silsbee can move jobs from is environmentally safe and main- Established in 1985, 4D Print- measurement and control system one press to the other and produce tains its certification. “We feel that ing is located in the historic Olde and a CIP3 interface. The press is the same high quality. it is responsible to our company and Towne district of Conyers. Many of able to wash the impression cylin- Every six months 4D Printing our employees to be in OSHA com- the buildings along the main street ders parallel to blanket washing, has an independent firm inspect its pliance,” says Silsbee. “If OSHA are preserved under a historic ordi- permitting further significant sav- facility to ensure that the company ever does a pop-up inspection, nance, creating a family-friendly ings in makeready time. we’re ready.” OSHA is the Occupa- idyllic town to raise a family and a Once the new press was in- tional Safety & Health Administra- business. The four Ds in the com- stalled, 4D had it fingerprinted to tion, the main US federal agency pany refer to Doug and his wife its existing two-year-old Rapida 105 charged with the enforcement of Donna along with their two sons B1 (41in) perfector press with safety and health legislation. who are active in the business and aqueous coating capability. In its Silsbee has already seen how work in the pre-press and cus- short two years of being on the job, productive the press can be. In the tomer service departments. Silsbee Silsbee praises the Rapida 105 for past, the firm was producing eight proudly cites that half his workforce its quality and versatility, allowing jobs in one eight-hour shift. But on has been with the company 12 of the firm to print or perfect jobs on the new Rapida 75 the press opera- the 25 years in business. “We have heavier board, such as 0.6mm tors were able to produce 13 jobs an open door policy at the com- (24pt) for posters, as well as its in an eight-hour shift using differ- pany,” says Silsbee. “I know all of fast 15-minute makeready and ent substrates and different size the employees, go fishing with extremely productive throughput. jobs. “This new press has shown us them, and we support the town’s how much more efficient and pro- local sports teams and elementary ductive we can be in the press schools. We donate paper to the room,” says Silsbee. “We can pro- two local grammar schools and duce jobs on a variety of substrates sponsor the baseball team.” The Rapida 75 is exceptionally energy efficient, highly automated and easy to from 50lb offset to 18pt board with Eric Frank operate much less makeready time.” [email protected]

Report 36 | 2010 21 Sheetfed Offset | Ecology

The new-generation KBA VariDry dryer is no plutonium-powered “blue” time machine, though a time-leap “back to the future” certainly would be a sen- sation. But Doc Brown from the cult sci- fi classic hasn’t cornered the market in ingenious inventions – our new VariDryBLUE infrared/hot-air dryer rede- fines the benchmark in energy effi- ciency. Drying at high production speeds while achieving enormous energy savings has thus been trans- formed from a distant vision to imme- diate reality.

New option for enhancing cost efficiency and green credentials: following the successful completion of an exhaustive test phase our big Rapidas with coaters can now be configured with energy-efficient KBA VariDryBLUE IR/hot-air dryers

Heat recovery can halve energy consumption Counting the calories Dryers basically consume a lot of power. Did you know that the in- Enhancing energy efficiency frared/hot-air drying process ac- counts for around 40 per cent of BLUE the total energy consumed by a with KBA’s new VariDry printing press? The dryer is thus one of the biggest energy guzzlers in the entire print production chain. And who wants a hyperactive elec- tricity meter? Put your dryer on a low-energy diet! Have no fear, you won’t have to hang up your wet coated sheets on a washing line and let them dry in the sun and the wind in order to conserve electric- ity. So how would you describe your “dream” dryer? Short drying time. Perfect results. Maximum gloss effects. Minimum energy con- sumption. And all that in one de- vice! Can’t be done? Can be done! VariDryBLUE is the embodiment of your dream. This new generation of VariDry IR/hot-air dryers was specif- ically engineered to dry high-gloss coatings energy efficiently and BLUE KBA VariDry : schematic showing the triple delivery to a superior standard of quality. extension on a large-format Rapida press with IR/hot-air BLUE dryers and heat recovery system to enhance energy efficiency VariDry slashes power consump- tion by as much as 50 per cent, even at maximum output levels,

22 Report 36 | 2010 Classic packaging configuration: six-colour Rapida 142 coater press with triple delivery extension for housing KBA VariDryBLUE IR/hot-air dryers and heat recovery system

Compelling benefits of KBA VariDryBLUE while at the same time supporting • More efficient energy utilisation = lower energy consumption, fewer carbon emissions 3 and in the swan neck. With this high production speeds. What is • Lower energy consumption = fewer overhead costs method it is possible to reduce the more, it is easy to access when the • Higher production speeds installed heating power by 2 x sheet guides need to be cleaned. • Lower specific energy consumption per good sheet 17.5kW. Reusing the warm air sev- Following their official market • Smaller volume of exhaust air eral times over also has the advan- launch at Ipex 2010 from 18 to 25 • Enhanced image quality = less powder consumption tage of reducing the volume of May our new range of VariDryBLUE exhaust air compared to other con- IR/hot-air dryers will be available for ventional IR/hot-air dryers. With all large-format Rapida presses con- our new VariDryBLUE dryer energy is figured with triple delivery exten- power consumption compared to ensure that the air is distributed utilised with maximum efficiency, sions. They can even be retrofitted conventional IR/hot-air dryers. And evenly onto the substrate surface. not blasted out into the environ- on existing press lines. this is how it works: the air drawn The unsaturated hot air from mod- ment. in is heated by two rows of lamps to ules 1 and 2 in the delivery exten- Conserve your heat, don’t waste it! the drying temperature pre-se- sion is recirculated through the Measuring efficiency in euros Recovering and re-utilising ambient lected at the console. Optimised air system (see schematic at the bottom The savings potential can best be circulating air in the VariDryBLUE nozzles with a uniform flow profile of page 22). The recirculated air can demonstrated using an example dryer can substantially reduce along their entire length are used to subsequently be reused in module from the shopfloor: a five-colour item of packaging was printed and given a protective coating on a Rap- ida 142 six-colour coater press with Table 1: Job and production data triple extended delivery and IR/hot- Anilox roller specifications 100 lpc; ART (Anilox Reverse Technology); 12 m³/cm² air dryer. The power consumed by Substrate GD2 (300 gsm) the dryer during the production run Production speed 13,000 sph was measured. The model calcula- No. of workdays per year 220 tion was based on an average price No. of shifts per day 3 of 13 cents per kilowatt hour of No. of hours per shift 8 electricity, although this may of Level of utilisation 85 % course vary according to the energy Average electricity price per kWh €0.13 provider and region. The sustain- ability of the VariDryBLUE dryer is re- flected in the potential savings. Calculated over an average machine life of eight years, a few kilowatts and cents quickly mount up to a sizeable item: the reduction in power consumption delivered a 6 Gloss coat 5 Yellow 4 Magenta 3 Cyan 2 Special colour 2 1 Special colour 1 saving of approximately €140,000 ($198,000). In the long term – and at a time when energy prices are Table 2: Energy and cost savings with KBA VariDryBLUE versus conventional IR/hot-air dryer rocketing – you can achieve big cash KBA VariDryBLUE dryer Conventional dryer savings. Average power So although the laws of physics consumption measured (kWh) 33 70 may mean that a journey through Power consumption (kWh/year) 118,500 251,300 time will remain nothing more than Electricity cost (euros/year) 15,400 32,700 a vision, you can still fulfil your Carbon emissions (t/year) 71 150 dream! Energy saving (kWh/year) 132,800 - Energy saving (%) 53 - Cost saving (euros/year) 17,300 - Carbon reduction (t/year) 79 - Anja Hagedorn anja.hagedorn@kba. com

Report 36 | 2010 23 Sheetfed Offset | Special applications

Fleece-covered sheet guide in the Synchronised rollers with air blasts Chromium-plated side lay Ink agitators prevent skin formation DriveTronic feeder on highly viscose UV inks

Printing on synthetics, plastic and other non-absorbent substrates No competition for cartonboard Marketing specialists are constantly seeking more effective ways of differentiating their products at the point of sale (POS). Their primary objective is to create an attractive, eye-catching design which, coupled with unusual shapes, colours and materials for the packaging, will inspire among consumers a desire to purchase these products.

ne in three purchasing deci- field, the situation has perceptibly 1. DriveTronic feeder to cool it and prevent the thin plas- sions is made in less than ten changed over the course of time. • Fleece-covered overhead sheet tic sheets from shrinking or de- Oseconds, and 47 per cent of guides to prevent scratches forming. such decisions are made directly at New potential for sheetfed offset • Chromium-plated side lays the point of sale. As a proportion of Synthetic packaging has become • Synchronised rollers with air 3. Coater total sales in the German food retail much more diverse both in form blasts The anilox roller system is particu- trade, which amount to some €130 and design. Thanks to the advent of • Flat, synthetic guide rollers larly effective at applying a consis- billion ($184bn), this represents a in-mould labelling (IML), surfaces • Flat, polished cover lays tently uniform coating film. The purchasing volume of around no longer have to be flat and • Synchronised guide bars with volume of coating is determined by €60bn ($85bn)! smooth for printing. This is good rollers and air blasts the roller’s pick-up volume. The Consumers today prefer func- news for sheetfed printers since in- • Suction and blower units at the pumping system for the coater is tional, modern and environmentally mould labels can easily be printed guide plate beneath the feed drum controlled from the console and is friendly packaging. While cardboard in offset. They also address the de- • High-performance antistatic cleaned automatically. The coater is still the material of choice, it is mand for a high-resolution print system for effective sheet separa- can be converted from one type of now closely followed by various quality with brilliant colours. UV tion coating to another in one to two types of synthetic material. And offset is frequently used for this minutes. Viscosity-controlled coat- where direct-printed synthetic particular application because it 2. Printing units and sheet guides packaging previously dominated the eliminates the risk of set-off and is • EPDM-covered rollers: being exceptionally scratch-resistant. compatible with UV inks and washes, EPDM does not swell and The UV press therefore causes no change in roller It is not just the UV process that volume poses a challenge when printing • Hoses and seals: UV wash-resis- plastic. The thermal sensitivity and tant hoses eliminate the risk of scratch-resistance of the (generally leaks fairly thin) plastic sheets will soon • Inking-unit temperature control be tested to their limits if the press maintains constant ink viscosity and configuration is inappropriate. The a stable ink/water balance plastic sheets must travel through • Ink agitators prevent skin for- the press without sustaining mation on highly viscose UV inks scratches or becoming deformed. • Sheet travel monitoring at each The following recommended fea- transfer point eliminates the risk of tures for our Rapida presses will en- damage from dropped sheets sure that UV print production on • Sheet-guide plates feature ven- synthetic substrates will be trouble- turi airblast control (presettable) Maintaining a stable working temperature at Impression cylinder cooling in a free and compatible with a high out- • Fans divert a cold (8°C) stream the inking unit ensures constant ink viscosity KBA Rapida 106 put: of air onto the impression cylinder and a stable ink/water balance

