DIGITAL COLOR PRESSES -- Digital Devices' Dance Card

BY MARK SMITH

Technology Editor

It’s been more than a decade since the first high-volume, modern digital color printing systems were introduced. Heidelberg and Presstek teamed up to launch the digital offset (GTO DI, in this case) product category in 1991. A few years later, the Indigo EPrint and Agfa/Xeikon Chromapress ushered in the era of the all-digital production color printing systems.

In the future, though, 2004 may be looked back upon as a key transition period in the maturation of digital printing as a business segment—both on the vendor and user side. No fundamentally new technologies were unveiled, but all the vendors introduced more robust and/or higher quality versions of what’s come before. There also was significant activity in the product marketing arena, headlined by the transfer of Heidelberg’s digital printing holdings to Eastman Kodak.

Given the myriad of announcements made, it can be difficult to keep straight what combinations of technologies (hardware, software, consumables) are being offered through which channels (direct sales, OEMs, resellers, etc.). The various business arrangements also raise the question: Who’s responsible for service and support after the sale?

The drumbeat for variable data printing and personalization for a time had all but drowned out any word of developments in digital offset. Advances in the technology and addition of a new channel now have this technology making news again.

Presstek Inc. introduced ProFire Excel imaging and ProFire Digital Media, which work in combination to produce a 16-micron spot that enables 300 lpi output and supports use of enhancing screening options. The company also announced it was seeking to broaden the market for DI (Direct Imaging) technology by launching an entry-level, ProFire-based platform through its OEM partners.

Since becoming one of those OEMs, Kodak Polychrome Graphics (KPG) has registered a steady stream of installs. Those machines have chiefly been the earlier KPG DirectPress 5034 DI configuration, which the company says is now being phased out.

High-end Takes Stage

KPG reports it began installing the higher end ProFire-based DirectPress 5634 DI model last summer. Toward the end of the year it also started installing the entry-level version, KPG DirectPress 5334 DI. Both can be driven by the KPG DirectWorks Suite workflow.

According to John Schloff, KPG vice president, digital printing, key differences in the machines include use of six lasers versus three, resulting in shorter makeready on the DirectPress 5634 DI, and a motor-driven paper feed/delivery tray as opposed to mechanical components on the DirectPress 5334 DI. “Otherwise, a KPG DirectPress 5334 DI can be fully optioned up to a KPG DirectPress 5634 DI press,” Schloff says.

These DI presses are based on a press platform (18.11x13.39˝ maximum sheet size) from Ryobi, which is marketing its own versions in the U.S. through xpedx/Import Group. Toward the end of 2004, xpedx was selling out the last of its previous generation models, the Ryobi 3404-DI, and had begun installing the higher end, ProFire-based Ryobi 3404X-DI, reports Don Trytten, vice president and general manager. He adds that entry-level Ryobi 3404E-DI models were on order and that the company was finalizing what would be standard equipment on the configuration offered in the United States. The company offers Harlequin-based front ends to drive the presses.

While its parent company offers versions of these presses (46 Karat) in other regions, KBA North America is concentrating on the larger (201⁄2x291⁄8˝ maximum sheet size) 74 Karat digital offset press. That machine continues to use Presstek’s PEARLdry plates and can process 1-bit TIFF files. Workflows specifically adapted for the press include the Creo Brisque and Adobe Extreme combination, as well as CGS Publishing Technologies’ O.R.I.S. workflow.

Heidelberg adopted an earlier version of ProFire imaging and has now introduced ProSpot technology to its family of Quickmaster DI presses. This imaging enhancement is said to optimize the laser spot size in relation to the dot generated and works in harmony with the screening method selected, especially Heidelberg Irrational Screening.

The product line now includes the QM DI Plus, Pro and ProSpot. The latter two are higher-end configurations with additional standard features such as a CP 2000 console, stream feeder with automatic adjustment, DryStar IR dryer, Smart Spooling, impression cylinder cleaning device and more, says Joerg Daehnhardt, Heidelberg product director, small format. Heidelberg’s Saphira Caleidoplate, an OEM product, is the recommended plate material for all models.

