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Business Printing Technologies Report <http://www.dmia.org/sol_center/bptr/04nov30_bptr.html> Open this issue in your browser. TABLE OF CONTENTS:
GRAPH EXPO 2004 HIGHLIGHTS By Ivars Sarkans The positive tone for the printing industry set by the big Drupa 2004 show in May continued to echo through this year's Graph Expo. Many exhibitors indicated a high level of satisfaction with visitor inquiries and actual sales of equipment. A positive outlook for the printing industry was also a common theme of the conference sessions held during Graph Expo. The printing industry seems to be adapting to the continuing restructuring of some supplier organizations, including Heidelberg's dramatic retreat from the digital and web offset printing segments of the industry to focus primarily on sheetfed offset and related prepress and bindery equipment. At Graph Expo 2004, it was clear that the product lines divested by Heidelberg will be available under other brand names, and Heidelberg itself, with one of the biggest exhibits at the show, will continue to be a very large and innovative supplier. "IT capabilities could become even more The changes in the printing industry evident at Drupa and Graph Expo 2004 give a strong indication that future success in most segments of printing will require a much higher level of Information Technology (IT) investments and skills. Practically every major press and prepress supplier at Graph Expo exhibited sophisticated workflow systems that automate many order planning, proofing, prepress, printing and finishing tasks. Some of these workflow systems facilitate interaction between printing plants and customers and create new service opportunities for printing. Customer service, prepress, presses, finishing and shipping are gradually being linked into a computer-controlled manufacturing network, and the effectiveness of systems and software will have a major impact on competitive position and profitability in the printing industry. Implementation, maintenance and the inevitable frequent updating of these systems require IT skills. While printers can rely on suppliers and outside specialists for some of this IT support, substantial internal IT capabilities offer the potential for significant competitive advantages. The ability to modify software, program specialized applications, integrate software and other technologies from multiple suppliers and develop electronic interfaces with customers can be as important as printing skills and equipment. IT skills can also determine the level of success that can be achieved in the growing digital printing field, especially in data management for variable imaging applications, printing from databases, preparation of databases for printing and management of customer data. As more of the traditional printing tasks are automated and skills built into software, IT capabilities could become even more important for success in printing than traditional prepress, press and bindery skills. This trend was clearly visible at Graph Expo 2004, and one of the implications is that larger firms that can afford more internal IT capabilities or smaller printers with unique IT initiatives will probably be the most successful and profitable future participants in the printing industry.
Graph Expo 2004 exhibits included two forms-type web offset presses, but both were set up as demonstration platforms for digital printing. One of these was a new Muller Martini variable size Concepta model with 2 offset towers, UV dryers and a compact sheeter with integrated batcher/stacker. The Concepta was demonstrated with a pinless tight-web Nipson Varypress 400 digital printer rated for a maximum speed of 410 feet/minute. The Nipson Varypress is a black toner magnetographic printer capable of 600 x 600 dpi image resolution. "...forms plants without this type of equipment will continue to lose work to service bureau operations, mailing houses and digital printing specialists." The second web offset press at the show was a variable size 2-color Rotatek RK-Perfect NT model with a sheeter delivery. This press was configured for in-line variable imaging with Kodak (previously Scitex) continuous ink jet heads capable of speeds up to 1,000 feet/minute. The demonstration included new 9" wide ink jet heads printing black variable data at 300x300 dpi resolution and 4.3" ink jet heads for variable highlight color. These Kodak ink jet heads represent the fastest current method of variable image digital printing on a press or an off-line web carrier. The two combinations of high speed offset and digital presses as demonstrated at Graph Expo 2004 were particularly suited for printing of statements, simple personalized direct mail and other documents (forms) with a mix of fixed and variable images. Additional offset towers could expand the application of these production lines to more complex personalized direct mail. Such combinations of offset and digital printing units will be some of the forms presses of the future, and forms plants without this type of equipment will continue to lose work to service bureau operations, mailing houses and digital printing specialists. The offset-digital hybrid presses displayed at Graph Expo 2004 signal a major opportunity for forms suppliers who can modify their business models to combine ink-on-paper production with a service bureau orientation and the higher level of IT skills needed for digital printing and management of customer data. Sheetfed machines dominated the rest of the press scene at Graph Expo 2004. These presses are becoming more and more productive in all size categories. Even in 2 page (14" x 20") presses, rated running speed on some models has reached 15,000 sheets per hour. In 2 and 4 page size presses, semi-automatic plate changing and automatic wash-up provisions are becoming more common. In the larger format 6 and 8 page presses, fully automatic plate changing is the norm. Console control of ink fountain settings and most other press adjustments has been brought to press sizes as small as 14" x 20". In the popular 8-page (28" x 40") press size, full automation of sheet feeder and delivery setup adjustments is now an option on many models. The changeover from straight single-side printing to perfecting has been reduced to a minor adjustment or even a push-button operation. Very significantly, more sheetfed presses are now designed for a wider range of papers, from very light sheets to folding carton board. One result of the huge advances in sheetfed press productivity and versatility, combined with a general shrinking of run sizes, was the absence of the typical web offset press demonstrations at Graph Expo 2004. Improvements in automation and productivity of small format 2 page (14" x 20" or smaller) sheetfed presses are now driven by advances in full-color digital printers. Color digital presses, mostly in the 12" x 18" to 14" x 20" sheet size range, present a serious threat to 2-page offset presses. The offset press suppliers are responding with capability and productivity improvements that will slow the rate of short run volume transfer from offset to digital printing. The general trend in 2 page (14" x 20" or smaller) sheetfed presses is towards more 4, 5 and 6 color machines, matched with off-line computer-to-plate systems or equipped with on-press direct imaging of plates. For forms manufacturers, the advances in sheetfed presses represent an opportunity to use the productivity of the new models as a competitive advantage to gain a greater share of the preprinted cut sheet document market. As more continuous forms are converted to cut sheets and distributors continue to grow their sales of commercial printing, forms plants will have to add efficient sheet printing equipment to prevent a loss of volume to commercial printers. "...forms plants will have to add efficient sheet printing equipment to prevent a loss of volume to commercial printers."