24 Report 36 | 2010 Antistatic nozzles and heads

Antistatic array

Antistatic power packs and generators

Antistatic electrodes

High-performance antistatic system in a Rapida 106 ing feed ensures that pump capacity 4. AirTronic delivery support scratch-free sheet travel the is automatically adjusted to coating The shape of the nozzles for the venturi guide plates feature a regu- viscosity. The benefits are consis- new multi venturi sheet-guide lated air flow system that can be tent production conditions, the plates, and their distribution be- switched from sucking to blowing. elimination of manual pump adjust- neath its surface, have been opti- For greater efficiency the guide ments and the automatic setting of mised to ensure that the sheets plate before the suction roller is the washing cycles to suit viscosity. float at a uniform distance from the Teflon-coated. Another key feature is semi- plate. The result is a scratch-free At the sheet extraction point automatic changing of the coating sheet transfer, a rapidly repro- there is a screen of special darkened plates, which cuts the sequence to ducible setting and the ability to glass to protect the press crew from just two minutes. It is also advisable handle a wide range of substrates. scattered UV radiation. During poly- The exceptionally user-friendly to equip the press with remotad- Where heat-sensitive materials merisation UV inks and coatings KBA VariDry plug-in dryer is controlled from the ErgoTronic console justment capabilities both for print- such as in-mould films are to be emit non-hazardous odours which ing pressure and for sidelay, cir- printed we recommend fitting addi- can be filtered and vented with the cumferential and diagonal register. tional water-cooled sheet guides. To aid of an optional extractor system. 7. Fount solution preparation 5. VariDry technology The most common method of print- • Interdeck UV dryers: the num- ing on metal-coated surfaces is to ber required depends on produc- apply opaque white as a primer and tion speed, the number of printing then print the other colours on top. units, solids coverage and the use of We urgently recommend bypass fil- hues (opaque white, metallic inks, tration for applications such as this dark hues). The standard number of in order to safeguard process stabil- interdeck dryers recommended for ity. a press with six printing units is Filtering the fount solution three. Additional plug-in points en- delivers a number of benefits: it hance press versatility. Since all sub- eliminates contamination, thus pro- strates, and plastic in particular, are moting consistent printing condi- The sheets literally float above sensitive to heat, it is advisable to tions and a superior print quality; it the venturi guides in the delivery work with the lowest effective lamp reduces the frequency with which power. the fount solution must be • End-of-press UV dryer: this is changed; and it trims maintenance normally equipped with three UV costs and therefore enhances the lamps which if necessary can be press utilisation level. plugged into any of the interdeck Printing synthetic and other dryers. No other system on the non-absorbent substrates demands market affords the same level of highly specialised production meth- flexibility. ods. These are discussed exten- sively in issue no. 5 of our techno- 6. Static elimination logy publication KBA Process, which Non-absorbent substrates, espe- can be obtained free of charge from cially synthetic materials, are prone the marketing department in Rade- to a build-up of static charge that beul or downloaded from http:// causes them to cling together. In www.kba.com/en/news/presseser- the most extreme cases the sheets vice/download_kba_process.html. can no longer be separated. Special antistatic components prevent or reduce the static charge on the sub- strate surface. The schematic above depicts the high-performance static The walkway floor between the units is free of obstacles because the interdeck UV dryer elimination system fitted in the Rap- Jürgen Veil is located underneath ida 106. [email protected]

Report 36 | 2010 25 Sheetfed Offset | Environment

eider Druck is the printing arm of Joh. Heider Verlag, a Hpublishing house which was established in 1889 and brought out a daily newspaper for Bergisch Gladbach and the surrounding re- gion the following year. Despite the fact that this was sold off to the Köl- nische Rundschau in 1952, among locals the name Heider is still syn- onymous with newspapers. Now a publishing, printing and media en- terprise, Heider has long since ex- panded its web-based portfolio to include freesheets, trade and feder- ation publications, magazines, sup- plements and telephone directories etc. It has also moved into sheetfed with brochures, magazines, books, calendars and many other com- mercial products. The publishing house’s media activities primarily Others may have a tiger in their tank – Heider has one on the fifth printing unit of the high-speed Rapida 106, symbolising the focus on ad acquisition for print company’s commitment to conservation and performance customers. Heider sees itself as a service provider to a customer base embracing publishers, federations Heider Druck proves that sustainability can be compatible with performance and advertising agencies. Cutting energy consumption Greener print production with coldset The two KBA newspaper presses which are currently in the press hall in sheetfed and web – a two-tower Journal installed in 2002 and a Colora tower added four years later – are used to print German print enterprise Heider Druck in Bergisch Gladbach makes no secret of its driving passion, and this is reflected freesheets. Today Heider can print in its logo, “Ecological printing”. The owners have been vigorously greening up their production chain since the turn coldset copies with a maximum of 64 pages in the Berliner format or of the millennium. New technology promoting this goal has broadened their options for conserving natural 48 pages in full colour. The presses resources while at the same time enhancing efficiency and profitability. were the first step towards enhanc- ing energy efficiency, since their energy consumption is relatively as much as 85 per cent less energy can be used because only uncoated led to the second step on the road modest compared to heatset: in fact per operating hour. Not unnaturally, and recycled paper is suitable. How- to green print production: FSC and when printing a 48-page product in coldset production imposes a re- ever, this is in keeping with Heider PEFC accreditation to support sus- the Berliner format they consume striction on the range of stock that Druck’s environmental goals and tainable forest management.

Next step: greening-up sheetfed The next step the company took to- wards reducing its carbon footprint was to fire up a new Rapida sheetfed offset press in May 2009. Once again the press of choice was a KBA, not least because in 2000 the Rapidas were the first offset litho presses worldwide to be awarded the German Industrial Safety Council’s “emission tested” environmental certificate. The 18,000sph Rapida 106 five-colour coater press at Heider has run alco- Frank Wipperfürth of the North Rhine-West- phalian Print and Media Federation presenting Hans-Martin, Guido and Roberto Heider (l-r front) couldn’t be happier with their first hol-free right from the start. The the PSO certificate to Guido Heider in 2009 KBA sheetfed press risk that operators might add IPA to

26 Report 36 | 2010 the fount solution in a moment’s aberration was nipped in the bud by the simple expedient of removing all alcohol measuring and monitor- ing kit. Only ecologically approved inks based on vegetable oils are run on the press. The cloth-based wash- ing system, which dramatically cuts the consumption of washing agent compared to a brush-based system, is a further contribution towards greener production – as is the Lo- goTronic networking software for press preset. Hans-Martin Heider, one of the fourth-generation family members heading the company, is Even though quality monitoring with QualiTronic colour control eliminates the need for delighted to report that “As a result, adjustments at the ink keys, Michael Dörpinghaus still checks the sheets out of sheer habit a lot of the products we print are of saleable quality from the very first sheet.”

Closed-loop inline colour control Thomas Walder printing one of many To help minimise waste the press freesheet titles on the Journal tower incorporates a QualiTronic colour control system that scans every sheet and automatically adjusts colour density values accordingly. The press is also linked to a Densi- Tronic Professional system that measures colorimetric values in the measuring strips or directly in the printed image, and carries out the relevant adjustments. This con- An 18,000m² plot of land acquired in the 1950s tinuous, integrated quality control For Benjamin Ommerborn, pumping out 18,000 sheets per hour on the Rapida 106 is a cinch offers plenty of room for further growth package enabled the company to achieved PSO accreditation in sum- mer 2009. The economic impact of the scheduled on this press in order to value-added finishing options. In services the company also provides new Rapida 106 became apparent make the most of its high-speed job fact the company is keen to move for its print customers include ad within a few weeks of its produc- changes. Its advanced level of au- upmarket, away from high-volume, management. tion start. The average print output tomation, which encompasses plate low-margin products. Wherever At present Heider has almost across the board (short and long changing, suction-ring positioning, possible it seeks to provide pre- 6,000m² (65,000ft²) of production runs) climbed well above the height-adjustable nonstop rollers mium-quality products expressly tai- space at its disposal. Since a plot of 10,000sph mark. Whenever possi- and sidelay-free SIS infeed, has lored to customers’ needs. This goal land acquired by Hans Heider se- ble the Rapida 106 is run at its max- boosted output by almost 40 per dictates the processes within the nior’s father is more than three imum speed of 18,000sph. Most of cent compared to its predecessors. company: the broad range of serv- times as big, there is ample room the short- and medium-run work is ices offered encompasses product for healthy growth. “We are a dy- Sustainability does design, image processing, editing, namic enterprise with ambitious not preclude finishing mailing, proofreading, addressing, plans for the future, so it’s good to The Rapida 106 offers a raft of ad- numbering (eg for prize draws in have plenty of reserves for future ditional benefits over the com- freesheets), inserting and attaching expansion,” declares Roberto Hei- pany’s previous presses, which (eg packets of seeds in or on direct der. The publishing house and print- were two-and four-colour B1 (41in) mail). ing plant employ a total of 90 and B2 (29in) models. For example, permanent staff, and there are also it is possible to apply a special Farsighted investment part-timers and temps. Print pro- colour in the fifth printing unit and Heider Verlag is headed by Hans duction normally runs in two shifts, a standard aqueous coating in the Heider senior and his third son, though this is increased to three coater, or a matt paste in the fifth Roberto. Their portfolio encom- whenever there is a surge in in- unit followed by a matt/gloss aque- passes publications on business and coming orders. ous coating to create a drip-off ef- social politics, books of regional in- Heider Druck’s “ecological printing” logo fect. So Heider Druck’s ecological terest and pictorial volumes. Along- Martin Dänhardt reflects its environmental credentials bent certainly doesn’t preclude side ad acquisition the media [email protected]

Report 36 | 2010 27 Sheetfed Offset | Investment

“ t was the recession that drove me to invest in new technology,” Isays Dominique Houot, Vagner Graphic’s managing director for the past nine years. “Because the future doesn’t wait.” Situated in Fléville, Lorraine, Vagner Graphic is the oldest print- ing plant in the Nancy area, having been started by Nicolas Vagner 167 years ago in 1843. Following 167-year-old French print enterprise growth of around 25 per cent the Vagner Graphic is situated in Fléville, not far from Nancy previous year, in 2009 the 20- strong workforce generated sales “If your production chain is working at full € capacity and the economy starts to slow down, worth some 2.8m ($4m), boosting that’s the time to invest.” Vagner Graphic value-added in the process. managing director Dominique Houot (r) Vagner Graphic has seen no sign of the recession in its order vol- Boosting output with two Rapida coater presses umes. For Dominique Houot the key to success is to make sure you stay ahead of the curve. In 2004 Vagner Graphic: the company purchased a 6,000m² (65,000ft²) plot of land on which it built a 1,500m² (16,000ft²) be- the future doesn’t wait spoke production plant, equipping it with two new KBA sheetfed French print enterprise Vagner Graphic picked the height of the recession to gear up for the future with a new presses. It also expanded the fin- press fleet. The kit it replaced was just four-and-a-half years old. An example of unshakable optimism at a time ishing department. Just four-and-a-half years later, when the print media industry is facing major upheavals. in September 2009, the presses were replaced with a four-colour Rapida 105 and a five-colour Rapida productive and therefore more cost- a boon, since it allows us to ionise is well on the way to achieving 75, both fitted with coaters. effective.” the sheets to remove static. This is PEFC accreditation. All the inks Job changes on the new Rapida becoming increasingly necessary as used on the presses are vegetable- Hard work, dedication 105 are even faster than on the the quality of the paper delivered is oil-based and there is no alcohol in and innovative technology press it replaced, while its high- steadily deteriorating.” the fount solution. Run lengths av- “If your production chain is work- speed package increases maximum He continues “The new five- erage between 3,000 and 4,000 ing at full capacity and the economy production speed by a full 1,000 colour Rapida 75 is also much faster sheets. A high print quality is a vital starts to slow down, that’s the time sheets per hour to 16,000. Do- than its predecessor, and delivers an instrument in promoting customer to invest in new kit. You can get it minique Houot is delighted: “It’s even better print quality. We use loyalty. at an attractive price and it puts you like piloting a Formula One racing the coater for just about every job Dominique Houot has no inten- one step ahead of the field, which car.” Yet despite the Rapida’s ad- because it means the sheets can be tion of resting on his laurels: “Over is a real morale booster for the en- vanced technology it is exception- finished without delay. The two the next four to five years I’m plan- tire workforce,” explains Houot. “I ally ergonomic and easy to handle. new KBA presses complement each ning to add another big building saw no need to switch to a different The practical automation modules other perfectly.” that will comply with all the latest brand because I had never had a deliver substantial savings both in environmental standards. I’m an op- problem with our two previous KBA time and labour, while also enhanc- Targeting organic growth timist by nature and act accordingly. presses. Having said that, the new ing quality. “The optional package Vagner Graphic was awarded “Im- I have supreme confidence in the ones are naturally that much more for printing lightweight stock is also prim’Vert” certification in 2008 and future of the print media industry and I love my job. In life you have to be prepared to take chances, you have to be bold, innovative and, of course, invest in the future. The se- cret of Vagner Graphic’s success is that we take our work extremely se- riously, but not ourselves.”

