DRUPA 04 REPORT Sheetfed & Web Offset Printing -- No Rain on P

By Mark Michelson

Editor-in-Chief

The rain may have made it a bit more difficult for visitors to maneuver between the 17 halls during the first week of the 14-day Drupa 2004 trade exhibition in Düsseldorf, Germany, last month, but that surely didn't dampen the spirits of the reported 394,000-plus attendees. Nor did it keep the 1,862 equipment, software and consumables exhibitors representing 52 nations from showcasing their latest R&D and product development efforts.

And while there may not have been any one "blockbuster" piece of equipment or technology that everyone at the show was buzzing about, there surely was an assortment of new product introductions—many that became commercially available at Drupa—as well as some future technology demonstrations that, in part, have become a hallmark of the Drupa tradition.

Whereas Drupa 1995 was called the "CTP Drupa," and Drupa 2000 the "Digital Drupa," this Drupa was hyped as the "JDF Drupa." Fittingly, most press manufacturer exhibits tried to illustrate the benefits of how JDF will enable true computer-integrated manufacturing throughout a printing plant using equipment from various manufacturers.

Perhaps the multi-vendor PrintCity exhibit in Hall 6 served as the best example of JDF being employed to complete entire jobs within a "Digital Smart Factory" of the future. As the press supplier for PrintCity, MAN Roland operated a selection of sheetfed presses in seven configurations, each corresponding to a different printing segment. A six-unit Rotoman 16-page heatset web press featured zero makeready imprinting, fully automatic plate loading, the QuickStart system, PECOM and ppi printnet network and control.

Showered With Sheetfeds

For sheetfed printers, MAN Roland highlighted its new EPL automated plate changing with diagonal register adjustment for the Roland 200; automated form changeover for the coating module on the Roland 500; higher speeds (16,000 sph) and quicker changeovers with the new QuickChange system available for the Roland 700; and a large-format, 73˝ Roland 900 XXL with a camera-monitored sheet travel system and MAN's InlineSlitter to produce two separate piles in the delivery.

As a future technology demonstration, a Roland 700 printing unit was shown with the Roland DirectDrive direct plate cylinder drive, which may some day make possible simultaneous plate changes and washup processes.

Also of high interest was the new Roland InlineFoiler Prindor cold foil laminating system equipped on a Roland 700 at the show. The system requires two printing units. In the first unit, the areas of the substrate where foil is to be applied are printed with a special glue by a conventional plate, and foil is then laminated to these areas in the second printing unit.

MAN Roland announced press sales to U.S. customers that included a six-color Roland 706LV sheetfed press with in-line coater and hybrid UV capabilities to Bentley Graphic Communications, Pottstown, PA, as well as two 64-page Lithoman double-web presses to Quad/Graphics (see article on page 5).

Another German press manufacturer, KBA, debuted several new sheetfed press models. Of special interest to U.S. printers was the new 41˝ KBA Rapida 105 equipped with a shaftless feeder with sidelay-free infeed—touted as a world first. Rated at 18,000 sph straight (15,000 sph perfecting), it can print 0.06mm paper to 1.2mm board. With automated plate loading standard, it incorporates a new

Windows-based control console with press preset and remote adjustment of virtually all press functions; ACR video register; and Densitronic Basic/S and ink temperature control for optimum print quality. Optional is the Qualitronic II sheet inspection system.

Waterless Makes Splash

Also attracting attention was the new Rapida 74G waterless offset sheetfed press with coater that generates minimal startup waste—10 sheets or less—and reduces operator skill requirements due to KBA's Gravuflow keyless inking technology. The patented ink duct (blade chamber) with doctoring blade and sealing blade allows a continuous, image-independent, keyless pumping system. Cartridges minimize ink waste and the drop-down chamber allows for easy cleaning with an automatic washup system.

In addition, the largest sheetfed press unit at Drupa was shown by KBA—a unit of the 803⁄4˝ Rapida 205. Capable of speeds of 9,000 sph, features include a shaftless feeder, video register, automatic plate changing, hybrid package and Logotronic Basic or Professional.

Among KBA sheetfed press sales announced at Drupa were a six-color Rapida 105 with coater sold to Mainline Printing, Topeka, KS; a six-color Rapida 105 with coater to Children's International, a non-profit organization based in Kansas City, MO; and a Karat press to Fibre Containers in City of Industry, CA.

