WAN-IFRA India Industrial Digital Finishing Solutions and Digital/Offset Hybrid Concepts. Alwin Stadler VP Digital Printing

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Deborah Hines
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1 Industrial Digital Finishing Solutions and Digital/Offset Hybrid Concepts Alwin Stadler VP Digital Printing

2 Finishing Solutions & Production Possibilities FoldLine FormerLine Flyer and Mailing Auxilary glued book-blocks Signatures for books and commercial Glued booklets/ inserts Inline Cylinder stitched booklets Broadsheet and Tabloid Newspapers 2

3 We are the integration partner for digital production systems in the graphic arts industry Workflow and finishing solutions for: HP Kodak Canon/Océ 3

4 FoldLine for Newspaper Production

personalization level High flexibility and maximized use for your digital line

5 Industrial digital finishing line FoldLine benefits at a glance Simply more finishing! Industrial performance Highest automation level for outstanding uptime and highest personalization level High flexibility and maximized use for your digital line Processing of all newspaper formats, book, brochures, commercial jobs with one finishing line 5

Infinite Product Flexibility A single finishing solution for the full range of your product portfolio Variable cut-off : 420 mm 800 mm Wide web width range : up to 42 Micro-zoning and personalization

6 Infinite Product Flexibility A single finishing solution for the full range of your product portfolio Variable cut-off : 420 mm 800 mm Wide web width range : up to 42 Micro-zoning and personalization features: Function DynaPage Function DynaSection Wide range of additional equipment available for more possibilities : Gluing, stitching, stacking, collating and much more Broadsheet and tabloid newspapers Cylinder stitched booklets Signatures for books and commercial Glued booklets/ inserts 6

Highest Productivity Industrial design for highest reliability and

operation Wide web for multi-use and maximized output: Maximum

Newspapers/h (32 pages Berliner) 16,000 copies/h (32 pages A4

7 Highest Productivity Industrial design for highest reliability and speed in digital finishing Speed: 300 m/min or 5 m/s in continuous operation Wide web for multi-use and maximized output: Maximum productivity with 42 web width ability Output per product 7,000 Newspapers/h (32 pages Berliner) 16,000 copies/h (32 pages A4 stitched boklets) 32,000 copies/h (16 pages A4) 2,600 book-blocks/h 150x210 à 280 pages 7

8 speed speed speed Fastest Make-Ready Highest Automation Level in Digital Finishing One Touch: job pre-setting from 0 to 3 min. maximum Precise positioning of all finishing components with optimized parameters set, for minimal start-up waste Perfect web control and response time of control loops Synchronization of new cut-off within 5 copies Automated calculation of optimum production parameters set enabling the pre-setting of new production within 3 min. Job Validation: don t print a job if it can t be processed in finishing DynaChange: automated job sequences Don t stop the line Change job on the fly Reduce line speed Set-up on the fly Speed-up again Stop the line Set-up: max 3 min Restart automatically Fully Automated Job Change Sequences Job 1 Job 2 Job 3 Job 1 Job 2 Job 3 Job 1 Job 2 Job 3 time time time 8

9 Intelligent Automation and Workflow Solutions Level I Smart Integration of printer and further post-press equipment: - JDF/XML-based open architecture - Enabling automatical pre-setting and control of the entire line Embedded Intelligence: - Calculation of optimized parameters set for a specific format or product - Automated DynaChange job sequences Tracking Standard - Counting with additional sensors and reprint within job functionality Customized Customized Customized Tracking and Reprint Solutions: - Enhanced solutions by manroland web systems and Böwe Systec DigiLink: - Production scheduling for mixed environment offset/digital - Intelligent job scheduling based on customer-specific strategies 9

10 Hybrid Solutions Offset+Digital

11 Technical Possibilities 1. Integrated narrow inkjet heads (mono and full color) 2. Inserting of digital printed sections 3. Producing inkjet-printed reels in the offset press 4. Hybrid newspaper press Digital + Offset 11

1. Integrated Inkjet Applications Alphanumeric codes for online Day-Pass Barcodes for Augmented Reality Imprint of logistic codes Lottery, Bingo, etc.