Some of the web-fed high speed black toner printer suppliers offer unique capabilities for applications that may be an opportunity for forms manufacturers. Delphax and Oce demonstrated twin engine duplexing machines where both print stations are built into a single frame, similar in concept to a perfecting web press tower. This configuration makes it easier to maintain accurate face to back print registration and is very effective for publications, documents and direct mail personalization requiring duplex printing. Delphax offers models rated from 200 to 450 feet/minute, all based on electron beam imaging technology. Standard Delphax toner is magnetic and can be used for MICR numbering. The Delphax machines have options for built-in slitting, perforating and punching stations. The Oce VarioStream 9000 series is a completely new family of printers, introduced at Graph Expo 2004, for duplex printing at 195 ft./min. with black toner. The unique feature of this Oce model group is the print engine configuration, which has provisions for up to 5 color stations on each side of the web. The VarioStream 9000 series printers are available now only for black toner duplexing. An additional highlight color on each side of the web for 2 over 2 printing will be a 2005 upgrade option. Further upgrades up to 5 over 5 colors are planned, but each additional color will reduce the rated speed. The VarioStream 9000 series has a non-contact radiant heat fusing station, important for materials that can be damaged in fusing units that apply pressure. Fusing is also an important feature of Nipson web-fed black toner printers. These printers employ flash fusing technology which does not apply heat or pressure to the web. That makes these printers especially well suited for variable imaging on labels, carbonless papers, forms with integrated cards or labels, films and other materials that may be adversely affected by fusing with heat and pressure. The magnetographic imaging technology used by Nipson requires magnetic toner which is suitable for MICR numbering. The show had several new models of monochrome sheetfed digital printers offering increased versatility such as the ability to print on very light, heavy, or coated papers, MICR toner, more feeding and pre-printed page inserting options, and more integrated in-line finishing modules. Xerox introduced the Nuvera printer line, planned as a group of products that will gradually succeed the Docutech generation of machines. The Nuvera models feature an upgraded imaging system for 4800x600 dpi print resolution and up to 125 lines/inch screening that sets a new level of print quality, according to Xerox. The initial models, Nuvera 100 and 120, are rated respectively at 100 and 120 pages per minute. Options include a dual head scanner that can simultaneously scan the face and back of documents at full 60 sheets per minute rated speed, and a built-in CD reader and writer. Konica Minolta added a new competitively priced black toner model to the sizeable existing population of mid-range sheetfed production printers available from various suppliers. The Konica Minolta Bizhub Pro 1050 is rated at 105 pages per minute and has a list price under $60,000. This model can run up to 12.75" x 18.1" sheets of paper ranging from 16 Lb. bond to 140 Lb. index from multiple bins, with one paper tray capable of feeding stock as heavy as 170 Lb. index. Print resolution is 1200 x 600 dpi. Graph Expo 2004 had similar examples from Xerox, Oce, Canon and others of the trend towards increased capabilities and versatility in economical midrange black toner printers. Xerox announced a major upgrade of their highlight color printer line from a maximum rated speed of 92 pages to 180 pages per minute. The redesigned machines will combine some technologies from the Xerox Docutech and iGen3 printers to achieve the higher speeds. The new series of highlight color printers, available in 2005, will have models rated at 128, 155 and 180 pages per minute. Print resolution will be 2400 x 600 dpi for black toner and 600 x 600 dpi for colors, with initial availability of red and blue toners. This announcement is significant for the forms industry, because a sizeable volume of preprinted statements, invoices and other documents has already migrated from forms plants to service bureau operations using the earlier generation of Xerox highlight color printers. In full process color digital printing, most of the Graph Expo 2004 announcements and demonstrations involved improved versions or models. These updated models included the 20" wide 5 over 5 color Xeikon 5000 digital web press, Xerox 14" x 20" iGen3 sheetfed color press, and the Hewlett Packard Indigo w3200 twin engine 13" wide web press. Xerox introduced the new DocuColor 8000 printer, rated at 80 color pages (8.5" x 11.0") per minute, to fill the performance gap between the existing 60 page/minute DocuColor 6060 and the 100 page/minute iGen3. The DocuColor 8000 can run sheets up to 12.6" x 19.2", ranging from 16 Lb. bond to 110 Lb. cover. Print resolution of this new model is 2400 x 2400 dpi. Xerox now has the most complete line of toner-based digital color printers, from entry level machines to a 100 page per minute digital press. In recent presentations, Xerox has indicated that revenue from color printing systems is growing at 20% in 2004 and similar results are expected for 2005. RISO introduced a new sheetfed ink jet printer for what the