Over the past few years, the printing preparation time has decreased dramatically. Due to the appearance of ink presetting, automatic plate change and other innovative functions, the process of moving from one job to the next can be completed in only 10 minutes. On this topic, several top-level printer manufacturers highlighted the technology suitable for jobs with short production cycles and few copies. With the holding of the Drupa International Printing and Paper Exhibition, the industry can expect to see more technological progress.
Komori: Faster, bigger and smarter
Mr. Doug Schardt, a sheet-fed product manager at Komori America, believes that the number of copies of short-form jobs continues to decrease. Although technology plays a decisive role in achieving maximum productivity, managers cannot stand by. He said: "Even if a printer with 4 or 5 sets of old equipment purchases a fully automatic printing machine, it will generally not raise the production standard due to the newly added printing machine. It is like the same Same as horse racing surrounded by horses. "Komori customers can enjoy" health check "to ensure the highest operating efficiency of their equipment.
Artificial intelligence will continue to push the printing press to a new level of sophistication and sophistication. Schardt said: "Although printing presses cannot think, they can make choices based on data."
Drupa provided a display stage for Komori's Lithrone SX40. The speed of the device is up to 18,000 sheets / hour, and it can print paper with a width of 41 inches. When Lithrone SX40 starts printing at 12,000 sheets / hour, it can save a lot of time and paper. Schardt said: "When the printing press is accelerating, the ink and water will not stabilize. Once the speed reaches 12,000 sheets / hour, it is close to the speed of the equipment, so it is reasonable to start feeding at this time."
The automatic plate change function realizes the replacement of 6 printing plates in 2 minutes, while continuously removing the printing plates. By using software that controls all inking functions, air and register presets, printing preparation time can be further reduced.
Komori's on-demand conversion booth will display Komori KHS-AI (Quick Print Toning System) with advanced interface on its sheetfed press. The self-learning function of the system can record any changes made by the operator to the CIP4 download information, and use it for subsequent jobs. This device is able to "perceive" the printing status and continue to update itself in response.
When the variable changes (for example, the ink roller shrinks), the self-learning function knows that the ink key related to the required ink volume should be adjusted. Schardt said: "The result is that you get the ideal ink density very quickly." Komori's pre-adjusted ink system's intelligent sequence features can automatically perform color correction and adjustment. In the case of one job after another job, the printer can choose the most suitable one from the three pre-programmable automatic operations to complete the setting of the printing machine. These automatic operations include deinking, cleaning, pre-inking, plate change and fully automatic printing preparation, the operator can choose the mode of "start of day", "replacement of job", "end of day" and so on.
Heidelberg: short ink road design
Bring high efficiency
At the Graph Expo in Chicago in 2006, Heidelberg first demonstrated the Anicolor inkless zone ink supply system for the 20-inch Speedmaster 52. The system's keyless inking and anilox roller technology enable it to maintain consistent ink film thickness. The engraved anilox roller transfers the ink from the ink cartridge to the inking roller, and then the ink is transferred to the pre-wetted standard offset printing plate. According to reports, it takes about 7 minutes to prepare a four-color job for printing on this type of printing press. As long as 10 to 20 sheets of paper are used, qualified samples can be printed.
Mr. Joerg Daehnhardt, Director of Sheet Paper Product Management at Heidelberg USA, said: "We are shortening the preparation time for printing, as long as the plate is released and the blanket is cleaned. Once you have completed both tasks, you are ready to print. "
The Anicolor ink supply system combines offset and flexographic components. Daehnhardt introduced: "On the one hand, you use standard offset printing plates, inks, and dampening units; on the other hand, you also use an anilox roller that is indispensable in flexo or anilox coating units. "Unlike conventional offset printing equipment that requires the operator to monitor 16 ink rollers, the operator of the Anicolor ink supply system essentially only has to handle two ink rollers. Daehnhardt said: "Your eyes have not stayed on the anilox roller and the plate ink roller for a long time, and they have been transferred to the printing plate. This is a short ink path design." The temperature controlling the anilox roller is ink The key to measurement. The operator raises or lowers the temperature on the console of the printing press to deliver the desired amount of ink.
