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October 8, 2002 Gravure Trends Rudy Wiesemann, GAA 1

Graph Expo 2002

Gravure TrendsGravure TrendsRudy Wiesemann

Technical Specialist

Gravure Association of America

Tuesday, October 8

Graph Expo 2002

9:45 a.m. -11:30 a.m.


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Gravure TrendsGravure TrendsPast: Gravure History

Present: Gravure Today

Future: The Choice


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Gravure TrendsGravure TrendsPast: The Legend

Present: The Myth

Future: The Choice


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High Quality

High Consistency

High Resolution

Brilliant Colors

Any Substrate


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Present: The Myth

Future: The Choice


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Gravure TrendsGravure TrendsPast: The Legend becomes Myth

High Quality = High Cost

High Consistency = Long Run

High Resolution = ExpensiveProducts, Long Lead Times

Brilliant Colors = High Cost

Any Substrate = Most Difficult


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Gravure TrendsGravure TrendsPresent: The Myth

The myth that gravure is only forlong runs is dead.

Short-run gravure is here!


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Gravure printers are profiting andprint buyers are gaining theadvantages of gravure in run

lengths previously only thoughtpossible with other print processes.


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Packaging gravure runs of 3,000 to5,000, and 100,000 to 300,000

done routinely.


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Present: The Myth

Future: The Choice


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Gravure TrendsGravure TrendsFuture: The Choice

Gravure becomes the process ofchoice.

Recent advances lower costs,

allow short runs,

short response times,

Quality advantages are retained orenhanced.


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Present: The Myth

Future: The Choice


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Future: The Choice


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What is Gravure, and how is it different than

Flexography and Lithography?


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Substrate

Impression Roller

From the BASIC GRAVURE training course, Copyright 2000, GAA


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From the BASIC GRAVURE training course, Copyright 2000, GAA

Gravure


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Lithography


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Flexography


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Future: The Choice


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Gravure TrendsGravure TrendsPresent: Gravure Today

� Technologies that enable gravure short runs

� Issues and options for organizing short runs

� The roles of automation and lasers

� Fingerprinting and quality issues


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Europe


Graph Expo 2002Belgian Market

• 10,000,000 people• 60% Dutch speaking• 40% French speaking

• Belgian magazines• 1st largest run : 460,000 copies weekly• 2st 400,000• 3st 280,000• 4st 180,000


Graph Expo 2002Cylinder Preparation

• 27 Workers• 9,568 Cylinders Engraved• 73,974 Pages• 1.1% Rejection Rate


Graph Expo 2002Gravure

3 HK 202 built in 1984 upgraded to 4 HK 406

(one scanner bedplate having been transformed into engraving unit)

Each one equipped with8 heliosprint headsautomatic test cutautomate head positioning

Filmless engraving : GIPSY NTIRIS proof


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Graph Expo 2002Lead Time

On September 11th, 2001Latest data from repro

received at 22:50 (local time) 16:50 (east coast time)

first «�good quality�» signatureout of the press at 04:15


Graph Expo 2002Electroplating

• 2 x Copper bath• 3 x Degreasing bath• 2 x Finishmaster• 1 x Duostar• 1 x Superpolishmaster• 1 x De-chroming bath• 2 x Chrome plating• 1 x Fully automatic cylinder handling and transportation


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• Cylinder cost• Salaries 1,000,000 US $• Maintenance 200,000• Depreciation 10% 400,000• Financial charges 100,000

– Total fixed costs 1,700,000 US $ / year– Material cost 60 US $ / cylinder

• For a yearly production of:– 5,000 cylinders : 60 + 1,700,000 = 400 US $ / cylinder

5,000– 10,000 cylinders : 60 + 1,700,000 = 230 US $ / cylinder

10,000

� Investment� Gravure upgrade 3,000,000 US$� Galvano upgrade 1,000,000 US$


Graph Expo 2002Our Equipment : Press Room• One 2.45 meters KBA press

• 8 groups• 8 ribbons• Single folders built in 1990

• One 2.45 meters Cerutti press• 8 groups• 8 ribbons• Double width folder built in 1995

• One 2.45 meters Cerutti press• 8 groups• 12 ribbons• 2 separate folder built in 2000


Graph Expo 2002Press

• Average makeready time : 1h 48 minutes

• Average makeready waste :3,298 cylinders revolutions


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Cylinders

are expensive


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Cylinders

are expensive

Cylinders are

devoted to long runs


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Cylinders

are expensive

Cylinders are


Demand forcylinders remains

low


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Cylinders

are expensive

Cylinders are



low

Cylinderpreparation

department is notfully loaded


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Cylinders

are expensive

Cylinders are



low

Cylinderpreparation

department is notfully loaded

90% of cylinderpreparation costsare fixed costs


Graph Expo 2002Improve theCylinder quality



Cancel theproof press



Lower cylinderproduction costs





Increase thedemand





Increase thedemand

Increase thecylinder

production Cancel theproof press




Increase thedemand

Increase thecylinder

production Cancel theproof press80 to 90% of

cylinder costs arefixed costs


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Europe


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• Faster Delivery

• Less system costs

• Shipped via FedEx for overnight delivery

• Safer


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• Covering differs depending on the application

• Precision-ground finish

• Minimum surface tolerances

• Variable surface finishes

• Solvent resistant


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Present technology withit’s COSTS & EXCESSIVE BAGGAGE


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Press cylinder carts are removed from the press.