Luc Emeriau [email protected] Automatic register setting with ErgoTronic ACR The Rapida 75 five-colour coater press is the perfect complement to its big sister, (video magnifier) is simple and reliable the Rapida 105

28 Report 36 | 2010 Web Offset | Brazil

Abril CEO Giancarlo Civita, KBA sales director Kai Trapp and Abril chairman Roberto Civita (from the left) poised to press the start-up button

Editora Abril in Sao Paulo Compacta 618 swings into action at market leader Sao Paulo-based Editora Abril, part of Grupo Abril, one of the biggest media groups not just in Brazil but also in Latin Amer- ica, has fired up a 48pp Compacta 618 commercial web press ordered at Drupa 2008. The company celebrated the inaugu- Roberto Civita personally checking the quality ration with an open house attended by staff, customers and representatives from fellow Brazilian printers Oceano, Plural and of the freshly printed magazines Santa Marta.

n their commemorative ad- capacity boost delivered by the rated as excellent by the discerning Tronic roller locks, has a fifth print- dresses, Grupo Abril CEO Gian- Compacta. The press then printed audience. The highly automated ing unit for handling special Icarlo Civita and chairman a corporate publication, Fique Compacta 618, which features colours. Roberto Civita emphasised the huge Sabendo, the quality of which was KBA’s unique automated Roller- One of the biggest communications enterprises in Latin America Since being launched in 1950 Grupo Abril has grown into one of the biggest communications enter- prises in Latin America, with over 7,000 employees. Of these, 1,100 work at Editora Abril’s 55,000m² (almost 600,000ft²) production plant near Sao Paulo city centre. Abril is the only printing company in Latin America to operate publi- cation gravure presses. It has an an- nual consumption of over 100,000 tonnes (110,000 US tons) of paper for printed products totalling more than 350 million copies comprising some 50 different titles.

Marc Decker [email protected] Customers, suppliers and staff thronged to the open house commemorating the inauguration of Editora Abril’s first KBA press

Report 36 | 2010 29 Web Offset | Latin America Website: www.editorialprimavera.com

n 2008 Editorial Primavera’s workforce of around 220 gener- Iated sales worth approximately 38.6 million bolivar (US$18m). The Compacta 215 represents the biggest investment in technology since the company was founded by Don Armando De Armas Melendez in 1967. From a modest printshop in Caracas it has evolved into a high- powered full-service provider.

Laying the foundations for growth The total investment package, which cost the equivalent of $15m, included a technology upgrade in both the pre-press and finishing de- partments. Editorial Primavera is part of Bloque De Armas, a family- Editorial Primavera deputy managing director Benjamin de Armas (l), who is pictured here with one of his press operators and Francisco Beaz (centre) owned trade federation whose of KBA’s agency Pack Print, is delighted with his new duplex press interests encompass television broadcasting, publishing and com- mercial printing as well as daily Editorial Primavera holds pole position in Venezuela newspapers (2001) and sports titles (Meridiano). The Compacta 215 press lines Duplex Compacta opens up have been in operation since the middle of last year in a new build- ing on the 10,000m² (110,000ft²) new options site that has been the company’s base in the satellite town south of Editorial Primavera in Guarenas, near Caracas, has reaffirmed its position as the leading commercial and magazine Caracas since 1979. The Compactas printer in Venezuela with the production launch of a new Compacta 215 duplex installation totalling ten printing joined an existing fleet of six 16pp web presses. Primavera has made units. The mirror-image constellation of two 16pp web presses is the only one of its kind in Latin America. the most of this formidable produc- tion capacity to become one of the top ten commercial printers in Latin America. tween the two presses allows both Surpassing all expectations for a high-output press at the very The two new Compactas, webs to be guided through a single For Editorial Primavera’s deputy cutting edge of technology, capable which replaced two much older folder to produce 32pp sections managing director Benjamin de of delivering a superior print qual- presses in a fleet dominated by which are generally collated into Armas, the Compacta 215 project ity and handling a wide range American and Swedish brands, un- catalogues. The two Compactas can was an unqualified success. “The of products, yet still within our derscore the high reputation that be operated separately as well. The award of the contract at Drupa budget.” KBA commercial web presses enjoy sheeter also allows the right-hand 2008 was the culmination of an ex- He continues: “We didn’t just in Latin America. There are already press to print covers in heavier haustive screening process. Our ob- rely on manufacturers’ demonstra- a number of Compacta installations grades of stock. jective was clear: we were looking tions – we set about gaining a com- in Brazil, Chile, Colombia and Mex- ico.

Broad product spectrum The left-hand Compacta 215 is a standard press line with four dou- ble printing units, a heatset dryer and an F3 gripper folder, while the right-hand one has six printing units, a UV coater, a dryer and a Vits-Rotocut sheeter. It supports the production of copies featuring spot colours, special-effect coatings and scents etc. A transverse link be-

Catalogues, magazines and supplements for the Venezuelan market make up the bulk of Editorial Primavera’s broad product spectrum

30 Report 36 | 2010 Web Offset | Compacta 215

The webs of the two presses can be guided over a transverse link to a single folder Benjamin de Armas (in shirt and tie) with his press crew at the new Compacta

ing of the press by KBA personnel. lion copies. Our other two major ment currency restrictions sadly “We received every possible assis- lines of business are fashion maga- prevent us from exporting on the tance with training our operators. zines and newspaper supplements. scale that we would like.” We are delighted with our decision, At present we print twenty to thirty The company operates a round- and so are our customers.” magazine titles, each with a circula- the-clock shift system six to seven tion of 30,000 to 60,000 copies, in days a week. “After three months of Catalogues, magazines fortnightly or monthly cycles. Our working with the presses we are prehensive and detailed picture out and Playboy insert business, too, is growing confident that we made the right in the field. We weren’t interested One of Editorial Primavera’s biggest fast.” decision. The quality, output, make- in the chef’s recommendations, we customers is Avon Cosmetics, a Three years ago Primavera also ready times, waste levels and ease wanted to see what the customers household name whose bulky cata- started printing the Venezuelan edi- of operation are on a whole new were eating.” The project team logues it has printed for the past tion of Playboy. Says de Armas: “We plane and have allowed us to slash inspected KBA installations at eighteen years. “Catalogues ac- have a long-term licence to print turnaround times. In 2010 the Panamericana in Colombia, Sogapal count for sixty per cent of our en- around 35,000 copies per month. Compactas will handle fifty per cent in Portugal and major customers in tire production, and most of them This is a premium quality contract of our entire output,” says a beam- Mexico. The basis of trust created are for Avon,” explains Mr de which we now run entirely on KBA ing Mr de Armas. in the process was reinforced by the Armas. “Every three weeks we re- presses. While we serve a huge cus- Gerhard Renn punctual delivery and commission- ceive an order for around 1.5 mil- tomer base in Venezuela, govern- [email protected]

KBA Compacta 215 for Litografica Gonzales in Gran Canaria

ne of the most prominent print- The new press will have four Oers on the holiday island of Gran printing units, a 620mm (24.5in) Canaria is Litografica Gonzales, a cut-off on a maximum web width of family enterprise based in Las Pal- 1000mm (39.37in), and shaftless mas, the capital. drives throughout. It will be config- Litografica Gonzales has been ured with an F3 gripper folder, printing commercials since the late gluing and softening devices and a 1970s, and in recent years these Pastomat C reelstand for a maxi- have mainly been promos for su- mum reel weight of 1.8 tonnes (2 permarkets and the tourist industry. US tons). Reel feed will be manual In 1995 the company bought a sec- with Patras M. The KBA ErgoTronic ond-hand Albert A101 eight-page console will feature LogoTronic pro- web press, followed by a 16-page duction management and a CIPLink KBA Compacta 214 in 1998 and interface to pre-press. again in 2001. Now the 1998-vin- tage Compacta is to be replaced by Pictured after signing the contract for a new Compacta 215 (l-r): Juan Diaz of KBA’s Spanish a new 16-page version of the Com- web press agency, KBA-Lauvic, Litografica Gonzales’ proprietor and manager Antonio Gonzales Marc Decker pacta 215. and KBA commercial press sales manager Fernando Ramos [email protected]

Report 36 | 2010 31 Web Offset | Italy

’Auria Printing’s entry into the high-volume league of Dcommercial printers at a time when the Italian economy was reel- ing from the global crisis was a bold decision. In addition to the 48pp and 56pp copies that dominate D’Auria’s production schedule the new 90,000cph double-circumfer- ence press can print 64pp copies with an untrimmed page format of 210 x 299mm (8.25 x 11.77in). In opting for the Compacta 818, managing director Dr Cris- tiano D’Auria continued an associa- tion with Koenig & Bauer dating back to the installation of a sheetfed press in 1998. The choice of press also reflected the firm’s unwavering focus on customer-oriented growth: “Just as in 2006, when we moved into web offset with a 16-page Compacta 215, our objective was to The slim-line Compacta 818 is custom-configured for D’Auria’s production requirements signal to our customers that we are aiming to expand our portfolio while enhancing performance and service on an ongoing basis.” D’Auria Printing, Italy D’Auria Printing’s production plant on the Destra Tronto indus- trial estate has been steadily ex- Taking the high(-volume) road panded to its present capacity of more than 12,000m²(130,000ft²). with slim-line Compacta 818 Opting for the happy medium Production manager Iolando De Luca says: “We started planning the When D’Auria Printing Group in Sant’Egidio alla Vibrata set out to raise its corporate profile in Italy’s fiercely next step in our development in competitive high-volume commercial market, the press type and configuration it chose were anything but run-of- 2008, just before Drupa. Initially the-mill. The Darfin Partecipazioni subsidiary opted for a slim-line 64pp Compacta 818 with a maximum web width we were contemplating a 48-page web press because a 32-page press of 1,680mm (66.14in) instead of the customary 1,905mm (75in). The new press rolled into action last September would have been too small and a and has fulfilled all expectations. standard 64-page press would have

D’Auria Printing Group’s headquarters in Sant’Egidio alla Vibrata has over 12,000m2 The Compacta 215 installed in 2006 is also embedded in the KBA Patras A automated of production space reel-logistics system

32 Report 36 | 2010 EasyTronic control software supports time- D’Auria production manager Iolando De Luca (right) and his press crew appreciate the and waste-saving production Compacta 818’s high level of automation

been too big relative to our existing quirements. The prime focus was maximise profitability, energy effi- 16-page press. Having worked with on the ability to print products that ciency, production reliability and KBA kit for more than twelve years could previously only be printed on quality. De Luca says: “Electricity now we have learned to value and wider presses, and on selecting the and gas are a major cost item in Italy rely on KBA’s competence and cus- optional equipment that would – compared to other EU countries tomer focus. After discussing the we must contend with much higher various options with them we de- prices. Another key criterion in cided to go for the 818 as the happy favour of the 818 was that it can be medium – a means of securing a started up, stopped and made ready competitive edge by promoting for the next job in a minimum of growth and efficiency in equal time and with a minimum of measure.” waste.”