Daehnhardt said: "In the Anicolor ink supply system, we removed a lot of automation functions and implanted color intelligence. For other small-format printers, even if you have a pre-press interface, you still have to use the ink key . It takes a long time to achieve the desired color and ensure the correct color. Using Anicolor ink supply technology, users can get the same ink at any location on the paper, provided that there are dots at these locations. All necessary on the printing plate Information-where there are outlets or no outlets, the corresponding is
Ink or not. Rather than using electronic means to calculate how much ink to use and how far to open the ink keys, we bring standardization to printers and workshops. "
The way to get the best results with the Anicolor ink supply system is to rely on good pre-press color management and precisely match the calibration curve of the direct plate-making machine. Proofing machine, direct plate-making machine and printing equipment should be consistent with the subsequent printing results.
The American Taylor Printing Company is the beta test point of the Anicolor ink supply system in the country. Later it added 5 Speedmaster 52 printing machines equipped with Anicolor technology. Taylor is generally a short-run printer, with less than 1,000 copies per job. This company's printing preparation time has dropped from 15 minutes to only 7 minutes or 8 minutes. These printers work 7 days a week, 24 hours a day; currently each device can produce about 3 jobs per hour, and Taylor ’s goal is 4 jobs.
Daehnhardt said: "You have to ensure that your business is continuous. The productivity of the Anicolor ink supply system is extremely high. About 35 printing preparations are completed in an 8-hour shift, but this number does not apply to every shift. It makes the most sense when you have a continuous workflow. "
The Anicolor ink supply system is now only installed on Heidelberg SM 52, and may eventually be equipped with Heidelberg's large format printing presses. Daehnhardt said: "We can only get the color of the Pantone color matching system (PMS) suitable for large format devices to cross the 20-inch device market. Depending on the color, traditionally PMS colors use different ink thicknesses. But in 2007 At the International Image Exchange Exhibition in Chicago, USA, Pantone introduced the Goe system based on uniform ink film thickness. Obviously, this system is a perfect match for the Anicolor ink supply system, but the Goe system still needs to be recognized by the market. "
KBA: Simultaneous version change saves time
KBA is pursuing shorter production cycles in several frontier areas. Eric Frank, vice president of KBA America, said: "We continue to introduce new technologies that can help customers print short-form jobs at low cost. We invite everyone to share KBA's latest technology together on Drupa."
KBA's new direct drive system for plate cylinders, DriveTronic SPC (Synchronized Plate Change), can also electronically set the start of printing, provide an electronically controlled circumferential register, and synchronize plate changes with other press processes . DriveTronic SPC will be demonstrated on Drupa and will soon be marketed in the United States. With DriveTronic SPC, plate replacement time has been reduced from the 3 minutes normally required by conventional six-color presses to less than 1 minute. During job replacement, synchronous printing plate replacement and synchronous blanket cleaning can save all printing units a lot of time, especially long double-sided printing machines.
Jobs with few prints and short time are extremely suitable for KBA's compact 20-inch sheet-fed offset press Genius 52UV. Applications include personal cards, prepaid cards, gift cards and membership cards for telephones and lotteries, as well as CDs and DVDs made from a large number of plastic materials such as PVC, ABS, PS, PE, PET and PC. Genius can also print paper and cardboard with a thickness ranging from 0.004 inches to 0.03 inches. Genius has a conventional format of 14.2 inches x 20.47 inches, and its printing speed can be as high as 8000 sheets / hour.
According to reports, Genius 52 UV's Gravuflow inkless keyless inking device can help users get up to 40% less printing preparation time than conventional offset presses. On Drupa, people will see for themselves that the new quick-replacement ink cartridges can be removed from the printing unit at any time without having to run out of ink cartridges. When the Genius 52UV is printing, other quick-change ink cartridges, that is, spot color ink cartridges on the fifth printing unit, can prepare for the next job.
Other options include an elongated glazing unit to add highlights online.
