Graph Expo Integration

More than 38,000 people attended this year's expo. Here's a glimpse of what they saw.

By Bob Neubauer

Integration was the big theme of this year's Graph Expo and Converting Expo.

Individual manufacturers like Heidelberg and MAN Roland showcased computer-integrated manufacturing (CIM) technologies connecting prepress, press and finishing. And vendor partnerships, both small and multi-faceted, foreshadowed future integration between multiple vendors' systems.

Notably, at a large press conference touting the Networked Graphic Production initiative, 27 companies proclaimed their commitment to defining, developing, testing and delivering JDF-based integration between their systems. They plan to define a standardized set of interfaces to create plug-and-play solutions that let job and production data flow seamlessly across the entire production process. Amos Michelson, CEO of Creo, which initiated the two-year-old partnership, predicted that in a year we might see system integration from the idea stage straight through to delivery.

This wasn't the only reference to future results at this year's show. Though plenty of new products were on display, some vendors simply hinted of great products to come at next year's Drupa trade show, in Germany.

Despite this, more than 38,000 industry professionals came to Chicago to visit the 580 companies exhibiting their wares. According to show organizers, this year's event marked "the long awaited rebound in sales, profits and investment in the graphic communications industry." And indeed a number of pieces of equipment on display were proudly marked with "Sold" signs.

Here's a look at some of the products In-Plant Graphics saw at Graph Expo.

Once again with the largest exhibit, Heidelberg had a lot to show. With its central focus on CIM, Heidelberg's JDF-enabled Prinect workflow product portfolio was a hot topic, as were its plans to integrate Printcafe's print management software with Heidelberg presses through open JDF connections. Added to Prinect were the Prinect Profile Toolbox, a new color management software, and MetaDimension 4.0, the newest version of its RIP and workflow solution.

At the show, Heidelberg launched a new 20˝ press, the Printmaster PM 52, designed for smaller operations that want to move into color printing. Available in one- to five-color models, the Printmaster PM 52 uses the same feeder as the Speedmaster 52. Its maximum speed is 13,000 sph, with a maximum print format of 14.56x20.47˝. All control and monitoring functions are operated from the PressControl panel. It uses the EasyPlate plate clamping system.

Heidelberg also unveiled the Speedmaster SM 52-D with die-cutting, allowing in-line finishing to be done in one pass. Another new product, the Dymatrix 105 CS, also allows high-speed die-cutting, producing 9,000 finished sheets an hour.

On the digital printing end, Heidelberg's Digimaster 9110cp was introduced to the North American market. It boasts enhanced paper handling, improved workflow and enhanced image quality. It can print on a wider range of substrates, and on sheets up to 14x18˝. To enable inline double-loop wire comb binding, Heidelberg introduced the Probinder at the show.

For the NexPress, Heidelberg unveiled three new configurations of its NexStation II digital front end and new automation tools for variable data color printing.

Xerox also had a few new items to talk about. Its iGen3 has gotten some enhancements, including new finishing options, tab stock support and the ability to process weights up to 300 gsm. Inline finishing options now include the C.P. Bourg BBF2005 perfect binder, the Xerox SquareFold booklet maker from Plockmatic or the GBC In-line Fusion Punch II. The new uPublisher is a digital learning simulation tool to help printers produce full-color books on the iGen3. Xerox is also reformulating its magenta dry ink to make iGen3 colors more vibrant.

Xerox replaced its 45-ppm DocuColor 2045 with the new 52-ppm DocuColor 5252. Boasting excellent color consistency and front-to-back registration, the 600x600-dpi printer is designed for cost-effective, short-run printing. It prints at full speed in color or black and white on a wide array of substrates, including coated stock. The engine automatically removes the curl from sheets.

The company went on to announce five enhancements to its DocuColor 6060, including PANTONE certification, an enhanced high-capacity stacker and new inline hole punching. For copy centers, Xerox debuted the WorkCentre M24 color copier-printer, using EA toner. The Xerox DocuColor 3535 also got three new print drivers: the Creo Spire CXP3535, the EFI Fiery EX3535 and the EFI Splash G3535.

