High Volume Digital Print Production and Workflow Automation

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1 High Volume Digital Print Production and Workflow Automation Market update Several market developments are having an impact on the current economic climate for printers. The recent economic decline has made it more important to look at developments in the market for communications and, in the case of Durst in particular, at the market for wide format print applications. Let s have a closer look at what s happening in this market segment and the potential implications for the differences between applications made using screen printing and those using high volume digital printing. Market developments Recent developments point to changes in the market. For instance, 80% of brand owners reduced their advertising budget (Source: POPAI, 2009), which could be the reason for the almost 20% decline in business in wide format print production. During the same period spending on broadcast and commercial print declined by 13% - 26% and spending on events and sponsoring dropped by 35% - 51%, depending on the country and/or the company. Less advertising space is booked for specific campaigns. However, there are also positive changes. For instance, spending on short run in store advertising is expected to rise by 24% (Source: POPAI, 2009). Although this is a positive trend, there are some negative effects and long term planning is becoming more difficult. Brand owners need shorter run lengths and shorter lead times as a result of more volatile demand that can no longer be forecasted accurately. Critical success factors Whereas the quality of promotional products never has to be an issue, products for in store POP advertising require the highest possible image quality. The challenge for printing machine manufacturers is to look also at the cost of the products to be made, particularly the low fixed costs arising from the lower overall print volume that has to be reached under the given circumstances. So the cost of actual short run printing in high quality will be crucial, as will be the turnaround speed. If swift reaction is needed due to unpredictable customer demand and short delivery times are requested, especially for in store advertising, the manufacturer has to create a printing system that accommodates all these needs. page 1

figure 01: Most Important Customer Demand Source: The World Wide Survey, March 2009.

2 figure 01: Most Important Customer Demand Source: The World Wide Survey, March InfoTrends Screen compared to digital UV Valuable comparisons can still be made in this field between conventional screen printing and digital wide format production printing, but the end result is different from the situation ten years ago. Compared to screen printing, digital wide format UV inkjet productivity has increased in a straight line in terms of volumes and run length, between 2000 and Moreover, as expected the inflection point between conventional and digital has changed. The reason being that conventional screen printing methods have not changed much, whereas digital production printing is developing almost year by year. The average run lengths per job printed with UV-inkjet increased from 100 in 2000 till 1600 in page 2

figure 02: Wide Format UV-Inkjet Productivity

printed with UV-inkjet 1800 1600 Number of

2000 2002 2004 2006 2008 2010 figure 03: Wide

3 figure 02: Wide Format UV-Inkjet Productivity and Run Length Digital Trend in run lengths printed with UV-inkjet Number of sheets per job figure 03: Wide Format UV-Inkjet Productivity and Run Length Digital page 3

4 Key factors However, this not only concerns the trend in the number of sheets per job printed with UV inkjet, it also relates to the larger volume that can be produced with shorter run lengths in a given period. In store promotion needs products in lower numbers (sometimes even personalized), in shorter run lengths and with shorter turnarounds - but still in top quality. Retailers and consumer brands require a faster turnaround because their customers demand faster time to market in order to gain more benefit from the shorter life cycles of their products. Looking at the turnaround time in job days in digital printing over the last ten years, we see that it has gone from weeks to days, to even hours, during this period. Turnaround Speed required by Retailers and Consumer Brands Turnaround Time in days figure 04: Turnaround Requirement page 4

Business growth opportunities As a result of analyzing these market developments digital short run printing is growing at a natural rate and new growth opportunities are presenting themselves in long

The break-even point will shift to longer run lengths, in favour of digital wide format printing.

and shipping. Job changes have to be highly efficient.

5 Business growth opportunities As a result of analyzing these market developments digital short run printing is growing at a natural rate and new growth opportunities are presenting themselves in long run digital printing. Screen printing will increasingly be replaced by digital wide format high speed and high production printing. The break-even point will shift to longer run lengths, in favour of digital wide format printing. Key success factors for long run digital printing include efficiency in the entire production workflow, starting with proficient media handling from stock to fast printing, to costeffective finishing and shipping. Job changes have to be highly efficient. High volumes combined with shorter run lengths are only achievable when jobs come and go very quickly in a highly automated environment, involving data management (variable data printing, job control and tracking) and printer automation (printing queues, media handling, unattended printing capability). It is obvious that wide format print production companies will benefit from having printing systems in place that can handle these criteria, including versatility and flexibility in long run printing and achieving a customer required quality level at production speeds. Enabling factors for productivity A printing system that is able to fulfil all these needs has to be state of the art in terms of print head technology, number of nozzles, firing frequency, reliable jetting, manufacturing design and print arrays. It benefits from precise engineering and manufacturing, media handling automation, inventive ink technology, drying properties for high speed printing, data handling, RIP capacity and data transfer to the print head. figure 05: Rho 1000 front page 5

