© 2010 WAN-IFRA

Latest Trends in Press Technology

Production Seminar, New Delhi, January 2010

Master of Science

Moritz SchwarzSenior Consultant

moritz.schwarz@wan-ifra.org

+49 6151 733 761

© 2010 WAN-IFRA, 2

Content

Production trends

Investment planning

Press trends

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Production trends

Shorter print runs

Format:

Smaller page sizes

Flexibility

Separation of Printer and Publisher

Semi-commercial:

Higher value newspaper (magazine)

Profit contribution instead of cost centre

2006

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Investment planning

Often big mistakes are made in the beginning of a project and can not be rectified afterwards

Involve most company departments and external expert(s) at beginning

Issues to clarify:

Product(s) planning

Evaluation of capacity

Cost calculation

Production timing}affected by level of automation

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Investment planning

Cost calculation: part of feasibility study

Check different productionsolutions to calculate final copy price

Method based on IFRA Special Report 3.37

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Influence of automation

Wages

Materials

Other (Energy, Maintenance, …)

Invest Depreciation

Production costs

Automation can reduce costs

Automation can increase capacity(time factor)

Wages

Materials

Other (Energy, Maintenance, …)

Invest Depreciation

Wages

Materials

Other (Energy, Maintenance, …)

Invest DepreciationPlate change

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Press trends

Jumbo

Compact

Automation

Configurations

Extras

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4 pages width/1 around

6 pages/2 around (2,52 m)

Lower production costs:

Less manning

Fewer webs reduce handling efforts

Minimise maintenance

Reduced investment costs (press, building)

Press trends: Jumbo

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48 pages broadsheet space requirement:

Length Height Width Floorspace

2/1 press: 78 m 11 m 5 m 390 m²

4/2 press: 28 m 12 m 6.5 m 182 m²

6/2 press: 21 m 12 m 7.5 m 157 m²

4/2 vs. 6/2: – 9 m ± 0 m + 1 m - 25 m²

2/1 vs. 6/2: - 57 m + 1 m + 1 m - 233 m²

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Manpower requirements example 4/2

2 printer for three towers = 4

1 printer at folder

2 helpers

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Manpower requirements example 6/2

1 printer per two towers = 2

1 printer at folder

1 helper

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Jumbo reel diameters

1000 mm in 1970s

1250 mm in 1990s

1500 mm since 2006

No manual transportation

Advantages:

Fewer web changes

Less work

Lower waste

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Press trends

Jumbo

Compact

Automation

Configurations

Extras

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KBA Cortina,Commander CT

Arch-type units

H-type units

Goss FPS

Compact tower height10

9

8

7

6

4

5

3

2

1

[m]

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Considerations of compact tower design

Low fan-out

Shorter web path

Accessibility

Reduced building costs:

Less building height required

Less climatisation capacity needed

Existing hall: 8/8 tower or dryer might fit

Reduced investment costs

Less heavy metal

Fewer interfaces

Lower installation efforts

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Compact building

UV Dryer

Minimizing building height

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Press trends

Jumbo

Compact

Automation

Configurations

Extras

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General considerations for automation

Easier operation: Fewer staff

Shorter make ready time/higher capacity

Higher investment costs (?)

Consistent high quality

Less waste

Experts required for repairs

Backup

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Automation of press controls

Modern pre-setting:

Ink-keys (RIP data, pre-run)

Speed-up curves according to conditions (temperature, paper, inks, plates)

Nip pressure

Closed loop controls:

Colour register

Web register

Web tension

Density (dampening)

Fan-out

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Cameras

Buzzle wheels / air nozzles

Controlsystem

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Automation of press set-up and supply

Paper supply

Webbing up

Ink supply

Plate supply

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Automation of paper supply

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Delivery preparedfor multiple web widths

Automatic nipping ring spacing

Folding cylindersprepared formultiple web widths

Moveable tabloid trolleys

Motorised former and tabloid slitter position

Automated web width change

Rellstand & in-feed

Units & out-feed

Turner bars

RTF, formers, …

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Automation of plate change

Old topic for commercial printers (1 plate)

Semi automatic plate change for several years

Full automatic plate exchange hot topic in Europe:

Change all or one plates in ~ 3 minutes !

Better colour register

Less staff and less presses required (lower investment cost!)

Especially high investment on single width towers

Fewer mistakes: less errors and waste

Full integration with CTP requires page buffer and plate lift

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Automation of plate change

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Automation of plate change

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Automation of plate changeManual transportation during previous run

Plate lift

Integration of CTP and press

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Plate change concepts

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Press trends

Jumbo

Compact

Automation

Configurations

Extras

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Configurations

Traditional line configuration

Other idea: short webs, web width flexibility

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Configurations

Mixing tower width

FPS: new cut-off

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Press trends

Jumbo

Compact

Automation

Configurations

Extras

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Popular extras for value added products

Change of web width

Stitcher (former, folder, mailroom)

Dryer

Ink-jet

Gluing-in of cards

Etc.

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Further readings