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© 2010 WAN-IFRA
Latest Trends in Press Technology
Production Seminar, New Delhi, January 2010
Master of Science
Moritz SchwarzSenior Consultant
+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