The press manufacturer also continues to offer the Speedmaster SM 74-DI, which has a 20.87x29.13˝ maximum sheet size. It was developed with Creo’s SQUAREspot DOP (digital offset printing) thermal imaging technology, and the recommended plate material is Heidelberg’s Saphira Thermoplate PL non-ablative polymer, aluminum plate material.

At Drupa 2004, Heidelberg showed a version of this digital press incorporating a new internally developed laser, but this was a research project only, explains Carsten Ruebel, product manager, 74 format presses.

The Quickmaster DI can be driven by MetaDimension 5.0, as well as Delta Technology and Harlequin RIP. The Speedmaster SM 74-DI currently has a Delta RIP front end, but MetaDimension support is said to be in development.

Hip to Be Square

MAN Roland also utilized SQUAREspot imaging technology in the original implementation of its DICOweb webfed digital offset press concept. The concept, which features the ability to image and de-image cylinders on-press, has undergone beta testing at two sites. In the PrintCity exhibit at Drupa 2004, Agfa demonstrated the ability of its ApogeeX workflow system to drive the DICOweb, which has also been interfaced to a Creo workflow solution.

Creo has now expanded into the consumables side of the digital offset business with the introduction of Clarus WL plate material. The company says the product is “drop-in compatible” with leading DI presses, including the Heidelberg Quickmaster DI, Ryobi 3404-DI and KBA 46 Karat. It is available directly from Creo.

Agfa continues to offer its Thermolite and Thermolite Plus plate materials for on-press imaging applications. In the past year, it has adapted the latter thermofusable technology for off-press imaging with the introduction of the Azura processless plate.

Konica Minolta has also introduced a short-run (up to 20,000 impressions), processless thermal plate—TF-200—that it says can be used in on-press imaging applications. The material has been adopted by Screen (USA) for use with its TruePress 344 digital offset press, which has a thermal MALD (multi-array laser diode) imaging system.

The TruePress 344 handles a maximum sheet size of 13.4x18.5˝ and offers a 2,400 dpi resolution that supports Spekta hybrid screening. A key difference in this digital press is that it uses a “wet offset” process as opposed to waterless printing. As a Trueflownet workflow component, it can be driven by a Trueflow front end or any RIP capable of generating a 1-bit TIFF. The press currently is only offered by Screen (USA).

In the all-digital press arena, the biggest business moves included NexPress Solutions and the renamed Kodak Versamark (formerly Scitex Digital Printing) becoming fully part of Kodak’s Graphic Communications Group.

Initially, Heidelberg retained a limited tie to NexPress in that the final value of the deal was impacted by the NexPress sales. Toward the end of 2004, KPG was signed on as a reseller of the NexPress 2100 digital color printing system (as well as the Digimaster monochrome product family).

Change in Ownership

The latest twist has Kodak set to become sole owner of KPG through redemption of Sun Chemical’s 50 percent interest in the joint venture. Kodak has said it initially plans to operate KPG as wholly owned subsidiary .

NexPress and KPG previously indicated they were already exploring integrating the NexPress 2100 press into the KPG DirectWorks workflow system. The print engine has been enhanced with a fifth imaging unit that enables application of a clear dry ink coating or use of a fifth color as part of an “intelligent color solution” that is said to achieve an 80 percent richer color gamut. The latter contributed to the NexPress 2100 being named a Pantone-licensed device.

In its announcement of the acquisition and creation of Kodak Versamark, Eastman Kodak noted that it had patents on ink-jet printing technology that it saw opportunities to exploit through this new entity going forward. For now, the latest V-series system is the Kodak Versamark VX5000e continuous ink-jet press. It is said to produce a print resolution comparable to 1,200 drops per inch and runs at speeds up to 325 fpm for throughput of more than 1,400 impressions per minute.

Kodak Versamark sells its own printing systems, but it did team up with EFI to jointly develop the new CS600 controller for the VX5000e. EFI also promotes its OneFlow workflow software as a solution for digital and CTP-based printing environments.

Xerox Corp. continues to develop a network of interconnecting business and technology relationships.