12 1. Integrated Inkjet Applications Alphanumeric codes for online Day-Pass Barcodes for Augmented Reality Imprint of logistic codes Lottery, Bingo, etc. Advantages High speed up to 15 m/s Flexible position of the inkjet imprint Disadvantages Retrofit depending on available space Limited width of the digitally imprinted image Retrofit of digital equipment to any installed press Springer Solution 12

2. Inserting of digital printed sections

13 2. Inserting of digital printed sections Newspaper Offset Digital Printer with FoldLine inserting Applications Advertising for smaller target groups Inserted local edition sections Advantages Independent press speed Flexible production time Disadvantages Time delay, pre-production required No single product together with offset 13

3. Unwind inkjet pre-printed reels in the offset press Application Advertising for small target groups Advantages Inline production of the digital printed reels

14 3. Unwind inkjet pre-printed reels in the offset press Application Advertising for small target groups Advantages Inline production of the digital printed reels Flexible production times Enable better utilization of the digital asset Disadvantages Time delay, preproduction required Register deviation can cause quality issues 14

4. Hybrid press: Digital print engine and existing offset press

Advantages Inline production with short deadlines No change-over

existing printing equipment Disadvantages Retrofit depending on

15 4. Hybrid press: Digital print engine and existing offset press Reel supply from the offset press Reelstands in ground floor Advantages Inline production with short deadlines No change-over time for edition change Less plates, less waste Use of the existing printing equipment Disadvantages Retrofit depending on available space Digital system limits the maximum speed of the offset press 15

16 Productivity: Digital print engine and existing offset press Scenario: Daily newspaper with change of 8 pages digital, collect production, 15 editions, compared with 2-tower production with 45,000 copies/h offset Total possible copies / shift Break-even appr. 5,000 copies / edition Offset productivity Hybrid productivity Copies total per job 16

17 4. Hybrid press: Digital print engine and new offset press Advantages Inline production No change-over time for edition change Offset press can be optimally configured for the digital system (speed) Less plates, less waste Disadvantages New offset equipment required higher investment 17

4. Hybrid press: Production Possibilities Digital

Product B2 Product A: Hybrid production Daily

digital production with variable formats Product

18 4. Hybrid press: Production Possibilities Digital part Offset part Product A Product A Product B1 Product B2 Product A: Hybrid production Daily newspaper with multiple editions Product B1: Daily digital production with variable formats Product B2: Classic newspaper production (or preproduction for inserting) 18

19 Productivity: Digital print engine and new offset press Scenario: Daily newspaper with change of 4 pages digital, straight production, 15 editions, compared with 2-tower production with 45,000 copies/h Total possible copies / shift With the same basic speed hybrid is faster because of no edition change Offset productivity Hybrid productivity Copies total per job 19

20 Cost per copy The productive range for the Hybrid model is in between of 150 to 5,000 copies. Cost per copy 0,60 0,50 0,40 0,30 0,20 Offset copy Hybrid copy Digital copy 0,10 0,00 Copies total 20

21 ROI ROI for the digital investment on a hybrid press: Daily newspaper production: With copy count less than 5,000 copies per edition Save of 0.01 EUR / copy, 200,000 copies per day, 300 days p.a. ROI for the investment of 3 Mill. EUR within 5 years Additional production in the day shift (digital) can improve the ROI dramatically! 21

Concepta Web Offset Press. Efficiency and Flexibility for the Most Demanding Requirements

Concepta Web Offset Press. Efficiency and Flexibility for the Most Demanding Requirements Concepta Web Offset Press Efficiency and Flexibility for the Most Demanding Requirements Concepta Fast Make-Ready Process with Minimal Waste The trend from long toward medium to short runs is noticeable.