company terms "communication color", suitable for newsletters, forms, brochures and other common products. The RISO HC 5000 prints fixed images in 4 colors at a rated speed of 105 pages (8.5" x 11.0") per minute in standard 600 dpi mode. A higher quality 900 dpi mode and limited variable imaging are available at reduced speed. Maximum sheet size is 12" x 18". The machine uses piezo drop-on-demand ink jet technology and pigmented inks. The base price of the machine is $40,000 and RISO claims that operating cost for full color pages with 20% ink coverage is close to 3 cents. This could be a very attractive digital color printer for in-plant printshops. The high-speed fully variable image color ink jet benchmark at Graph Expo 2004 belonged to the Kodak Versamark VX 5000e web printing system designed for direct mail and other high volume applications. This machine, rated at 350 ft/minute in 4-color mode, uses continuous ink jet technology with water-base inks. Image resolution is 300 x 1200 dpi. The Kodak (previously Scitex) Versamark product line includes a wide range of optional web carrier and ink jet head configurations for black, highlight color or full process color printing on webs up to 20.5" wide.
Esko-Graphics introduced a new platesetter that can image conventional UV-sensitive plates up to 25" x 29". The Esko Espresso has a fixed 2400 dpi imaging system. Depending on plate sensitivity, it can produce 13 to 20 four-page plates per hour. Plates are loaded manually and automation makes the machine easy to operate. The Espresso may be a practical CTP systems choice for some forms plants. Automated setup provisions and computer controls dominated the new features introduced on bindery machines. Some folders, cutters, sheet collators, binders and trimmers can now be set up by entering job specifications from a console or a central production management computer. Many recently introduced models of these bindery machines have on-board computers that can communicate with a plant production network using the new standard Job Definition Format (JDF) for order specifications and exchange of digital information. In one demonstration at Graph Expo, job specifications developed in prepress were sent to a bindery control computer, which printed operation specification sheets with bar codes containing machine setup information. The computer built into each bindery machine would read the appropriate bar code and activate the motorized setup adjustments. Bindery machine computers can also be linked directly to a central production control computer for transmittal of digital instructions. This level of automation was evident in several of the finishing machines integrated with digital presses. Graph Expo 2004 had a separate section devoted to fulfillment and mailing, signaling the importance of these services as a complementary business opportunity for printers. Exhibits included software for web-based fulfillment systems, mailing list management, personalization of direct mail and address sorting to minimize postage costs. One of the forms industry prepress suppliers, Amgraf, introduced new software for automating the management of personalized direct mail programs. With Amgraf's ReadyClickMail software, imprinted template documents can be designed, addressed and ordered on line. The software has provisions for managing mailing lists and grouping individual orders for efficient digital printing and mailing at the most economical rates. The direct mail ordering and personalization software integrates with other Amgraf design and prepress system components used in the forms industry to give manufacturers and distributors a powerful set of tools for developing and implementing direct mail programs. "Developing IT skills is a major While less visible than presses and bindery equipment, digital infrastructure exhibits included some of the most important technological advances that will shape the development of print production businesses in the future. These exhibits ranged from complete printing enterprise management information systems to plant production management and prepress workflow systems. Graph Expo 2004 again showed the slow but steady progress towards computer-integrated manufacturing in the printing industry that has been evident at major shows for several years. This means that printers will become even more dependent on computers and software. So far, relatively few printers have tried to develop IT skills and systems into a competitive advantage, but Graph Expo 2004 sent a clear message that this is a major opportunity to create distinctions from competitors. Eventually, a high level of IT skills may become as much of a competitive necessity as printing and business management skills. Companies Mentioned in this Article: Agfa Corporation, Ridgefield Park, NJ Amgraf, Inc., Kansas City, MO Canon USA, Inc., Lake Success, NY Creo, Billerica, MA Delphax Technologies, Inc, Minnetonka, MN Esko-Graphics, Kennesaw, GA Glunz & Jensen, Inc., Elkwood, VA Heidelberg USA, Kennesaw, GA Hewlett-Packard Company, Corvallis, OR Kodak Versamark Inc., Dayton, OH Konica Minolta Business Solutions, U.S.A., Inc., Windsor, CT Muller Martini Corp., Hauppauge, NY Nipson, Elk Grove Village, IL Oce North America, Boca Raton, FL Presstek, Inc., Hudson, NH RISO Inc., Danvers, MA Rotatek, SA, Barcelona, Spain Xeikon America, Itasca, IL Xerox Corporation, Stamford, CT
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