Early in 2004, it expanded existing relationships with Creo and Enovation Graphic Systems with agreements that authorize each to resell entry-level and mid-range Xerox production color printing systems on a national basis. These agreements were extended to include the DocuColor 8000 (2,400 dpi, 80 ppm, 12.6x19.2˝ sheet) with its introduction in the fall, but iGen3 sales are still handled as referrals to Xerox with assistance from the Creo and Enovation organizations. Xerox provides service after all sales.

Through its Spire color server product line, Creo has had a long-standing digital printing relationship with Xerox. Both now can sell packages that bundle a color print engine with that server.

Creo has leveraged this relationship to enable integration of offset and digital printing workflows by interfacing its Prinergy and Brisque prepress workflow systems with the Spire server. This past year, Creo introduced the Prinergy Digital Print Interface with support for Xerox’s FreeFlow software suite and DocuSP color controller.

Enovation has an agreement with EFI that enables it to offer the Fiery print server lineup, as well as the EFI OneFlow solution for digital and offset workflows.

For its part, Xerox is in a position to offer systems that bundle any of these front ends—DocuSP, Spire or Fiery. The company says it considers the customer’s existing workflow and infrastructure to help determine which option is the best fit.

Front end Choices

“Since we manage all three front ends to the same rigid performance and quality specifications, and their feature sets are essentially 95 percent common, using (the existing) workflow to help position a specific front end with a customer works extremely well,” explains Xerox’s Fred DeBolt, vice president, color line of business. Xerox assumes responsibility for service and support after the sale for all three front ends.

Acquisitions, as opposed to partnerships, have been the story at Hewlett-Packard Co., even if the Indigo deal did get overshadowed. It touts the HP Indigo Press 5000 as the “first of a new series of commercial presses co-developed by HP and the former Indigo organization.” Outputting 4,000 pages per hour with seven-color capability, the press boasts innovations in paper handling, inking systems and production software tools. It is driven by the new HP Press Production Manager front end.

For a time, ABDick did offer a version of the Indigo EPrint under an OEM agreement. Now that the company’s assets have been acquired by Presstek and given that ABDick also has a long-standing relationship with Ryobi, a future DI press offering would hardly come as a surprise (if the existing business agreements permit such a move). Currently, ABDick offers the CXP 3000 direct-to-print system that is based on a Konica Minolta print engine and is driven by the S300 Fiery RIP at a maximum 50 ppm rated speed.

Konica Minolta offers its own version of the print engine, the CF5001 digital imaging system. It features additional finishing options for on-demand printing, including bookletmaking and tri-folding for direct mail flyers.

Another company on the list of acquired digital print vendors is Xeikon International, which was taken over by Punch International N.V. The company has since essentially gone through a rebirth, most notably with the introduction of the Xeikon 5000 digital web press that is said to be a new design from the ground up. It prints at speeds up to 130 ppm with a 20˝ maximum media width, and is driven by the new X-800 digital front end.

Digital Partnership

Xeikon recently entered into a business partnership with Stora Enso, albeit on a very limited basis. The companies formed a joint venture, Stora Enso Digital Solutions, to conduct sales, service and development of the Stora Enso DBS production line (powered by Xeikon) for on-demand CD and DVD packaging production from paperboard.

The bulk of the announcements from Canon Inc. in 2004 pertained to its black-and-white business. It did announce an agreement with KPG that allows the latter to resell current Canon branded CLC color systems and accessories in the United States. The companies also will continue to offer the KPG Matchprint Professional Server bundled with the CLC 1100 as an integrated proofing and short-run printing solution.

Two purely product-related developments also are worth noting.

RISO Inc. may be pioneering a new production color product category with the introduction of its HC5000 ForceJet ink-jet printing system. The low-cost device is the size of a mid-range copier/printer, but uses a Piezo ink-jet system to print up to 105 color ppm and supports a 13.3x17.3˝ maximum sheet size. The company bills it as producing “communication color” quality at a 600- or 900-dpi resolution.

Océ continues to develop its VarioStream 9000 webfed printing platform toward the goal of supporting full process color, and potentially even five-color printing. The line currently tops out at the VarioStream 9220, a two-over-two highlight color printing system that prints 353 images per minute with a 19˝ maximum width.