Customised press line for D’Auria High level of automation Even with a narrower web width of The lean, mean Compacta 818 was On 1 January 2010 the D’Auria Printing Group The Compacta 818 is extensively 1,680mm the Compacta 818 can print 64pp merged its sheetfed and web offset activities copies measuring 210 x 299mm untrimmed custom-configured to meet D’Auria in a new enterprise, D’Auria Printing automated to minimise mainte- in addition to 48pp and 56pp copies Printing’s specific production re- nance work and roller wear. Auto- mated features include RollerTronic roller locks, EasyTronic control soft- out a hitch. We are confident that ware, a LogoTronic production man- we can achieve the ambitious tar- agement system and Grafikontrol’s gets we have set ourselves,” says Densiweb colour density control. Iolando De Luca. The press rolled into action on schedule and just in time for the Positive market response pre-Christmas surge in business. The slim-line Compacta 818 has Since then it has run in three shifts, aroused a lot of interest among both five to seven days a week. “The fact customers and other commercial that our operators had already printers, and according to De Luca worked with the Compacta 215 for the press hall has already had a some years, and were therefore stream of visitors. At present familiar with KBA presses, proved to around 70% of the products printed be an enormous advantage. Thanks are flyers, the remaining 30% cata- to the support provided by KBA, our logues and magazines, all in long departmental head Flavio Martinelli runs and consistently high quality and our longstanding technical on stock weights of between 36 and consultants Attilio Dalfiume and 130gsm (24 -90lb book). The five-colour Rapida 162a installed in mid-2008 is D’Auria’s fourth KBA sheetfed press Norberto Bucciarelli, press com- Gerhard Renn since 1998 missioning and training went with- [email protected]

Report 36 | 2010 33 Newspaper Production | Germany

ommenting on the choice of a further KBA press Armin Alt, CParzeller’s print production manager, says: “We have worked successfully with KBA for decades The Commander press line and are happy with the perform- for Parzeller Druck- und Mediendienstleistungen in ance of the presses from Würzburg. Fulda After running a rule over all the possible alternatives we opted for the high productivity, acknowl- edged superior quality and persua- sive price/performance ratio of a Commander satellite press.” Pub- lisher Michael Schmitt agrees: “The innovative newspaper press tech- nology will allow us to meet our challenging production targets. This in turn will furnish the foundation for safeguarding the future of our Investing amid crisis regional title, and the many other ti- tles we print, in a media arena where competition is becoming in- KBA Commander satellite press creasingly fierce. We are firmly con- vinced that print will continue to play a major role in a multimedia for Parzeller in Fulda environment.”

Innovative media enterprise Parzeller Druck- und Mediendienstleistungen in Fulda signed up in late summer Parzeller was established in 1873 in 2009 for a double-wide KBA Commander satellite press. The 32pp press for Fulda, whose abbey houses the tomb of Devon-born English mis- high-quality full-colour production is slated to go live this summer in a new, sionary St. Boniface, who later be- conveniently located printing plant on the Eichenzell industrial estate. Alongside came the patron saint of Germany. the Fuldaer Zeitung and diverse local editions with a total daily circulation of some The Parzeller media group now comprises eight companies. Its flag- 50,000 copies the Commander will print external and in-house freesheets, such ship title, the Fuldaer Zeitung, has as Marktkorb, with a weekly circulation of 250,000 copies, plus other publications The stacked nine-cylinder satellites deliver evolved strongly in recent years as a top-quality print and allow straightforward including address directories. 4/4 production, which will not be confined the result of a consistent market solely to newspapers focus and skilled expansion. Says Schmitt: “A media analysis in 2008 revealed that the Fuldaer Zeitung’s modern layout and the targeted Focus on flexibility Advanced level blanket and impression cylinders structure adopted last year has en- The double-wide KBA Commander of automation plus the inking and dampening abled it to attract a much higher press can pump out 90,000 copies The highly automated press will units. Other productivity- and qual- proportion of young readers than per hour in straight production and comprise two Pastomat reelstands ity-enhancing automation modules any other daily.” handle a range of infinitely variable with Patras A automatic reel han- will include ink pumping, colour web widths to accommodate multi- dling and stripping, two towers of density control, RollerTronic roller Broad spectrum of printed products ple print formats. On top of this the stacked nine-cylinder satellites, two bearings, cut-off register, web-guid- and services press has been configured to accept double turner bars, a folder super- ance and web-travel controls plus In addition to newspapers Parzeller 7/8 and 3/8 webs and a broad structure with two formers, a KF 5 pre-former web guides. The press prints mono- and polychrome choice of stock weights for printing jaw folder and diverse auxiliaries line will be controlled from two EAE books, catalogues, dictionaries, tele- unusual ad formats such as half cov- such as a cross perforator and sec- consoles with PRINT job-scheduling phone directories and similar publi- ers and spadias. Armin Alt, a print tion stitcher. Provision has been and press-presetting software, a VIP cations, complete with post-press savant with a reputation extending made for the optional addition of a statistics system and a logistics and and distribution. The group’s port- well beyond Hesse, has plenty of skip slitter, Zip’n’Buy variable maintenance system (LMS). The folio also embraces media-neutral other ideas up his sleeve, and these length perforator, card gluer and digitally downloaded pages will be data handling services and website will feature more fully in a later ribbon stitcher. The press will have checked visually via a proofing sys- design. “Today Parzeller is a major issue of Report. automatic washing systems for the tem. European player in the market for compact colour books, and from the payroll perspective we are the “We are firmly convinced that print will continue to play a major role in a multimedia environment.“ biggest commercial printer in Klaus Schmidt Hesse,” says Armin Alt. Publisher Michael Schmitt [email protected]

34 Report 36 | 2010 Newspaper Production | China

Pictured after signing the contract in Beijing Koenig & Bauer ships further Comet press line to China (seated, l-r): Walter Zehner, head of KBA’s sales and service organisation in China; Mei Ning Hua, president of Beijing Daily Group; and Li Jun, vice-president of the importing corpora- tion. Looking on are the project teams includ- ing Beijing Daily Group printing plant manager KBA newspaper press Guan Hong Jin (8th left) and his deputy Jia Fu Dong (on his right), KBA China web press sales managers Andreas Friedrich (behind them) and Wang Hong Feng (3rd left), and web depart- technology for Beijing Daily ment manager Han Shao Sheng (4th left)

Beijing Daily Group has switched to KBA for a new press line following a detailed market comparison and a tour of inspection in Germany. Comprising three reelstands, three towers and one folder, the KBA Comet will go live this coming summer printing a free title launched last year for distribution in the Beijing underground (subway). Provision has already been made for the addition of three more towers for printing further titles.

Leading media group in China struction News, Beijing Daily Mes- The Australian Chinese Times and Beijing Daily Group publishes nine senger and The First the group also the Europe Times. It also distributes daily newspaper and three maga- owns the Beijing Evening News and news items under the name Beijing zine titles, among them Journalism Beijing Daily, established in 1958 Today. and New Writing, China Campus and 1952 respectively. The Beijing and Beijing CPC Party Monthly. The Daily’s circulation of 400,000 Comet wins on David Brandstätter (l), managing director of newspaper titles have a combined copies per day makes it the capital’s quality and productivity the Main-Post in Würzburg, expounding the benefits of the company’s new, compact KBA daily circulation of around two mil- most popular newspaper. In addi- Single-width Comet presses from Commander CT to Beijing Daily Group president lion copies in the Beijing metropol- tion to maintaining its own foreign KBA’s Würzburg production plant Mei Ning Hua (2nd right) and his colleagues itan area alone. Alongside the correspondents the Beijing Daily co- are in operation the world over. Ac- during an information-gathering tour of the Beijing Morning Post, Beijing Sub- operates with the China Press and cording to Beijing Daily Group, printing plant urbs Daily, Beijing Business Today, International Daily News in North what tipped the balance in favour of Beijing Social News, Capital Con- America, China Today in Canada, a Comet was its outstanding quality and productivity. The press line for Beijing will be capable of handling web widths from 635 to 880mm (25 - 34.64in), have a cylinder cir- cumference of 1092mm (43in) and a maximum rated output in straight production of 78,000cph. It will also feature fan-out compensation, automatic ink pumping and blanket washing. The highly automated KF 3 jaw folder will be fed via two stacked formers. The press line will be controlled from three KBA consoles with ink-key presetting software, a RIP interface and a diagnostics PC for remote mainte- nance. Klaus Schmidt The Comet, which will be Beijing Daily Group’s first KBA press, will go live in summer 2010 [email protected]

Report 36 | 2010 35 Newspaper Production | Innovation

With KBA PlateTrans it is possible to partially or fully automate plate transport to, loading at and removal from the PlateTronic automatic plate changers at Cortina and Commander CT presses

Closing the automation gap between pre-press and press Automated plate logistics with KBA PlateTrans In the industrialised world, rapid advances have been made in automating and integrating the individual sequences in newspaper production. And, as so often, Koenig & Bauer has taken the lead in the empowering technology. As early as Drupa 2000 we launched a totally new type of newspaper press – the water- less, ultra-compact Cortina boasting automatic plate change. This was followed in 2007 by a conventional counterpart, the equally compact Commander CT. At Ifra Expo 2009 we unveiled a key link in the printshop automation chain. Developed in collaboration with Beil-Registersysteme in Abensberg, the modu- lar KBA PlateTrans plate-transfer system closes the automation gap between pre-press and press in plate logistics for these innovative compact presses, allowing productivity and cost reserves to be exploited to the full.

epending on the equipment eases the press crew’s workload by liver the best possible product. The plates are processed. PlateTrans chosen, KBA PlateTrans fully relieving them of peripheral tasks so result is a substantial boost to pro- eliminates the risk of costly down Dor partially automates the sup- that they can concentrate on con- ductivity and cost efficiency, partic- times due to misallocation – a fre- ply of plates to the feed magazines trolling the printing process to de- ularly where large numbers of quent occurrence with manual at the Cortina and Commander CT and the disposal of the used plates – sequences which at present are executed manually and entail a lot of legwork. KBA PlateTrans can even be retrofitted on recent models. The automatic register-true plate change itself is still performed by our practice-proven KBA PlateTronic system. But this new development

KBA teamed up with the Beil Group at Ifra Expo 2009 to demonstrate KBA PlateTrans, a module-based system for automating plate logistics between pre-press and press. The photo shows the PlateRail track with PlateTrain transport vehicle for PlateBox transport magazines

36 Report 36 | 2010 plate loading and mounting. The Plate logistics management (PLM) Specifications system can be automated in stages. Tracking level KBA PlateBox transport magazine Plates conveyed as if Printshop management and tracking system • Max. weight: 3 kg by an unseen hand • Capacity: 4 single or two-double-spread Automatic plate feed and disposal at plates plus used plates the press are controlled by a com- Planning level • Identification via 2-D matrix code puter-assisted plate logistics man- KBA PlateTrain transport vehicle agement system (PLM). In the first Production scheduling system Console • Max. load: 50 kg step the exposed plates are seized • Average speed: 0.7 to 1 m/s from the delivery of the punching and bending machine by KBA Plate- Co-ordination level Sorter, an intelligent robot gripper. They are then identified via a bar- Plate workflow control code, subjected to a quality check (optional) and sorted according to Unrivalled plate-changing speed the designated printing couple into KBA PlateBox In the next step the PlateBox maga- Plate logistics management system scheduling the KBA PlateBox transport maga- zines with the new plates are trans- zine, which has already been locked ferred by the KBA PlateLoader robot onto the transport vehicle. to the KBA PlateTronic automatic KBA KBA KBA The intelligent transport vehi- Pre-press KBA PlateTronic PlateSorter PlateTrain PlateLoader plate change plate-changing units in the press. cle, KBA PlateTrain, can hold up to Prior to this the robot will have re- five magazines, one of which is re- KBA PlateTrain moved any magazines with used served for the first used plates to be Execution level plates and transferred them to the removed from the tower. Each of train. the other magazines holds four new Sequence The plate-changing sequence it- single plates or two new double- self takes just two minutes or so Exposure Plate bending Plate inspection Magazine loading spread plates plus slots for used and is thus twice as fast as any other plates. Two and three carriages re- robotic systems available on the Plate change Plate exchange Interim storage Magazine transport spectively are required for one side market. of a 4/2 and a 6/2 tower. KBA Plate- Magazine transport Plate removal Ready Train, which is suspended from an High-performance overhead rail that is freely config- Multicar system urable to suit plant architecture, KBA PlateRail is an unmanned sys- conveys the plates to a position The computer-controlled PLM system co-ordinates, monitors and controls all individual sequences tem for conveying plate magazines above the relevant tower. as well as the entire KBA PlateTrans plate-logistics process to the Cortina and Commander CT printing towers. Unlike similar sys- tems from other manufacturers KBA PlateRail incorporates Swisslog- Telelift’s MultiCar system, which al- KBA PlateLoader removes the PlateBox magazines from the PlateTrain lows the individual towers and transport vehicle and passes them, correctly positioned, to the optional buffer sections to be PlateTronic automatic plate changers in the press reached via a system of switch- points. On its return journey the train stops at an offloading station where the used plates are removed auto- matically and the PlateBox maga- zines reallocated. The magazines are subsequently reinserted in the train at the loading station ready to accept new plates. The flow chart above shows how the relevant sequences are co- ordinated and controlled, how the processes in subordinated systems interact, and how the entire process is safeguarded and monitored by the computer-assisted plate logistics management system PLM.

