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
3 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
5 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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 !
6 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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…
7 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
8 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
9 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
11 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
12 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
13 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
14 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
15 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
16 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
17 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
18 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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)
19 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
20 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
-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
21 WAN-IFRA India 2014 © manroland web systems GmbH 18 Sept 2014 Alwin Stadler
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
Top Related