Direct-to-print

Elsewhere, A.B.Dick was very excited to introduce its new X-Press 3000 direct-to-print solution. Specifically intended for use in in-plants, the new printer outputs 3,000 sheets per hour for color or black and white. It uses new color polymer dry ink, which offers sharper text, better halftone clarity, higher image stability over long runs and improved quality by eliminating the need for fuser oil.

Xeikon was running the DCP 500 D press and IntelliStream 3.6 Digital Front End in demonstrations that had the machines producing a direct mail brochure using demographic and geographic information along with buying histories to print one-to-one brochures. The system utilizes the PPML 2.1 and PPML/VDX capability of the IntelliStream 3.6 DFE to assemble each page of the brochure and print at 138 PPM.

Hewlett-Packard was on hand hand to show off a number of devices, including the web-fed Indigo Press w3200 and w3400. The presses turn out 8,000 and 16,000 A4 images per hour respectively, and boast 800x800 dpi at 180 lines per inch.

Océ Printing Systems USA announced the general availability of its new VarioPrint 2105, a high-volume digital printer/copier/scanner. At 101 ppm, the printer offers a monthly duty cycle of up to 1.5 million prints. The device boasts simultaneous printing, RIPing and scanning and external finishing attachments. Océ also took the opportunity to demonstrate its VarioPrint 5160 digital sheetfed system for short-run, on-demand output at 158 images per minute.

After its successful Books For Schools program at the On Demand show, Delphax, together with Muller Martini and other vendors, produced books at the show for the Chicago public school system. At its booth, Delphax showed off the CR1300 continuous-feed digital printer with one-pass duplexing. Printing up to 1,300 ppm duplex at 600x600 dpi, the CR1300 handles an array of papers, both coated and uncoated, running from roll stock to delivery of untrimmed books.

Building on its forms printing expertise, Scitex Digital Printing showcased its VersaMark Printing Systems. With print speeds reaching 230 meters per minute, which the company says translates to 2,000 ppm, VersaMark can handle black-only and full-color variable data output. It produces output as roll-to-roll, roll-to-fanfold or roll-to-cut-sheet.

Canon USA unveiled the 51-ppm CLC 5100 color printer for professional-grade workflow demands and the entry-level 40-ppm CLC 4000. Running them are the new ColorPASS-Z6000 and ColorPASS-Z7000 controllers. Both printers feature a combination of four-drum technology and Canon's exclusive Finer Brighter (FB) toner and Automatic Image Refinement. The CLC 5100 offers resolutions up to the equivalent of 800x400 dpi and the CLC 4000 features up to the equivalent of 800x400-dpi resolution.

Canon also announced the new imagePROGRAF W8200, Canon's first large-format print engine to support pigment ink solutions with the imagePROGRAF architecture. Two devices, the W8200D (dye) and W8200PG (pigment) boast a 1.07˝ high-density print head and 44˝ media support.

New from Standard Duplicating Machines was the SD420 digital duplicator, using new ink and master technology. The micro-porous percolation technology master enables the SD 420 to print large solid fill areas at all speeds while reducing image setoff. Standard also previewed a new Ultra-Violet ink drying system for use with its SD450, SD650 and SD622 duplicators. Not yet available, the Seri-Printer uses special UV light-sensitive inks to cure images as the duplicator produces them.

Encad, a subsidiary of Eastman Kodak, debuted the VinylJet 36, a solvent-free, direct-to-vinyl wide-format ink-jet printer. Offering a 36˝ width and resolutions at 600 dpi, the printer requires no special ventilation because it uses environmentally safe inks.

Offset Printing

On the offset side, redesigned and boasting a new perfector, the Lithrone 28P from Komori drew a good turnout at demonstrations. With a new cosmetic design, the six-color press features standard double-diameter cylinder configuration and grippers for added sheet control. The operator can preprogram the next job's makeready while the previous job is printing.

Hamada's Impulse 452P Perfecter was available at the show, and the company trumpeted the four-color machine's EPS system, suction tape feeder, and its power ink roller washer and blanket washer. The press also offers a perfecting unit, and its ink control system is designed to work with CIP4.

Sakurai scored a sale of its Oliver-SI/SIP series press at Graph Expo. Sporting a compact design and printing 15,000 images per hour, the Oliver also offers perfecting and a CIP4 interface. Ink temperature control and a blanket wash-up device are optional.