Klaus Schmidt [email protected]

Report 36 | 2010 37 Newspaper Production | India

Over 2,000 guests attended an open house on 14 November last year commemorating the inauguration of a new printing plant – Print Planet – in Ahmedabad

Gujarat state Chief Minister Narendra Modi (centre) officially fired up the big Prisma production line in Ahmedabad attended by a host of political and business luminaries

Successful completion of major project at DB Group

Host of VIPs at official launch in Ahmedabad Going for growth with The new press line, which has nine reelstands, one double folder, one single folder and four control con- fleet of Prisma presses soles, was set in motion by Naren- dra Modi, Chief Minister of India’s In December 2007 Diligent Media Corporation and DB Corporation, two enterprises owned by Indian media major business-friendly Gujarat state. The Dainik Bhaskar Group (DB Group), signed a contract with KBA for seven Prisma newspaper presses, totalling commemorative publication printed at the inauguration illustrated the 25 printing towers, for multiple locations. The first Prisma, a four-tower configuration, went live in December 2008 course of the project from the at the group’s Bangalore operation, and was followed in July 2009 by an eight-tower press in Jaipur. On 14 initial investment decision to suc- November last year the biggest installation, comprising three sections and nine towers, was officially inaugurated cessful completion. The inaugural ceremony in the presence of DB at the group’s production plant in Ahmedabad, northwest India. The ceremony was attended by over 2,000 repre- Group chairman Ramesh Chandra sentatives from politics, business and the media industry. Agarwal and guests of honour from all over India was an event of major significance for the fast-growing In- …for ambitious growth strategy They are planning to use the Pris- Bhaskar, and an English-language dian newspaper industry. This major investment in three mas’ formidable colour capabilities daily, DNA (Daily News & Analysis), brand-new printing plants high- and high productivity to boost the which also includes an entertain- Cutting-edge newspaper press lights the determination shown by circulations of their many titles, ment section, After Hours, and a technology… DB Corporation and Diligent Media which include India’s biggest Hindi business section, DNA Money. The The double-width, single-circumfer- Corporation to secure a sizeable newspaper, Dainik Bhaskar, Gu- DNA titles, which first hit the ence KBA newspaper presses in slice of the expanding media pie. jarat’s leading regional title, Divja streets in 2005, quickly established Bangalore (Karnataka), Jaipur (Ra- a foothold in the market and have jasthan) and Ahmedabad (Gujarat) become a serious challenger to the are the most technologically ad- Times of India which was first pub- vanced of their kind in the country. lished back in 1838. The fleet of Prismas is also evidence In the words of Girish Agar- of the steep growth trajectory pur- waal, DB Group director, the entire sued by the Indian print media, par- Prisma project has been an unmiti- ticularly in the north-western and gated success: “We are all delighted south-western states. While the at being able to complete such a newspaper industry in many Euro- major investment bang on time pean countries, the USA and Japan despite a challenging economic en- has been severely hit by competi- vironment. Our award-winning mar- tion from the internet, with many keting strategies have been highly titles seeing their circulations effective, and in tandem with our steadily dwindle, printed newspa- high-powered KBA press technology pers in a densely populated country give us grounds for boundless opti- such as India still offer huge poten- mism. Over the next few years we tial for growth fuelled by increasing The Prisma in Ahmedabad, with its nine four-high towers, nine reelstands, one double and are confident of maintaining or prosperity. one single folder, has a formidable production capacity even enhancing the growth trajec-

38 Report 36 | 2010 On 14 December 2008 the first of seven Senior KBA fitter Steffen Thoma (front right), Rakesh Singh (centre), the DB Group’s A Prisma press line went live in Jaipur Prisma press lines rolled into action at head of production in Gujarat, and the Ahmedabad press crew were delighted at the on 6 July 2009 DB Group’s high-tech plant in Bangalore smooth production start tories we have achieved in the print surpassed. We opted for the Prisma DB Group publishes India’s sector in previous years. For us, the after viewing a number of KBA in- biggest Hindi newspaper, Dainik Bhaskar, Gujarat’s printed word is still the most au- stallations, among them those at leading regional title, Divja thentic way of disseminating infor- the Bangkok Post and Singapore Bhaskar, and an English- mation.” Press Holding. Technology, price/ language daily, DNA (Daily performance ratio and delivery News & Analysis), which in- cludes an entertainment The best choice deadlines were most closely aligned section, After Hours, and a Although the DB Group originally with our specifications.” business section, DNA Money focussed on production plants in Mumbai, Ahmedabad and Jaipur, Smooth execution at all locations after conducting a painstaking mar- Dinesh Sharma, DB Group head of ket survey the final choice was production, emphasises the trouble- changed to Ahmedabad, Jaipur and free collaboration with KBA: “The Bangalore. Of the seven Prisma timing, installation quality, commis- press lines ordered, six were sioning and training were excellent brought on stream within the space at every facility. The first of the Pris- of the first press in Bangalore. For layout options. This is a huge bonus of one year. The location for the mas, a four-tower press line in Ban- our company this represented the not only for advertisers but also for seventh press has not yet been con- galore, went live on 14 December harmonious completion of a circle.” our own PR and marketing activi- firmed. R D Bhatnagar, DB Group 2008, just twelve months after the ties.” CTO, is certain that, of the possible contract was signed. The eight- Rapid transition options offered by German and tower Prisma in Jaipur followed on to new technology A leader, not a follower Japanese press manufacturers, the 6 July 2009. The project culminated According to Sharad Patel, who is Rakesh Singh, head of production in KBA Prisma was by the far the best in the start-up of the nine-tower responsible for engineering at the Gujarat State, says: “The feedback choice: “The production figures Prisma installation in Ahmedabad Ahmedabad plant, the DB Group from readers, advertisers and other prove that we made the right deci- on 14 October 2009, and technical was previously the biggest user of newspaper publishers following the sion. Our expectations have not just acceptance took place twelve Orient presses built by KBA’s new production start of the first Prisma been fulfilled, they have often been months to the day after the start-up alliance partner, The Printers House presses has been overwhelmingly (TPH): “Thanks to the outstanding positive, they have all shown training provided by KBA instruc- tremendous interest. Since the new tors, our press operators mastered press line came on stream at our The new printing plant the transition without a hitch. plant in Ahmedabad more than in Ahmedabad Alongside their much bigger colour 5,000 visitors have come to see the capabilities the Prisma presses offer Prismas in action. We have become us unprecedented format flexibility a showcase for cutting-edge KBA and output levels. Our production newspaper press technology in line in Ahmedabad can print as India and are helping to open the many as 85,000 copies per hour, door for KBA to a market with enor- each with up to 72 full-colour pages mous growth potential. This is typ- in three sections. The prefolding fa- ical of the DB Group mentality: we cilities in the KF 5 folders allow us are a leader, not a follower.” to print quadruple spread ads or Gerhard Renn posters, which gives us additional [email protected]

Report 36 | 2010 39 Newspaper Production | Sudan

The Comet press line at Khartoum-based IGPP rolled into action last summer The press crew was given in-depth training in the Comet’s new-generation technology

Premium-quality colour printing in Sudan Cutting-edge newspaper technology at IGPP in Khartoum The quality and colour content of the diverse daily and weekly titles printed under contract by Khartoum-based International Group Printing Press (IGPP) in Sudan have received a huge boost following the successful start-up of a two-across Comet newspaper press. The new installation – the first of its kind in the country – is part of a growth strategy pursued by Yassir Hamad Madani, who along with two partners set up the company in 2005 on an industrial site on the outskirts of the city.

Professional production launch KBA Comet has substantially en- perb image and colour quality de- off and a web width variable be- Says Mr Madani: “Coupled with our hanced both our output and our livered by the new press, while its tween 630 and 870mm (24.85 - high-powered pre-press and mail- production flexibility. Our cus- huge potential means we are well 34.25in), with 760mm (30in) the room technology the start-up of the tomers are delighted with the su- equipped to meet future market de- standard. The three Pastoline reel- mands. In fact, we are already con- stands are embedded in a Patras M templating an extension.” Madani reel-handling system. The two four- was equally impressed by the per- high towers feature automatic ink formance of KBA’s installation team, pumping, colour-register controls who commissioned the press under and pneumatic fan-out compensa- challenging circumstances: “We tion. The superstructure for the KF have never experienced such a 3B jaw folder (2:3:3 cylinder sys- smooth press start-up as with the tem) has a single former. Extras in- KBA Comet,” says Madani. clude gluing, perforating and quarterfold capabilities. Console Automated and technology for the press line in- highly flexible press cludes ink-key presetting and a RIP The 75,000cph floor-mounted interface. Remote maintenance is Comet has a 578mm (22.75in) cut- possible via a diagnostics PC.

Yassir Hamad Madani is making the most of the Comet’s formidable print quality and output to Klaus Schmidt expand his business still further [email protected]

40 Report 36 | 2010 Websites: www.onlineprinters.com | www.kba-metronic.com UV Offset | Web to print

And the printing process is pretty simple because the press has no ink keys. Since our entire production process conforms to the German Process Standard for Offset Print- ing, the minder can rely on pre- press data being one hundred per cent accurate. Without PSO accred- itation the growth our company has achieved in recent years would not have been possible.” Installing the Genius 52UV made virtually no difference as far as pre-press was concerned. The waterless plates could be exposed with the existing ctp platesetter and washed with the plate exposure de- vice supplied by KBA-Metronic. L-r: press operators Achim Frühwald and Jonas Haupt with plant manager Bernd Schürmann and printshop manager Stefan Hagen While 70lpc (175lpi) is the standard at the new Genius 52UV screen used on the Genius 52UV, it is possible to print up to 120lpc (300lpi) or frequency modulated New options with waterless UV screens.