For web printers, KBA demonstrated its 16-page Compacta 217 (rated at 70,000 cph) with a new P3 pin folder—all integrated into a JDF workflow. The press illustrated automatic and semi-automatic plate changing, as well as flying imprint changes at maximum production speeds.

JDF/CIP4 data transfer also played a major role in demonstrations at the Komori booth, where the company's DoNet digital network featured JDF integration for eight presses, including the latest 60,000 iph System 38S web press incorporating the new DC38 folder with double chopper.

The complete 16- and 32-page press, including the web fold format, was set via JDF data. A feature on the press includes KHS-AI self-learning software that further reduces job changeover time, costs and workload.

As part of its "Perfecting Your Printroom" theme, Komori operated the new eight-color, 40˝ LS840P four-over-four perfector. It features Komori's unique three-cylinder perfecting mechanism that incorporates air controls plus ceramic jackets on the second four impression cylinders, which assist in mark-free passage of the reversed sheets through to the delivery. Heavy grade stock was being printed at 15,000 sph.

Completely new is the four-color, 29˝ SPICA 429P two-over two-convertible perfector (speed: 13,000 sph), a compact and competitively priced sheetfed press designed for short run, fast turnaround color work. Features include Komorimatic dampening, remote control of plate register and transfer cylinder cocking, plus automatic blanket and ink roller wash. The control panel is located at the delivery and provides touch panel remote operation.

During Drupa, Komori announced the sale of three sheetfed presses to Houston-based Consolidated Graphics, a national industry consolidator. A six-color LS640 with coater and UV capabilities will be installed at Wetzel Brothers in Cudahy, WI; a six-color LS640 with coater at Carqueville in Streamwood, IL; and an eight-color LS840 perfector with coater at AGS Custom Graphics, Cleveland.

The biggest news out of the Heidelberg camp was a joyful announcement by CEO Bernhard Schreier the day before Drupa that RWE—Heidelberg's largest shareholder—had divested its 50 percent stake with institutional investors, increasing Heidelberg's stock market "free float" from 22 percent to 57 percent (will reach 72 percent by 2007, at the latest).

As expected, sheetfed printing played a starring role in Heidelberg's two halls at the exhibition. Drupa served as the worldwide launch of the new 18,000 sph, 41.3˝ Speedmaster XL 105 press designed for label and packaging printers that handle long runs. Increased productivity of 30 percent or more is achieved with such features as its unique Air-Transfer system for contact-free sheet transport; Preset Plus feeder and delivery; Hycolor integrated inking/dampening system; and an innovative coating unit.

Also noteworthy was the Speedmaster CD 74 that is now offered with both a new feeder and a convertible sheet reversing device. This enables high-quality perfecting with short changeover times between paper and board, and between straight and perfecting modes. The press runs at 15,000 sph in either mode.

In addition, a new perfecting coating system was shown on a 10-color Speedmaster SM-102-10P. This solution allows the fifth and 10th printing units to be flexibly used for either printing or dispersion coating. It enables commercial printers using a 10-color press to print either five-over-five color or four-over-four color with a double-sided dispersion coating in a single pass.

Web Whets Appetite

Heidelberg Web Systems operated a fully revamped M-600 printing at 70,000 iph with a Multidrive system, new JDF-compatible control functions and a new JF-70 combination folder. The press also featured an Ecocool dryer with chill rollers. Operators at the show used the Autoplate automatic plate changers and a new Omni make-ready control module.

Also, the new Sunday 3000/32 is said to be the first web offset press with a single circumferential format that offers the benefit of an eight-page-wide cylinder configuration. With a web width of 72.05˝, 32 magazine-format pages can be printed with each revolution.

From a sales standpoint, Clifton, NJ-based Sandy Alexander purchased an eight-color Heidelberg Speedmaster CD 102 and a six-color Speedmaster XL 105, as well as a seven-color M-600 web press for its MGA facility in Florida.

Williamson Printing, in Dallas, signed on for a 12-color Speedmaster SM 102-12-PLX perfector with coater, PC2S and CutStar; a 12-color Speedmaster SM 102-12-PLX perfector with coater and UV interdeck drying; an eight-color Speedmaster XL 105-8-LX2; and a unique eight-color

Speedmaster CD 102-LYY8LYYLX Duo press (equipped with three coaters, four dryers and an extended delivery). Also, Quad/Graphics purchased eight 64-page Sunday 3000/32 double-web presses.