Mitsubishi: No operator required
At the 2006 Graph Expo in Chicago, the United States, Mitsubishi demonstrated the fully automatic full-color simultaneous plate changer SimulChanger. The system is aimed at the time-consuming printing preparation process. This optional system for Diamond series printers can replace the old version of any printing unit with a new version in one seamless operation. On multi-color printing presses, SimulChanger allows the printing plates on all printing units to be replaced simultaneously without requiring the presence of an operator. The complete process of replacing the printing plate, including the disassembly of the old version, the wrapping of the new version, and the phase adjustment of the plate cylinder, only takes more than 1 minute. Printing companies using SimulChangers reported that the plate replacement time was less than 70 seconds.
In a typical automatic printing plate replacement process, each printing plate used for printing jobs takes 60 to 90 seconds. For a ten-color printing press, SimulChanger alone can reduce the time by almost 15 minutes. On an ordinary sheet-fed printing press, a series of grippers on the impression cylinder and the transfer cylinder are responsible for transferring the paper. If the gap between the printing plate and the blanket cylinder touches the gripper on the impression cylinder, vibration will occur. The purpose of the roller positioning is that the gap will not meet the gripper during rotation. When the printing press is completely stopped, the cylinder position of each printing unit is different. For this reason, each plate cylinder must be individually positioned when changing plates.
SimulChanger's simultaneous plate cylinder phasing system uses the highest and lowest adjustment devices for positioning. The plate cylinder of each printing unit automatically rotates to the optimal plate-changing position and stops. This arrangement allows the printing plates of all units to be replaced simultaneously. Once the printing plate is replaced, the cylinder will return to the optimal printing phase. The operator can place the new version on the plate holder while the printing press is running. All other plate-changing functions include automatic and simultaneous removal of plates from multiple printing units at the press of a button on the Mitsubishi COMRAC press console. After the old version is unloaded, the new version that has been placed in advance is automatically picked up and installed on the plate cylinder.
The American MWM Dexter printing company is good at producing short edition publications, calendars and church announcements. Since the average number of copies of these jobs is 3000 copies, it requires an ultra-fast printing preparation process and an extremely short lead time. To meet job requirements, the commercial printer recently installed a new Diamond 3000S four-color printing press equipped with SimulChanger. Mr. Chris Dale, President of MWM Dexter, said: "With SimulChanger, we can schedule 50 print preparation processes within 24 hours. I expect SimulChanger to reduce print preparation time by 50%, so that we can spend less time More work is done within. We have a large client ’s work piece that is always 400 single pages of 28 inches by 40 inches. The client ’s printing time for each work piece is equal to the time for one printing preparation. â€
Mitsubishi's highlights at the Drupa show include Diamond Color Navigator (color adjustment interface device). While visually observing the color based on the operator, Color Navigator automatically corrects all necessary ink key openings through a color wheel on the touch screen. Without complicated movement of the ink key, Mitsubishi's new color adjustment interface ensures fast and accurate fine-tuning of colors. Compared with manual ink key adjustment, Color Navigator reduces color adjustment time by half and improves color reproduction accuracy by nearly 1/3.
The system consists of touch screens above and below. The two touch screens are connected to a separate console next to the COMRAC console. The upper touch screen is used to select a single ink area. The operator enters the desired color adjustment on the lower touch screen, and then sends the adjustment to the printing press. A hand-held densitometer also allows the operator to correctly color-match spot colors on printed sheets.
Ryobi: bigger and faster
American xpedx Printing Technologies is the exclusive distributor of Ryobi printing presses in North America. Mr. Tim Kirby, the company ’s national sales manager, said: "We undoubtedly recognize the market demand for short-form jobs. We have changed the degree of automation , Can achieve faster printing preparation, while wasting less, and ultimately earned more profits for printers. "Kirby believes that ink key automation and fully automatic plate replacement makes the printing preparation time dramatically reduced. Ryobi's pre-adjusted ink volume software uses pre-press data to calculate the image area ratio for each ink fountain key opening. All necessary data including the printing start position, the number and width of the ink fountain keys, etc. are pre-entered into the device-the operator only needs to indicate the type of device.
Ryobi's Program Inking ink supply system makes printing the right amount of ink from the beginning. Kirby said: "You can't chase the color in the next printing, but must grasp the current." Program Inking ink supply system automatically sets the conversion curve for each color according to the proportion of the image area calculated before printing. The setting of the ink key, the speed of the ink fountain roller and the number of times it is touched by the ink fountain roller are all controlled based on the conversion curve to ensure the optimum amount of ink. During job replacement, the ink supply system automatically corrects the ink density to match different printing conditions, thereby reducing downtime and paper waste.