Fast turnaround Onlineprinters expands Onlineprinters’ finishing equip- ment includes a number of guil- lotines and folding machines offerings with Genius 52UV alongside new-generation gang stitchers plus diverse creasing and When Onlineprinters, a German enterprise based in Neustadt an der Aisch, fired up a small- die-cutting machines. So orders format Genius 52UV B3 (20in) press from KBA-Metronic at the beginning of December it expanded placed via the internet can be fin- ished in-house and mailed without the range of substrates it can handle to include synthetics and non-absorbent or coated paper up to delay. 0.8mm (32pt) thick. The company maintains two online printshops, one German (www.diedruckerei.de) and the he waterless Genius 52UV has are beyond the capabilities of our Senior manager Stefan Plo- other English (www.onlineprint- increased the number of offset conventional presses. The waterless mitzer agrees, adding: “Another ers.com). “Jobs are sent in from all Tprinting units in Onlineprint- Genius 52UV can be made ready in benefit of running UV inks is that over Europe and are printed and fin- ers’ press room to 62, for sheet for- next to no time and runs up to they cure instantaneously, so there ished here at our Neustadt plant in mats up to B1 (41in). There are also saleable colour in just a few sheets. are no time-wasting delays prior to a minimum of time,” says managing a number of digital presses. Along- That’s what got our vote,” says sending the prints for trimming, director Walter Meyer. Looking side a broad spectrum of business Schürmann. folding, die-cutting and packing etc. back on his company’s dynamic stationery such as letterheads and growth, he adds: “Our focus on the business cards the company prints online market over the past five flyers, postcards, posters and even years has enabled us to evolve into adhesive-bound catalogues and one of the leading print enterprises stitched brochures. in Europe. We have really put our backs into it since the company’s A new dimension launch with just one employee back “The Genius 52UV has added a in 2004. In 2008 Onlineprinters be- new dimension to our existing came a limited company and today fleet,” says plant manager Bernd we employ around 250 people.” Schürmann. “Being waterless and The customer base includes adver- UV, the press is ideal for materials tising agencies, retailers, printing such as high-gloss cartonboard, plants, businesses and private indi- polyethylene, PVC and other plastic viduals. films.” Onlineprinters installed the Genius with the aim of expanding into lucrative niche markets with high potential. “There are always Johannes Schaeben going to be certain materials that Onlineprinters’ production plant on the Neustadt an der Aisch industrial estate [email protected]

Report 36 | 2010 41 UV Offset | Switzerland

Flip-flop images / 3-D hang tags Wine labels made of metallised paper Menus on wood veneer Business cards / calendars with unusual optics

Druckstoff in Horw addresses lucrative niche market First Genius 52UV in Switzerland Swiss print enterprise Druckstoff in Horw, in the canton of Lucerne, was launched last summer with an attractive business model powered by the installation of the first Genius 52UV in Switzerland. The waterless press is ideal for printing new, unusual products on substrates that are often beyond the capabilities of conventional offset presses. These include diverse plastics and paper with a non-absorbent surface. Eye-catching transparency

n the Genius, UV inks harden in fication in the marketplace in re- Conserving the environment by the delivery. As a result it can spect of everyday printed products. using sustainable resources and re- Ieven print sensitive substrates We are therefore specifically on the cycled substrates ranks high on such as PVC, ABS, PET, PS and PC lookout for niche products made of their list of priorities. The waterless cost-effectively. synthetics, metal, wood or carton- Genius 52UV dispenses with iso- board, with the main focus on pre- propyl alcohol and the other sta- Raising profile with mium-quality, beautifully finished bilisers which in conventional offset premium products promotional and packaging goods. are normally added to the fount so- The driving forces at Druckstoff are With the first Genius 52UV to be lution. Its keyless inking system Peter Glanzmann, Stefan Scalet and installed in Switzerland we are able means that emission levels are ex- Beat Vogel. Stefan Scalet says: “Our to deliver top-quality prints at com- ceptionally low. skill and inspiration in pursuing petitive prices. We are also able to new business lines have convinced achieve some special effects that Big demand for new ideas us that there is far too little diversi- Weatherproof plant tags were previously impossible.” Druckstoff sees itself as a purveyor of ideas for unusual types of pack- aging and products, and creative designers from the advertising in- dustry are on hand to offer guid- ance and support to the UV press operators. The company’s products are heavily promoted to establish

Stefan Scalet, Peter Glanzmann and Beat Vogel (l-r) are delighted with their Genius 52UV

User-friendly mobile touch-screen console

42 Report 36 | 2010 UV Offset | Australia

Mousepads Display wobblers Flexible rulers as advertising media them in the marketplace. Says Ste- even when disposed of as waste. Scalet continues: “We are con- as ten sheets. The press can handle fan Scalet: “We provide our cus- The office supplies we can print fident that our customers consider substrates measuring 360 x 520mm tomers with products that are out on the Genius 52UV include us a competent provider of prod- (14.17 x 20.47in) and up to 0.8mm of the ordinary, for example with mousepads, transparent sleeves and ucts that meet their specific needs. thick (32pt). UV curing allows the haptic properties to stimulate the document cases with personalised This is because we are a one-stop sheets to be turned and printed on user’s sense of touch. Our products corporate advertising, tablemats, shop for both design and manufac- the reverse side and die-cut, scored, attract the eye while at the same mobile phone cases, desk mats, ture. We see ourselves as a creative folded, embossed or trimmed im- time projecting the customer’s cor- smart pocket diaries, rulers and so ‘forge’ for substrates of exception- mediately after impression. porate image – that is a key function on. There is also a big demand in ally high quality.” The Swiss company is delighted of the advertising business today. the catering, hotel and manufactur- with the high-speed job changes Among other things they can in- ing industries for durable, water- Waterless UV delivers and the outstanding quality deliv- clude 3-D or flip-flop images on spe- proof products. Examples of these raft of benefits ered by its Genius 52UV. “We cial lenticular film. We also use are door hangers, restaurant An anilox screen roller in each of trawled the press market but were environmentally friendly products menus, printed die-cutting compo- the Genius 52UV’s five inking units unable to find any other press with such as wood veneers and organic nents, wipe-clean labels, tags and ensures that the image is inked 100 the same level of versatility and abil- resources that can be processed to signs, and magnetic foils and adhe- per cent uniformly. Semi-automatic ity to print such a broad range of create unusual substrates. Exam- sive films that can be applied to plate changing reduces job change- substrates as the Genius 52UV,” ples of these are loyalty cards and smooth surfaces without using overs to just a few minutes with says Peter Glanzmann. stickers which are non-polluting glue.” run-up to saleable colour in as little

Sustainable print production at Fishprint Website: www.fishprint.com.au Genius 52UV scores high on low emissions Emissions reduction is as big an issue in Australia as elsewhere, and to this end Fishprint in Melbourne’s Brighton East has installed a Genius 52UV five-colour waterless offset press, adding a new dimension to its range of products.

pioneer of environmentally liable image reproduction and pro- greener printing processes within friendly printing techniques in duction run stability, a high print the industry. Fishprint serves many AAustralia, Fishprint proudly quality and brilliant colour. environmentally aware corporate, calls itself a “100% waterless print- Founded in 2001 by Peter local, state and federal government ing company”. Its existing Rapida Booth and boosted by the arrival of bodies for whom sustainable print 74 B2 (29in) press has been in wa- Tony Murphy in 2003, Fishprint purchasing is a top priority. For a terless operation for some time was the recipient of a prestigious long time now alongside our normal now. The Genius 52UV has enabled Australian Savewater! Award in commercial work we’ve been look- the company to expand its portfolio 2007, and in 2008 was commended ing for environmentally friendly to include non-absorbent paper for its commitment to the environ- ways to print on extravagant sub- (metallised, iridescent) and plastic ment at the Premier’s Sustainabil- strates such as magnetic foils, foil (PVC, PC, PS, ABS, PP). ity Awards sponsored by the State stickers, plastic cards and tags, Fishprint strives to provide its of Victoria. The company boasts mouse pads and table mats. The Ge- customers with the highest quality Ecolabel ISO 14024 accreditation nius is ideal for such applications.” Instructor Helmut Herbert of KBA-Metronic prints while promoting greater en- along with the State of Victoria’s The decision was made last handing over the Genius 52UV to Fishprint director Peter Booth following installation vironmental responsibility and sus- ‘Waste Wise’ certification in recog- May at the Pac Print trade fair in and training tainability. As far as production staff nition of the fact that it recycles Melbourne, where a compact five- are concerned, the Genius delivers 98.8% of its waste. colour Genius was exhibited for the a raft of additional, process-related Says director Peter Booth: “Our first time by KBA-Metronic’s Aus- Johannes Schaeben benefits: minimal start-up waste, re- aim is to be at the forefront of tralian agency Jet Technologies. [email protected]

Report 36 | 2010 43 Shorts

First KBA Rapida 106 in Belarus

he inauguration of the very first Belarus Deputy Prime Minister Vladimir KBA Rapida 106 in Belarus, at Nikolaevich Potupchik (2nd right) and KBA T sales director Sven Strzelczyk cutting the Minsk-based print combine Poly- ribbon to mark the inauguration of the high- grafkombinat J. Kolas on 2 De- performance KBA press cember, was a high-powered event attended by the Deputy Prime Min- ister of Belarus, Vladimir Nikol- aevich Potupchik, Minister for Information Vladimir Vasilevich ing houses. The Rapida 106, which Rusakevich plus a large number of features a special lightweight paper directors and senior engineers from capability, sets a new benchmark in other printing plants throughout cost efficiency and print quality, the country. Orders for three Rap- while its maximum output of ida 75 half-format (29in) presses in 18,000 sheets per hour is twice as various configurations have already high as that of the older presses. It been placed this year by Belarusian also boasts a raft of automation companies. centre of Minsk. Prior to the new sion of the large-format Varimat. modules, eg for plate changing, and Polygrafkombinat J. Kolas has press installation the company ran Most of the presses were installed a productivity-enhancing CIPLink utilised press technology from Ra- five Planeta Super-Variant medium- back in the 1980s. The combine’s interface to pre-press. DensiTronic debeul for many decades now at its format presses with four printing main products are illustrated books colour control software raises qual- magnificent premises right in the units apiece, plus a two-colour ver- for Belarusian and Russian publish- ity monitoring to a whole new level.

Beyaert Sioen Printing moves up to superlarge format

hen Beyaert Sioen Printing Win Waregem installed a five- colour Rapida 205 at the turn of the year it was the first printer in Bel- gium to move up into the 9B (81in) format. Established in 1882 in one of Europe’s economic powerhouses – the area bordered by the Ruhr, northern France and the southern Netherlands – Beyaert sees huge potential in being the region’s sole VLF print provider. “In a radius of several hundred kilometres there is currently not one competitor capa- ble of delivering this level of qual- ity, so we are confident that the superlarge format will open up to- tally new markets. Since we are al- ready well positioned in large format, the step up to VLF was an obvious move,” explains company proprietor Bernard Ramboux. KBA presses have been in operation at Beyaert for many years Beyaert Printing evolved from three operations which have since addition the company has a four- The new Rapida 205, which can Since sheets of this size are so un- been united under a single roof in colour 3B press that mainly prints print stock thicknesses of 0.1 to wieldy, automatic plate changing is Waregem. Its three five-colour 3B paper. Most of the presses have 0.8mm (4 - 32pt), is fitted with a standard feature. Extensive prepa- (41in) presses print packaging, aqueous or aqueous/UV coaters. heavy-duty pile boards in the feeder rations had to be made prior to the while two Rapida 162a 7B (64in) Two of Beyaert Printing’s speciali- and delivery, and sheet-travel mon- Rapida’s arrival because it was in- coater presses with extended deliv- ties are bronzing and blister pack- itoring devices between the print- stalled in what used to be the paper eries handle commercials as well as aging, but the finishing department ing units. It also has inking unit store. Beyaert also added a new packaging. The most recent model can also die-cut, score, window-glue temperature control and Densi- platesetter. was installed in summer 2007. In and convert folding cartons. Tronic networking with pre-press.

44 Report 36 | 2010 Shorts

Second Rapida 75 for Länggass Druck

ast year Bern-based Länggass A sure-fire winner: Länggass Druck proprietor Druck was the first printer in Michael Wasescha (2nd left) and production L manager Hans Rudolf Roth (2nd right) shaking Switzerland to fire up a B2 (29in) hands on the purchase of their second half- Rapida 75 following the press format Rapida 75 with Peter J Rickenmann launch at Drupa 2008. The com- (left) and Franck Rocaries, managing director pany’s satisfaction with the five- and capital-goods sales manager respectively of KBA’s Swiss agency Print Assist colour coater version it had already installed prompted it to place an order with KBA for a four-colour all expectations right from the very perfector version of the same first day, delivering a huge quality model. The new press rolled into and productivity boost. The four- action at this old-established firm in colour version has the same ad- January. vanced technology as its five-colour This second investment within counterpart: double-size impression a matter of months is part of a move and transfer cylinders in a seven by Länggass Druck to standardise o’clock arrangement, semi-auto- and modernise its press room. In matic plate change, remote pre-ad- the current challenging market en- justment of sidelay, circumferential vironment the two presses will en- and diagonal register, and the same able the company to respond to sophisticated console technology. customer demands with much The washing systems for the rollers, greater agility, flexibility and effi- blanket cylinders and impression ciency. cylinders can be programmed indi- Even though it was a new vidually. The feeder and delivery are model, the first Rapida 75 fulfilled fitted with pile boards.