Akiyama introduced its new 40˝ eXtreme one-sided sheetfed press, offered in four, five and six colors, with coating and closed-loop color capabilities. Able to print thin paper to cardboard, the CIP3/4-compliant press runs at 16,000 sph. The sheet transfer mechanism employs a double-diameter impression cylinder and triple-diameter transfer cylinder, ensuring higher productivity. Also, speeds of its existing Jprint perfector line have been increased to 13,000 sph.

Also from Japan, the new B2 size Sakurai 75 SD/SDP range is available in four-, five- and six-color configurations. The SD model range offers double-diameter impression and transfer cylinders in the 7 o'clock position for snatch-free sheet transport after impression.

Standard equipment includes: Sakurai Plate Changing; automatic ink roller wash; remote control running register with cocking from POD; continuous dampening with refrigeration and pH control; presetting of sheet size and impression; high-pile delivery with non-stop change; automatic blanket washing; and an ultrasonic double sheet detector.

In addition to its new Ryobi 3404X-DI press, the xpedx/Import Group promoted the Ryobi 522GX two-color press, the 524GX four-color model with low-pile delivery and the 524GXP four-color convertible perfector with low-pile delivery. New press features include speeds up to 15,000 sph, the PCS-H Printing Control System, pull side guide preset and impression pressure preset systems, optional hickey picker and ultrasonic double sheet detector, and more.

Grafitec displayed its Polly Prestige 74 family of 201⁄2x291⁄8˝, two-, four-, five- and six-color sheetfed presses. The double-sided impression and transfer cylinders with a 7 o'clock cylinder arrangement provide a minimum of transfer points and a smoother sheet flow. Grafitec's Ecomatic dampening system offers control of solution flow to the plate and the ability to run alcohol-free. It allows setting for a minimum amount of water without skewing the rollers.

Mitsubishi Lithographic Presses used Drupa to showcase several prototypes, including its Diamond 16MAX-V shaftless web press featuring a variable cutoff for printing multiple-size products. It employs sleeves to which plates and blankets are attached, and these are inserted over respective plate and blanket cylinder shafts. Replacing sleeves with ones of different diameters changes the print length.

Also shown was the Diamond 3000TP Tandem Perfector sheetfed model, which is now available with double coaters for aqueous coating of both front and reverse sheet sides—all in one pass. It also featured a new plate changer, still in development, with automatic plate cylinder phasing to allow simultaneous plate changes.

Getting in the Zone

Mitsubishi's RPS-X1 Reusable Plate System was shown in the Future Technology Zone. An off-press system, it images reusable aluminum plates in the same fashion as thermal CTP systems, so the plates can be erased and re-imaged up to 20 times. Plate life is said to be 100,000 impressions per imaging. This recycling feature reduces plate consumption by 95 percent.

Also shown in dramatic fashion as a future concept in its Technology Theater was the new Goss flexible printing system, which will allow for different size news-papers—all from one press line. Expected to be available in about two years, inkers slide away from the core unit on tracks for access to the inner cylinders. The totally new press design will feature low-height towers, automated plate changing capabilities and Goss' "Pre-set and Forget' technology.

A variable cutoff web press was also shown by Muller Martini, which debuted its 1,500 fpm Alprinta. Available in 201⁄2˝ and 291⁄8˝ widths, the servo-driven press can be equipped with new size-variable insert modules for special applications such as package printing. They enable quick format changes in repeat lengths ranging from 20˝ to 34˝.

A new option for the inserts is the availability of repeat lengths in millimeter increments, allowing in-line production of product-specific formats without gap cutting.

And Timsons showed a video of its ZMR (Zero Make Ready) option for the Timson T48A book press. The ZMR's twin over-and-under printing units mean that, while one unit prints, the press operator changes plates on the other unit. As soon as the active unit finishes printing the last signature, the second unit—already accelerated and synchronized at web speed—immediately begins printing.

Space limitations precluded Printing Impressions from highlighting all of the new offset printing presses, related auxiliary equipment and pressroom consumables in this article, but more detailed product descriptions do appear in our special "Drupa New Product Showcase" that begins on page 52. And, if you missed making the trip to Germany last month, many of these new introductions will play starring roles at Graph Expo in Chicago this fall.