6 Rho 1000 The Rho 1000 is a continuous inkjet production system designed to integrate into your manufacturing process, as described above. It has exceptional productivity due to continuous board printing and it can print up to 200 sheets/hr (4 x 8 ft / 250 x 125 cm), or 600 m 2 /hr. In POP 6c quality it produces 90+ sheets/hr (4 x 8 ft / 250 cm x 125 cm) or >300 m 2 /h. The media handling system features an automatic loading table, a Rho 1000 vacuum belt transportation system and an automatic unloading table. A screen printing feeder/stacker can be integrated to interface with an existing screen printing production line. Media handling modes include full automation, three quarter automation, manual feed and a rollto-roll system. figure 06: Rho 1000 back page 6

7 Advantages The advantages of this continuous inkjet production system comprise a short set-up time, automated continuous printing of boards and sheets, maximum material flexibility (heavy boards, sheets, roll-to-roll printing), maximum sheet size flexibility (250 cm x any length), fast media changes to enable the printing of a complete campaign using different media in one operation. Existing loading and unloading devices can also be connected to the Rho Short set-up time Automated continuous printing of boards and sheets Highest material flexibility (heavy boards, sheets, roll-to-roll printing) Highest flexibility of sheet sizes (250cm x any length) Fast media change enables the printing of a whole campaign using different media in on operation Existing loading and unloading devices can be connected to the Rho 1000 Actual case study - Screen printing versus Rho 1000 UV inkjet printing The requirement is to produce an image of 5900 x 2270 mm (232 x 89 ), divided into five 1180 mm (46.5 ) panels on PVC sheets, with a total of 375 sheets / 5022 m 2 54,056 sq ft (300 for sale m 2 43,250 sq ft). The printing machines used in the comparison are the Thieme 4 colour screen printing line and the Durst Rho figure 07: Example of a print-job page 7

8 Screen printing workflow In the screen printing environment prepress is followed by the preparation of the screen, machine set-up and printing. A 26 MB PDF print ready file is delivered by the customer, loaded onto a Macintosh G5 with an ISO coated colour space and divided into 5 rows with CS3 Indesign. A PostScript file is created for a Harlequin Rip, the file is being RIPped and viewed on the monitor providing a soft proof. After accordance, the file is loaded onto the screen imaging machine. There is no ICC output colour management involved. Prepress Screen preparation Machine set-up setup Printing figure 08: Screen printing workflow Screen preparation requires 20 screens for the job, with a single screen taking 1 hr 20 mins to be produced. Then the fabric has to be stretched onto the frame. A screen wash unit and drying are needed (emulsifying and imaging washing out emulsion and masking). Then the screen machine itself has to be adjusted, including alignment of the frames for all colours, unloading old and loading new screens. It takes about 5 minutes to change 4 frames, i.e. 55 minutes to get the 4 frames aligned. Tuning the colours to match a fogra proof requires 30 minutes to achieve the required colours. The machine set-up will take another 10 minutes, to discuss colour and eventually print another proof. page 8

Prepress Screen preparation Machine setup Printing Machine adjustment unloading old/loading new screens Aligning the

- machine setup Printing follows, 375 sheets are printed in 1 hr 25 mins.

all colours. Unloading old and loading new screens requires 5 minutes to change 4 frames, i.e. 55 minutes to get the 4 frames aligned.