1,000th large-format Rapida rolls into action at Berlin-Mitte

n 4 December the 1,000th Website: Olarge-format KBA Rapida to leave www.druckhaus-berlin-mitte.com the production line was officially in- augurated by German printer Druckhaus Berlin-Mitte (DBM) at manager Jürgen Veil, who took his a new plant in Wustermark. Repre- audience through a fast, automatic sentatives of the Brandenburg Min- change of coating plates. A world istry for the Environment and the map on 135gram (36lb bond) paper Wustermark parish council were in was followed by a DIY Christmas attendance along with large num- tree on board. bers of customers and suppliers. Berlin-Mitte has gained four en- After all, the inauguration of the vironmental accreditations to date, 1,000th press from a globally popu- and offers the option of climate- lar series is hardly an everyday neutral print production (Climate event. Partner Process). The press has Appropriately enough, DBM as- been emissions tested and certified sistant vice-president Ronald Krö- Ronald Krögler (r) starting the first print run on the 1,000th large-format Rapida to leave by the BG Druck and Papierverar- gler and KBA sales manager Michael the KBA production line beitung (the industrial safety coun- Grieger unveiled a plaque naming cil for the printing and paper the big press Katharina (Catherine). Productivity-enhancing features in- DBM’s headquarters in Berlin city processing industry). All the lubri- Specifically engineered to print clude nonstop facilities at the centre, while DensiTronic Profes- cants used in the Rapida 162a are packaging and microflute corru- feeder and delivery, automatic plate sional spectral and densitometric non-toxic, and 25 per cent of the gated, the highly automated Rapida changing, Inkline ink pumping and colour measurement and control materials consumed are FSC-certi- 162a five-colour coater press with Impact washing systems. Logo- ensures a superb print quality. fied. The company’s entire opera- extended delivery can handle piles Tronic Professional software net- The maiden print run was tion is driven by hydroelectric up to two metres (6ft 6in) high. works the press with pre-press and hosted by KBA sheetfed marketing power.

Report 36 | 2010 45 Shorts

Amcor manufacturing manager Dave Wilson is delighted at the expanded production capacity and enhanced print quality which the new press has brought to the company

The new press is a fully speci- fied Rapida 105 with six printing units plus a coating unit and ex- tended delivery. It is raised up on special cast blocks eliminating the need for a costly concrete plinth and can handle substrates up to 1.2mm (0.047in) thick. The 16,000sph Rapida features a DensiTronic system for measuring densities and making on-line ad- justments to the inking profile of each printing unit. Says Wilson: “We believe the DensiTronic fea- ture on the new KBA press will give us faster makereadies and much better colour consistency.” Usually it takes press operators a while to achieve maximum speed KBA Rapida 105 at Amcor Cartons in Auckland production, especially with an unfa- miliar machine. But the Amcor press crew and production manage- uckland, New Zealand, known has its first Rapida 105 installed lo- but we are also looking for more re- ment staff mastered the new tech- Aas the City of Sails because it has cally at Amcor Cartons. Manufac- liability, colour consistency and nology in no time and were soon the highest per capita ownership of turing manager Dave Wilson says: quality enhancement. We know the making the most of its high speed sailing boats in the world, now also “Increasing capacity is important KBA Rapida 105 will give us that.” and quality.

Hasselt University picks KBA as technology partner for Lumoza

t the official launch in Novem- product marketing and presentation Aber of Lumoza, a joint spin-off for both indoor and outdoor adver- from Belgium’s Hasselt University, tising and the packaging industry. major nanotechnology research in- Not only that, they support a totally stitute IMEC and screen printing new genre of printed product. company Artist Screen, it was an- The various players involved, nounced that KBA had been chosen among them professors at Hasselt as the technology partner for print. University, had approached KBA at The new company specialises in an early stage. Always keen to build large-format screen-printed elec- on our prowess in packaging press tronics for novel forms of advertis- technology and expand from print, ing and luxury goods etc. Potential our traditional power base, into applications include wafer-thin, lu- new lines of business offering minous animated billboards or DVD sound potential for growth, we covers that display special light ef- were happy to join a project whose fects in the dark. The effects, which aim is to promote cross-platform re- are created by dielectric barrier lay- search to create previously unimag- ers between the individually applied inable products. inks, open up new perspectives in KBA sales director Thomas Kagemann (r) with consultant Addi Burmanje (centre) Website: www.uhasselt.be/lumoza

46 Report 36 | 2010 Shorts

ongstanding KBA customer LOceano in Brazil is expanding ca- pacity with two identical heatset Comet presses. One will be in- stalled this summer at Oceano’s fa- cility in Cajamar near São Paulo, the other in the autumn at Oceano Sul down south in Criciúma. Oceano, which is part of fast-growing Brazil- ian print media major Grupo Escala founded in 1992, already runs two 16pp Compacta 215 and two 48pp Compacta 618 press lines in Caja- mar and a further two 16pp Com- One of two identical Comet press lines scheduled for installation in summer and pactas in Criciúma. autumn this year at Oceano’s plants in Cajamar near São Paulo and Criciúma in southern Brazil Since 1996 group founder Her- cilio de Lourenzi has regularly invested in new KBA web and Two KBA Comet press lines for Oceano in Brazil sheetfed presses. Today Oceano em- ploys around 500 staff and prints Vogue and Vogue Homme, a popu- 1000mm (24.85 - 39.37in). Each ture, a KF 3 jaw folder with semi- over 200 magazine titles a month. lar Brazilian title, Corpo a Corpo, will be configured with a Pastoline commercial capability, a quarterfold It also prints telephone directories, a lifestyle magazine, Tempo, plus reelstand linked to a Patras M man- facility and gluing, perforating and a business publication, Brasil Eco- diverse special-interest titles and ual reel-handling system, and will stitching devices for greater prod- nomico, and numerous advertising comics. comprise one four-high tower for uct versatility. Cut-off register, web- supplements for chain stores such The 75,000cph Comets will 4/4 with bustle wheels, colour-reg- edge and web-centre controls will as Walmart, Pão de Açucar and Car- mainly print Brasil Economico, sup- ister controls and automatic cylin- ensure a high standard of quality refour. More than 3,000 tonnes plements and flyers. Both floor- der washing. In addition to the and productivity. The press lines (3,300 US tons) of paper and over mounted presses will have a heatset package with hot-air dryer will be controlled from high-tech 70 tonnes (74 tons) of ink are con- cylinder circumference of 1156mm and chill-roller stand, press specifi- consoles complete with production sumed each month. Magazine titles (45.5in) and the ability to handle cations include a double turner bar scheduling software and RIP inter- include the Brazilian editions of any web width between 630 and with one former in the superstruc- face.

L.N. Schaffrath orders new commercial press from KBA

ucking the recession, major Ger- Bman media provider L.N. Schaf- frath in Geldern am Niederrhein recently signed up for a capacity- and productivity-boosting 16pp commercial web offset press from Pictured after inking the contract for the KBA. Schaffrath, whose customers new commercial press (l-r): KBA’s Martin Schoeps (sales manager) and Christoph Müller include a raft of prominent publish- (executive vice-president for web press sales) ing houses, offers a complete range with L.N. Schaffrath’s joint managing directors of services from concept, design Dirk Devers (finances, technology) and Dirk and layout to print production and The new 16pp KBA commercial press line for L.N. Schaffrath in Geldern Alten (sales) distribution. At present its primary focus is on periodicals, magazines ($60m). Descendents of the found- changing with PlateTronic and fast The ErgoTronic control console and supplements, but it is keen to ing family are still heavily engaged conversion of the P3 folder to sup- will be supplemented by a conven- expand its offerings still further. in day-to-day management. port high-speed job changes. The in- ient operating display panel at the The new press line will join a fleet The press line will comprise feed unit with its environmentally folder. LogoTronic Professional pro- of web and sheetfed presses in a four double printing units with a friendly regenerative braking sys- duction management software will modern, well-equipped production 620mm (24.5in) cut-off and a max- tem will be integrated in the reel- capture and store operating and job plant. imum web width of 1000mm stand to save space. Shaftless drives data for press preset and rapid con- Founded over 250 years ago in (39.37in). Its advanced level of au- throughout will ease operation and version to both new and repeat 1743, Schaffrath, which is also tomation will extend from reel lo- trim makeready times. Other kit jobs. EasyTronic and its one-button known as Schaffrath DruckMedien, gistics with Patras A, including reel will include closed-loop colorime- control will shorten start-up and employs some 300 staff and in loading and reel-stub ejection in try, cut-off register controls and a slowdown times while minimising 2009 posted sales exceeding €43m the Pastomat C reelstand, to plate Contiweb hot-air dryer. waste.

Report 36 | 2010 47 Shorts

Atlantic Books wins two prestigious British awards

t the British Book Design and Left to right: awards presenter Hardeep Production Awards 2009 At- Singh Kohli, Atlantic Books production director A Alan Craig and KBA (UK) area sales director lantic Books, the UK subsidiary of Chris Scully American independent publishing house Grove/Atlantic, carried off the KBA (UK)-sponsored Trade Il- uct, design, colour, choice of sub- lustrated Award for its production strate, print and bind quality this of The Wizard of Oz by acclaimed book stood out at every stage and collage artist Graham Rawle. The deserves the accolade of Book of 304pp, 240mm x 265mm (9.5 x the Year.” 10.4in) landscape book, which was Key KBA customer Butler Tan- printed in China by Eurasia Inter- ner & Dennis was also recognised national, features over 100 collages for producing The National Cook- re-imagining L Frank Baum’s en- book, winner of the Best British chanting story. Book category. According to the award panel, work it has taken to produce it is said: “The Wizard of Oz was chosen KBA (UK) managing director “This book is truly outstanding in clearly visible. Stunning!” for its ingenious artwork style and Christian Knapp said: “The dedica- every way. The illustrations are Atlantic Books went on to exceptionally high standards of pro- tion and creativity of printers and dark, moody and totally different to scoop a second award. In deliberat- duction. From the concept through publishers in such a highly compet- anything out there. The amount of ing the overall winners the judges to all aspects of the finished prod- itive and vibrant sector is inspiring.”

The environmental benefits of waterless newspaper production Cortina users garner eco points

n the newspaper sector, environ- Print jobs for the Greens in the European mental awareness and emissions Parliament, the Belgian branch of the WWF I and other conservation-minded customers reduction play an ever greater role underscore the green image nurtured by in terms of acceptance by readers Belgian Cortina user Eco Print Center in and advertisers, and the acquisition Lokeren of print contracts in the market- place. Users of our ultra-compact Cortina waterless press are appar- customers and an increasingly sen- ently finding that their green cre- sitised general public. After being dentials give them a key advantage. singled out for an environmental award by the Belgian Greens in Freiburg environmental award 2007, last year the ECO Print Cen- for Badische Zeitung ter booked print jobs from the Bel- In autumn last year the German city gian branch of the WWF, the Green of Freiburg, whose longstanding ferred its 2009 Environmental agents and 210,000 cleaning rags Party in the EU parliament and from Lord Mayor has a reputation for Award on local print enterprise per year. Cutting waste has reduced other conservation-minded cus- launching green initiatives, con- Freiburger Druck for the Badische the company’s annual paper con- tomers at home and abroad. The Zeitung, which is printed on a sumption by 1,300 tonnes (1,430 outstanding print quality possible Cortina. A year earlier the same US tons). The above savings help with waterless press technology has title gained first place at the Ifra trim production costs as well as encouraged management in Lok- Colour Quality Club, and Freiburger conserving natural resources. In eren to focus increasingly on pre- Druck has twice been voted news- economic comparisons with con- mium coldset production with paper printer of the year. The ventional wet offset presses this is standard and improved stock. Since Cortina has enabled the company to often accidently or deliberately this consumes less energy than slash annual carbon emissions by overlooked. semi-commercial production using 3,500 tonnes (3,850 US tons), the press line’s heatset capability it while waterless technology has EPC in Lokeren the printer of choice reduces per-copy costs still further saved around 730,000 litres (almost for WWF and Greens – a big advantage in the recent eco- 193,000 US gallons) of water, Belgian media major De Pers- nomic meltdown. It is only a ques- Wolfgang Poppen (r), publisher of 28,000 litres (7,400 gallons) of ad- groep’s ECO Print Center in Lok- tion of time before more rigorous the Badische Zeitung, and Freiburger ditives, 15,000 litres (4,000 gal- eren also heavily promotes the environmental regulations are in- Druck plant manager Patrick Zürcher proudly displaying the city of Freiburg’s lons) of developing fluid, 24,000 ecological benefits of its big Cortina troduced in the newspaper indus- environmental award for 2009 litres (6,340 gallons) of washing press line, raising its profile among try. Cortina users are well prepared.