The printing area of ​​the Ryobi 784 printing machine can hold 6 sheets of 11 × 17 inches, and it has a semi-automatic plate change function. The operator can prepare for the next job when changing the version. Ryobi ’s highlights on Drupa include the new 40-inch press Ryobi 1050, and online UV casting and foiling options for the Ryobi 755 model. The Ryobi 525GX printer is equipped with a light-emitting diode UV curing system. Ryobi will also showcase the 24-inch x 36-inch Ryobi 924 and Ryobi 3404E DI direct imaging equipment.
Ryobi 1050 will be available in the US in 2009, and the double-sided model is scheduled to be launched in 2010. The current speed of Ryobi 1050 reaches 16000 sheets / hour, and two configurations of "S" (41.73 inches x 31.5 inches) and "XL" (41.73 inches x 33.46 inches) will be launched. The skeletal paper transfer roller with movable shell minimizes scratches and spots. When printing on a large amount of cardboard material, the part of the shell will be loaded into the paper transfer cylinder. Featured options include an online printing quality control system that can control ink density during the printing process. This system has a CCD camera installed in the receiving area. Digital images are used to measure the density of color patches on printed sheets. The value required to correct the color density to match the target density is calculated and provided as feedback from the printing control system, which adjusts the ink fountain key when necessary.
Ryobi will demonstrate an online UV casting and foiling system for its 750 series equipment. Both the casting and foiling processes can be completed in a single unit. When the unit is not in use, the UV lamp goes up so that the road is usually unobstructed. This unit can also perform conventional printing and glazing processes. During the UV casting process, the relief structures and patterns on the film were transferred to UV varnish. The printed surface has a holographic effect after UV curing. In the foil attaching process, the UV curing glue is first applied by the printing or glazing unit, then the film-based foil is attached to the printing surface, and finally the UV lamp fixes the foil on the printed sheet.
Ryobi developed a light-emitting diode UV system with Toyo Ink, which will be displayed on the Ryobi 525GX press. Unlike conventional UV lamps, this system combines low-energy light-emitting diodes, and its composition includes a diode ultraviolet irradiation system from Matsushita Electric Works and a Toyo spot color ink.
Gauss International: an alternative to long duplex printers
Mr. Greg Norris of Goss America said: "In terms of rotary equipment, we clearly see a trend towards accelerated development of shorter operating cycles. By convention, rotary printers are printing jobs with fewer than 5000 copies, each Complete multiple print preparations in hours, and at the same time waste is extremely low. "
At the Drupa exhibition, Gauss will show for the first time a new rotary press without a drying device, designed to be an option for some traditional offset printing applications. This equipment uses the standard Goss M-600 printing unit and the new web paper cutter technology developed jointly with VITS. It is designed to print high-quality sheet paper products on coated materials, and it is not used. Drying device. The live demonstration will emphasize fast printing preparation, less waste and short-run work printing efficiency. Norris explained: "The simplified drying-free device configuration makes the printing effect close to that of a long double-sided printing machine, but it is more than twice as fast. We believe that the production efficiency advantage, combined with the printing quality, is lower The cost of paper and the total return on investment will provide a new attractive option for some printers who are considering buying double-sided printing presses. "
Gauss ’Autoplate automatic plate change option was first introduced in 1996 and is now installed on 400 devices worldwide.
Gaussian Automatic Transfer (AT) automatic job conversion system realizes the seamless conversion of jobs in the printing process. When the printing press is in operation, the operator can prepare for the next job on the idle printing unit, and then press these units together, while depressurizing the unit that is printing the previous job. Gauss's automatic job conversion system meets the growing market demand for versioning and the production of more short-form jobs.
Gauss also noticed that sheet-fed printers are constantly moving toward rotary offset printing. North American sheetfed printers, including Boyd Brothers and Trade Secret Printing Inc., have recently purchased their first batch of rotary presses—all Goss Sunday 2000 systems.
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