The four-color 3404DI was a familiar offering from Ryobi, and the product's distributor, xpedx, was spreading the word about its A3-size portrait format with built-in direct imaging. Featuring a compact design and advanced RIP technology, the press supports both PostScript and PDF data and turns out copy at either 1,270 or 2,540 dpi.

Though KBA North America talked about a new 20˝ offset press called the Genius 52 in its press conference, the keyless, waterless press won't be on display until Drupa. But the company did announce a plastics printing option for its 74 Karat digital offset press. This would allow the press to print plastic cards, adhesive labels, signage and more. KBA also introduced the Logotronic Professional System, an integrated computerized data exchange system to control machine parameter setting, job tracking, production reporting and more.

Plate Action

Heidelberg introduced the Saphira Quickplate 46, which allows the Quickmaster DI to produce well defined jobs with hard-edged structures that are extremely accurate and consistent. Run lengths exceed 20,000 impressions.

At the Presstek exhibit, attendees were standing in the aisles to get a peek at the live printing demonstrations of the process-free Applause plates. The plates were imaged on a Dimension 400 CTP system and printed live on a Komori Lithrone 420 press. Applause plates eliminate processors, safelights and chemistry. They also provide faster roll-up and makeready, greater ink/water latitude and more reliable reprints.

Presstek also announced it will provide a new OEM CTP system to A.B.Dick. The system will include the new two-page Vector platesetter and the new chemistry-free, non-ablative thermal metal Freedom plate, both manufactured by Presstek. Like Presstek's Anthem plate, Freedom requires only a simple wash with water before printing. The main difference between Freedom and Presstek's other chemistry-free plates is that Freedom is a non-ablative plate designed for run lengths of less than 25,000 impressions.

Kodak Polychrome Graphics couldn't wait to show off the SWORD EXCEL printing plate. The plates deliver run lengths of up to 500,000 impressions and hard dots that yield resolutions ranging from 1 percent to 99 percent at 200 LPI. The plates are compatible with stochastic screening at 20- and 10-micron dot diameters. The hard dots reportedly provide faster roll-ups by producing sharper edges.

Another plate, the Delta 830 thermal polymer CTP plate, was unveiled by Printing Developments Inc. It requires no baking and just a single piece of processing equipment. With a specially treated aluminum base, it supplies optimum ink/water balance, letting printers bring presses up to color faster.

In other plate action, Creo launched its Positive Thermal Plate, suitable for long run lengths with no pre- or post-baking.

Prepress Prowess

Electronics For Imaging—soon to acquire Printcafe—was among the voices stressing the need for vendor integration and open standards. EFI revealed plans to integrate Printcafe's print management software with Heidelberg presses through open JDF connections, as well as with CTP devices from Screen (USA).

EFI also announced partnerships with Screen, Presstek and Kodak Polychrome Graphics to sell EFI's Velocity OneFlow prepress software. And EFI's Velocity Balance was integrated with Xerox DigiPath Production Software 4.0 to extend DigiPath's capabilities with centralized job management and automatic job processing, among other things. EFI also launched its Fiery S300 and S500 servers to drive mid-range and high-volume print engines at full speed.

Visitors to Agfa's booth were directed to an expanded version of ApogeeX, which boasts an enhanced PDF- and JDF-based workflow. Live demonstrations showcased the offering as fully scalable, and company reps revealed that it will be available this January.

Maintaining 250 plates in four cassettes, the PlateManager was introduced for Agfa's Xcalibur 45 thermal platesetter. Making its debut at the show, the Xcalibur 45 offers automated plate loading.

Agfa also rolled out its new contract digital proofer, the Sherpa 44m. The Sherpa offers a high-resolution ink-jet system that includes seven-color piezo-electric ink-jet technology, advanced in-RIP color management, quality control software and specially formulated proofing media. The new RIP, version 2.2, delivers variable-sized drops at higher speeds.

Agfa also highlighted :Sublima, its cross-modulated screening solution. In the midtones, :Sublima uses AM technology for reproduction. In the highlights and shadows, it uses FM technology. Instead of simply switching between the two, :Sublima uses patented technology to smoothly transition from one to the other. Even though FM uses smaller dots, they are still properly aligned using the AM screen angles. Because :Sublima RIPs at a moderate 2,400 dpi to produce 340 screen ruling, it speeds RIPing time and platesetting. :Sublima also takes press characteristics into account so it compensates for dot gain and won't produce a dot that the press can't hold.