48 Report 36 | 2010 Shorts

Rapida enthusiast Hendrik Heidenreich (left) of specialist printer and finisher Heidenreich Print in Bünde proudly flourishing the Druck&Medien Award for Supplement Printer of the Year Photo: Johannes Eisele

alogues employs around 100 staff and operates a 16pp KBA Compacta 217 commercial press. The Druck&Medien Award for Supplement Printer of the Year went to offset litho printer and vet- eran KBA Rapida user Heidenreich Print in Bünde. This highly suc- cessful family business headed by Hendrik Heidenreich specialises in sophisticated finishing and helped pioneer the UV and hybrid finishing KBA users among winners of Druck&Medien Awards 2009 techniques developed by KBA in re- cent years. KBA environmental award for Evers-Druck The title of Finisher of the Year was claimed by Lechte in Emsdet- ten, a company long revered in the t the 2009 Awards sponsored by offset printing plant on the North continuous reduction in carbon trade for its creativity and product AGerman trade magazine Druck& Sea coast has been steadily trim- emissions. We are delighted that quality. Leche’s Rapida presses are Medien, KBA users were up among ming its carbon emissions for the Evers-Druck, like KBA, pursues a specifically configured for the inline the winners once again. past 25 years. In 2004 Evers-Druck long-term commitment to conserv- application of unusual and chal- However, this year the jury con- joined the EU’s Eco-Management ing natural resources, and congrat- lenging coatings. The firm operates ferred the KBA-sponsored award for and Audit Scheme (EMAS) which ulate them on winning this award. more than 40 printing and coating the Environmentally Oriented En- entails annual certification proce- As in previous years, the UPM units in diverse configurations and terprise of the Year on a north Ger- dures for environmental manage- Award for Magazine Printer of the employs 150 people. man company, Evers-Druck in ment. The jury was won over by the Year (Web) was won by Kunst- und Stark Druck in Pforzheim, Meldorf, whose presses were sup- company’s complete and detailed Werbedruck in Bad Oeynhausen. whose press room includes large- plied by other manufacturers. This documentation of its environmental The full-service specialist printer of format Rapidas, scooped two pres- 350-employee sheetfed and web activities in conjunction with its premium-quality magazines and cat- tigious Druck&Medien Awards. Top place in the category Catalogue Printer of the Year was secured by a sumptuous catalogue for major tour operator TUI Cruises. Stark Druck’s enduring success is largely attribut- able to its managing director, Hans Heer, who was voted Plant Manager of the Year. The Pforzheim produc- tion plant and a second operation in Speyer have a total workforce of 350. The event was hosted by Ger- man actress Barbara Schöneberg.

Jürgen Fischenich (centre), head of sales subsidiary KBA-Nordwest, presented KBA’s Environmentally Oriented Enterprise of the Year to Evers-Druck in Meldorf in recognition of its longstanding and successful commitment to conserving natural resources. Photo: Johannes Eisele

Report 36 | 2010 49 Shorts

KBA and TPH enter strategic sales alliance n September last year KBA and 1:2:2 folder. Outside India, TPH IThe Printers House (TPH) in presses can be found in China, Rus- New Delhi, India, entered a strate- sia and the Middle East. gic alliance to expand their busi- One of the biggest press manu- nesses worldwide. TPH now facturers in the world, KBA is con- promotes KBA’s high-performance sidered an engine of innovation in newspaper and commercial web the newspaper and semi-commer- presses on the Indian sub continent cial sectors. Focussing on kit for and in certain threshold countries, medium to high performance lev- while KBA’s global sales and service els, KBA offers newspaper printers network promotes TPH’s 2/1 Orient a complete range of presses in all web presses in the rest of the the current configurations. TPH’s world. The alliance – the biggest Orient presses expand this portfo- of its kind in the newspaper indus- lio into the budget-priced cate- try – allows both partners to cater gories. to any requirement ranging from Mon Mohan Kohli, director of 16,000iph to 95,000iph web offset TPH, said: “KBA’s excellence, com- presses. bined with world class price com- TPH is an industry leader in petitive machines from TPH, will web offset presses with thousands open new vistas in the web offset of printing units installed world- printing industry globally.” wide. The Orient range includes Christoph Müller, KBA execu- offset presses with speeds of tive vice-president for web press 16,000iph, 30,000iph, 36,000iph sales, said: “TPH with its brand and 50,000iph. The printing ele- name Orient is a highly respected ments include mono units with in- company in many growth regions tegral reelstands, stacking units, worldwide. The tie-up between us ARC with stack, three-colour satel- will complement our product range lites, four-high towers, a tucker Soon after entering the sales alliance TPH made a joint appearance and further enhance our standing in folder and jaw type folder including with KBA at Ifra Expo in Vienna the global market.”

MSO Cleland, Belfast: 40 per cent productivity gain with Rapida 106

A new Rapida 106 at Belfast-based packaging new Rapida 106 at MSO Cle- printer MSO Cleland has delivered substantial Aland has recorded a 40% in- gains in terms of productivity, quality and crease in productivity for the flexibility Belfast-based major B1 (41in) pack- aging print house. The eight-colour tomated nonstop pallet-to-pallet UV coater version was chosen in ad- changeovers at both the feeder and dition to the two existing Heidel- delivery deliver further efficiencies. berg presses as part of an ongoing Among the other headline features strategy to increase capacity and are the automated coating unit al- competitiveness in the high-pres- lowing perfect registration on the sure packaging market. first sheet. There is also the quality CEO Dominic Walsh says: “Our control aid DensiTronic Professional key focus was to improve our per- that scans the sheets at a resolution formance and the Rapida has cer- namic flexibility is definitely en- Three different jobs of 4,500 of 330dpi and compares them with tainly achieved that. In the current hanced with the installation of this sheets, 6,000 sheets and 90,700 the original PDF to identify even economic climate of uncertainty KBA press. Improved productivity sheets were run on the press and it minimal deviations and automati- with ever decreasing run lengths and resulting increased capacity achieved almost 40% increased pro- cally record them in the quality log; and shortening lead times we can means we are well positioned for ductivity on UV packaging material and KBA WashTronic, which strips now deliver superior quality across future growth, especially in the compared to the existing press. the ink on the last eight to ten a broad mix of output, so dovetail- very demanding luxury packaging The 18,000sph Rapida, now sheets reducing the amount of ink ing our capacity to our customers’ sector where the superior print running in a 24-hour shift pattern, debris on the blankets at wash-up needs. Price and quality are a given quality achieved with the KBA is a was installed on a 450mm (17.7in) and helping to speed up makeread- in the packaging market but our dy- real bonus.” plinth to maximise pile heights. Au- ies.

50 Report 36 | 2010 Shorts

Print Week editor Darryl Danielli, Buxton Press executive director George Briddon and operations director Kirk Galloway with the host of the awards, BBC presenter Jeremy Vine

Report is the corporate magazine issued by the Koenig & Bauer Group (KBA):

Print Week Awards 2009: Koenig & Bauer AG, Würzburg Friedrich-Koenig-Strasse 4 97080 Würzburg KBA customer expertise celebrated Germany Tel: (+49) 931 909-4336 Fax: (+49) 931 909-4101 Web: www.kba.com he Print Week Company of the E-mail: [email protected] Year Award 2009 went to KBA Koenig & Bauer AG, Radebeul Thouse Buxton Press. The Friedrich-List-Strasse 47 achievement is all the more re- 01445 Radebeul markable since the Derbyshire- Germany Tel: (+49) 351 833-2580 based sheetfed magazine specialist Fax: (+49) 351 833-1001 faced closure as recently as 2004. Web: www.kba.com But a tightly controlled investment E-mail: [email protected] programme helped redefine its KBA-Metronic AG business model. Buxton Press, Benzstrasse 11 which has a bank of Rapida B1 97209 Veitshöchheim (41in) presses, achieved commen- Germany dations at the same awards in 2005 Tel: (+49) 931 9085-0 Fax: (+49) 931 9085-100 and 2006 and reached the final Web: www.kba-metronic.com shortlist again in 2008. Its focussed E-mail: [email protected] approach has led to considerable re- cent accolades including Environ- KBA (UK) managing director Christian Knapp presenting the KBA-sponsored Environmental KBA-Grafitec s.r.o. Opocenskᡠ83 mental Company of the Year, Company of the Year award to Stralfors UK group managing director John Carter. Also pictured is BBC presenter Jeremy Vine 51819 Dobruška Environmental Printer of the Year, Czech Republic Best Environmental Printer and En- Tel: (+420) 494 672-111 Rapida 162s, two 105s and a 205, Fax: (+420) 494 623-675 vironmental Performance of the cellence Awards and People In Print Web: www.kba-grafitec.cz Year. went one better last year to top the Awards. It claimed the coveted En- E-mail: [email protected] At the same event Leicester Point-of-Purchase Printer category. vironment (>100 employees) and Karat 74 user Taylor Bloxham The Bromley-By-Bow operation was Corporate Social Responsibility ti- Publisher: Koenig & Bauer Group claimed the title of Customer Mag- also commended in the Poster tles at the former and the Environ- azine Printer of the Year. Judges par- Printer of the Year group, while mental Award at the latter. Editor in chief: ticularly noted the quality of London-based SMP Group, which The Blue Printing Company Klaus Schmidt, Calibre, a bi-annual magazine for has a Rapida 162 and a 105, was a of Harlow was shortlisted in the KBA director of communications, Würzburg premium watch retailer Watches of finalist. Customer Service Team of the Year Switzerland. Another Karat 74 user, Cambrian Printers received a category. Layout: London-based Screaming Colour, commendation in the Environmen- KBA (UK) managing director Pia Vogel, VOGELSOLUTIONS.COM took home the title of Digital tal Company category. The latest Christian Knapp presented the KBA- Printer of the Year for all four of its recognition of the Aberystwyth fam- sponsored Environmental Company Translation: Christina Degens-Kupp, KBA work samples. ily-owned company’s dedication to of the Year award to Stralfors of After twice finishing as runner- environmentally responsible print- Redruth. Printed in the Federal Republic of Germany up, Augustus Martin, with two ing follows accolades at the BPIF Ex-

Report 36 | 2010 51 KBA and the Environment

Ecology and economy from a single source

More and more printers are seeking to green up their image with environmentally responsible products. We have been honing our commitment for a long time now with energy-efficient, eco-accredited sheetfed presses and innovative waterless offset technology for sheetfed and newspaper production. Proving that press ecology and economy are not mutually exclusive. We’ll be glad to show you how.

Koenig & Bauer Aktiengesellschaft (KBA) Würzburg, phone: +49 931 909-0, [email protected], www.kba.com

KBA.I.710.e Radebeul near Dresden, phone: +49 351 833-0, [email protected], www.kba.com