9 Prepress Screen preparation Machine setup Printing Machine adjustment unloading old/loading new screens Aligning the frames for all colours 5 minutes to change 4 frames 55 minutes to get the 4 frames aligned figure 09: Screen printing - machine setup Printing follows, 375 sheets are printed in 1 hr 25 mins. Then another machine set-up is needed for the second panel and machine adjustment for the alignment of the frames for all colours. Unloading old and loading new screens requires 5 minutes to change 4 frames, i.e. 55 minutes to get the 4 frames aligned. Other problems may occur, for instance, when the colours don t match and have to be adjusted by modifying the linear speed and squeegee pressure. page 9

With a set-up time of 1 hr 40 mins for the 1 st panel, 1 hr 15 mins for the 2 nd panel, 1 hr 35 mins for the 3 rd

10 Prepress Screen preparation Machine setup Printing Problem: colours do not match Colour has to be adjusted by modifying linear speed and squeegee pressure é~åéä=çåé= é~åéä=íïç= figure 10: Screen printing - colours do not match With a set-up time of 1 hr 40 mins for the 1 st panel, 1 hr 15 mins for the 2 nd panel, 1 hr 35 mins for the 3 rd panel, 1 hr 40 mins for the 4 th panel and 1 hr 50 mins for the 5 th panel the total machine set-up time amounted to 8 hours. page 10

overall production time was 16 hrs 47 mins.

11 Prepress Screen preparation Machine setup Printing S 1st panel: 2nd panel: 3rd panel: 4th panel: 5th panel: Total machine setup: 8 hours figure 11: Screen printing - machine setup for panels The overall production time was 16 hrs 47 mins. Prepress Screen preparation Machine set-up setup Printing Production time Product efficiency is only 38% figure 12: Screen printing - production efficiency page 11

12 Rho 1000 workflow Prepress including ICC optimized proof Rho setup Printing POP quality 300 sqm/h figure 13: Rho 1000 printing workflow In this case the overall production process appears to be much easier. Prepress includes an ICC optimized proof, while the Rho set-up has a printing POP quality of 300 m 2 /hr. 300 sheets (4018 m 2 in total) require hrs. The set-up for the Rho itself is 0.25 hrs and 0.33 hrs. The total production time for 300 sheets is 15.3 hrs!! Prepress including ICC optimized proof Rho setup Printing POP quality 300 sqm/h 0,33 h 0,25 h 14,75 hrs for 300 sheets (4018 sqm) Total Production time: 15,3 hrs for 300 sheets Production efficiency is 96% figure 14: Rho Production Efficiency page 12

13 Conclusions In terms of production time the Rho 1000 is faster than the screen printing machine. Time Comparison Rho 1000 Screen Printing Difference Process Time Man hours Process Time Man hours Process Time Man hours Prepress 0,33 0,33 1,00 1,00 0,67 0,67 Screen Preparation - - 8,00 32,00 8,00 32,00 Machine Setup 0,25 0,25 8,00 16,00 7,75 15,75 Printing 14,75 14,75 6,47 12,94-8,28-1,81 Total Time 15,33 15,33 23,47 61,94 8,14 46,61 figure 15: Time Comparison Rho 1000 vs. Screen Printing In terms of cost, including prepress and screen preparation, machine set-up and machine cost incl. operators, ink and printing cost, printing on the Rho is less expensive. Prepress including ICC optimized proof Rho setup Printing POP quality 300 sqm/h figure 16: Cost Comparison Rho 1000 vs Screen Printing page 13

14 Summary of Critical success factors Finally, we are able to draw some conclusions comparing the Product quality and The critical success factors of both printing methods. Product quality In terms of product quality, the Rho 1000 is provided with standardised colour management with ICC profiles. Moreover, a Proof can be printed of all the panels immediately after the prepress (ripping) process and before the production run. Colour consistency is achieved via electronically repeated dot setting. With Screen Printing on the contrary, Colour matching has to be based on trial and error (40 minutes for colour matching and proof for a single panel). Proofs can be printed panel by panel only. Full image can only be proofed after printing the last panel. There s an ongoing colour adjustment required via linear speed and squeegee pressure settings. Two factors determine the critical success: Product cost and turnaround speed Product cost and turnaround speed With the Rho 1000, there s a high share of variable cost (48% of total cost for the job), that enables rapid adjustment to volatile demand. There s also a better cost transparency and contribution margin calculation facilitates that will improve customer specific pricing. Last but not least there s a high production efficiency (96%) maximising flexibility and swift reaction to customer demands. Compared to that advantages, with Screen Printing it will be difficult to adapt to rapidly changing demands with 80% fixed cost, which consists of machine and labour cost process steps. Moreover, because of the high share of fixed costs, optimum utilisation of capacity is vital for the survival of the company, in a poor economic climate with unpredictable demand. created by Durst Phototechnik Digital Technology GmbH page 14

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