WAN-IFRA India 2014€¦ · Industrial Digital Finishing Solutions and Digital/Offset Hybrid Concepts Alwin Stadler VP Digital Printing WAN-IFRA India 2014 ©

Industrial Digital

Finishing Solutions

and

Digital/Offset Hybrid

Concepts

Alwin Stadler

VP Digital Printing

WAN-IFRA India 2014

2 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler

FormerLine

FoldLine

Broadsheet

and Tabloid

Newspapers

Inline Cylinder

stitched

booklets

Signatures for

books and

commercial

Glued

booklets/

inserts

Auxilary glued

book-blocks

Flyer and Mailing

Finishing Solutions & Production Possibilities


We are the integration partner for

digital production systems in the graphic arts industry

Workflow and finishing solutions for:

Canon/Océ

HP

Kodak

FoldLine for Newspaper Production


Industrial digital finishing line

FoldLine – benefits at a glance

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

Simply…more finishing !


Infinite Product Flexibility

A single finishing solution for the full range of your product portfolio

Broadsheet

and tabloid

newspapers

Cylinder

stitched

booklets

Signatures for

books and

commercial

Glued

booklets/

inserts

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…


Industrial design for highest reliability and speed in digital finishing

Highest Productivity

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

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

Output

per product


Highest Automation Level in Digital Finishing

Fastest Make-Ready

Job 1 Job 2 Job 3 Job 1 Job 2 Job 3 Job 1 Job 2 Job 3

time time time

sp

ee

d

sp

ee

d

sp

ee

d

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

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


Intelligent Automation and Workflow Solutions

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 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

Level I

Customized

Customized

Hybrid Solutions

Offset+Digital


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


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


2. Inserting of digital printed sections

inserting

Digital Printer with FoldLine Newspaper Offset

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


3. Unwind inkjet pre-printed reels in the offset press

Advantages

Inline production of the digital printed reels

Flexible production times

Enable better utilization of the digital asset

Application

Advertising for small target

groups

Disadvantages

Time delay, preproduction required

Register deviation can cause quality issues


4. Hybrid press:

Digital print engine and existing offset press

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

Reelstands in ground floor

Reel supply

from the

offset press


0

50000

100000

150000

200000

250000

10

10

0

1.0

00

5.0

00

20

.00

0

30

.00

0

40

.00

0

50

.00

0

60

.00

0

70

.00

0

80

.00

0

90

.00

0

10

0.0

00

11

0.0

00

12

0.0

00

13

0.0

00

14

0.0

00

15

0.0

00

16

0.0

00

17

0.0

00

18

0.0

00

19

0.0

00

20

0.0

00

21

0.0

00

22

0.0

00

23

0.0

00

24

0.0

00

25

0.0

00

26

0.0

00

27

0.0

00

28

0.0

00

29

0.0

00

30

0.0

00

31

0.0

00

Offset productivity

Hybrid productivity

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

Copies total per job

Total

possible

copies /

shift

Break-even appr. 5,000 copies / edition


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


4. Hybrid press:

Production Possibilities

Digital part Offset part

Product A

Product B1

Product B2

Product A

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)


0

50000

100000

150000

200000

250000

300000

350000

400000

450000

10

10

0

1.0

00

5.0

00

20

.00

0

30

.00

0

40

.00

0

50

.00

0

60

.00

0

70

.00

0

80

.00

0

90

.00

0

10

0.0

00

11

0.0

00

12

0.0

00

13

0.0

00

14

0.0

00

15

0.0

00

16

0.0

00

17

0.0

00

18

0.0

00

19

0.0

00

20

0.0

00

21

0.0

00

22

0.0

00

23

0.0

00

24

0.0

00

25

0.0

00

26

0.0

00

27

0.0

00

28

0.0

00

29

0.0

00

30

0.0

00

31

0.0

00

Offset productivity

Hybrid productivity

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

Copies total per job

With the same basic speed hybrid is

faster because of no edition change


-0,10

0,00

0,10

0,20

0,30

0,40

0,50

0,60

Offset copy

Hybrid copy

Digital copy

Cost per copy

The productive range for the Hybrid model is in between of 150 to 5,000 copies.

Copies total

Cost per copy


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!

alwin.stadler

@manroland-web.com

Documents

WAN-IFRA India 2014€¦ · Industrial Digital Finishing Solutions and Digital/Offset Hybrid Concepts Alwin Stadler VP Digital Printing WAN-IFRA India 2014 ©