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The cylinder with drive gears The cylinder with drive gears are removed from the pressare removed from the presscylinder cart and mounted cylinder cart and mounted on the mandrel mounting cart.on the mandrel mounting cart.


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The sleeve is removed fromThe sleeve is removed fromthe mandrel, and can then bethe mandrel, and can then bescrapped if damaged or if not scrapped if damaged or if not needed in the future.needed in the future.


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Or restocked for later use.Or restocked for later use.


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Air WaveAir Wave™™ sleeves can then sleeves can thenbe picked up from the existingbe picked up from the existinginventory for remounting ontoinventory for remounting ontothe mandrels.the mandrels.


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Or ! The The sleeve can be can bereceived the day that it is scheduledreceived the day that it is scheduledto go onto press via FedEx or any ofto go onto press via FedEx or any ofthe other overnight carriers.the other overnight carriers.


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After mounting the cylinderAfter mounting the cylinderis then returned to the pressis then returned to the presscylinder cart.cylinder cart.


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The cylinder press carts The cylinder press carts are then reinstalled into are then reinstalled into the press ready to run.the press ready to run.


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Air WaveAir Wave™™ is a system allowing engravings to be is a system allowing engravings to beremoved and replaced at press-side onremoved and replaced at press-side on

conventional press cylinders that have beenconventional press cylinders that have beenmodified to accept these engravings, ormodified to accept these engravings, or

FiberlyteFiberlyte™™ mandrels designed for this system. mandrels designed for this system.


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The Air WaveThe Air Wave™™ sleeve, which is only 0.011 of an sleeve, which is only 0.011 of aninch in thickness, is placed on the end of theinch in thickness, is placed on the end of the

FiberlyteFiberlyte™™ cylinder. Once in position the air is cylinder. Once in position the air is connected to the cylinder.connected to the cylinder.


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Within 10 seconds, the sleeve is ready to beWithin 10 seconds, the sleeve is ready to bepositioned.positioned.


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Your Air WaveYour Air Wave™™ sleeves are easily shipped sleeves are easily shippedanywhere in the World within 24 hours.anywhere in the World within 24 hours.


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Transfertexand the way to very short runs


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1991 Changeover from conventional to mathematical colormatching- conventional: colormatching by recipe- mathematical: colormatching by computer

1992 Changeover from a can storage system to a container storage system (70 % from our stock)1993 Startup with teamwork

- two printmachines work together1994 Changeover from conventional washup to a more economical way on our old printmachines

- conventional: wash-up by hand with brushes and sponges by each colorway and cylinder change

- economical: machine speed to max. for two minutes and flushing with clean solvent on 80 % of our runs1996 First Schiavi machine with automatical wash-up

- in cooperation with Schiavi1997 Automatical cylinder change on our own account


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Design changeover times

49

46,8

44,4

40,8

35,636,8

32,2

2523,4

2119,7

18,3

13,3

0

10

20

30

40

50

60

1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Schiavitoday

Teamwork automatical cylinder change Schiavi

machine


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Colorit changeover times

19,3

20,1 20,1

16,5

12 11,8

8,8 8,8 98,3

7,67,1

6,4

0

5

10

15

20

25

1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Schiavi today

Teamwork

automatical wash-up Schiavi machine

wash-up improvents


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Color matching times

16,2

11,6

10

11,911,3

12,2

10,7

7

4,8 4,43,8

3,3

0

5

10

15

20

1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002

color matching by computer

pigment change=> new color library

finishing new color library


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Future: The Choice


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Gravure TrendsGravure TrendsFuture :The Choice

�What technologies will change gravure in the 21st century?

�Technologies that will impact prepress

�Press technologies that will change gravure

�Automation—how far can it go?

�Operational issues that will affect gravure operations

�Growing job market vs. stagnant labor pool


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Reducing down time

Reducing run length

Increasing Productivity and Profit

All require Increased and Improved

Formal Training


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Go to www.gaa.org


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Who Should I Attend?Gravure is a robust process that has been subject to more than its shareof "folklore" solutions. The new challenges of the process and customer

demands make it essential to formalize this approach. The Basic Seminaris designed to separate the "myth and legends" from the theory and bestpractices. Primarily designed to teach a solid foundation to those new to

the process, the seminar also fills knowledge gaps of experiencedpractitioners who have not yet had an opportunity to be formally trained in

the practice of gravure.


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Courses: Basic GravureFingerprinting

Conferences: Fall TechPressroom

On Site Services: Plant and Operations AuditsProcess Application Development

¨ Production Trouble Shooting¨ Seminars and Customized Training

Training Tools: PackSim Press SimulatorGravure TextbookManuals and reference material

The GAA is there to help!

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