Fresh from the IGAS show in Japan, Kodak Polychrome Graphics debuted its new Kodak Approval NX Digital Color Imaging System. The halftone proofing system uses thermal imaging technology. Featuring Rapid Recipe Color technology, the Kodak Approval NX system can accurately produce millions of spot colors, reportedly in a fraction of the time it took previous Approval systems, by laying down up to four densities each of CMYK and spot colors simultaneously.

KPG also featured its MatchPrint Virtual Proofing System, which the company boasts can speed up the approval process. The proofing system consists of customized CRT monitors, proprietary color management technologies and a suite of Web-based image-viewing and collaboration tools from RealTimeImage.

Fujifilm introduced PictroProof II, the successor to the PictroProof digital contone proofer. PictroProof II boasts all of the same features, including a quick print time, ease-of-operation, automatic calibration and high resolution, but now also offers a network adapter. This allows users to connect to a network via an Ethernet connection, letting them run the PictroProof II remotely from the software driving it. PictroProof II now supports several additional Fujifilm RIPs and drivers. Now with a built-in calibrator, engine calibration takes a mere 60 seconds.

PlateDriver HS is a high-speed, 40mW platesetter from Esko-Graphics capable of imaging violet polymer plates in addition to violet silver plates. Pushing the need to go digital to its visitors, company reps explained that up to 46 four-up plates can be exposed per hour on the PlateDriver 4HS, while up to 42 eight-up plates can be exposed on the PlateDriver 8HS (at 1200 dpi). Plates can be exposed in metric and imperial resolutions from 1,200 to 3,200 dpi.

FlowDrive 5.0, Esko-Graphics' updated workflow for small to medium sized printers, supports PDF 1.4, including transparency. TrapPro, the new trapping engine, provides more controls for how the trap is built and new ColorPro color management adjusts proofs for dot gain and supports screen rulings and dot shapes. With user queries, Smart Numbering helps to automatically impose each page correctly in a signature.

Preflighting & PDF Editing

Markzware unveiled FlightCheck Professional version 5 at a press conference. Using a drag-and-drop interface, it scans a variety of file types (e.g. InDesign, QuarkXPress, PDF, etc.) and warns operators about problems, including font and graphic incompatibilities. Now with Mac OSX support, FlightCheck Professional v.5 verifies critical file elements like color space and resolution and generates a detailed report.

Enfocus unleashed the PitStop Professional 6.0, a software package designed to handle PDF editing, preflighting, auto-correction and certification. The kit is compatible with Mac OS X, Adobe Acrobat 6 and Adobe PDF 1.5, and features built-in Pantone color support, Smart Profile comparison and integrated support for the recently released CertifiedPDF.net.

Capitalizing upon a recently announced partnership with Datalogics, Printable Technologies was eager to showcase PrintFusion 3 variable data technology, which offers interfaces that allow control over layout, font selection and images. Printable also revealed its plans to acquire the PrintReady line from Extensis. PrintReady provides preflight inspection, compression and transfer capabilities designed to simplify job transfers.

Digital Job Submission

Creo released version 3.5.5 of the Synapse InSite prepress portal for remote job submission, proofing, collaboration, approvals and workflow automation. The software tracks uploads, approvals, comments and more for accurate billing and better job management.

T/R Systems walked customers through an introduction to Digital StoreFront Express, a web-based job submission solution. Based on T/R Systems' Digital StoreFront, Digital StoreFront Express is an entry level, web-based solution that runs independently of the MicroPress document production server but is fully compatible with and can reside on the DX and MX platforms of the MicroPress X Series. Standard features of Digital StoreFront Express include Print Messenger, online PDF preview, job ticketing, Web interface and integration to the MicroPress X Series or IKON PowerPRESS.

Folding, Stitching & Binding

New at the Standard booth was the Standard Horizon PF-P330 automated suction-feed folder. Its rotary pulse vacuum feed system provides mark-free feeding on a range of stocks, including laser and coated sheets. The noise level is reduced due to its advanced vacuum pump system. The PF-P330 can handle four paper sizes with push-button setup, and can fold up to 14,400 letter-sized sheets per hour.

Baum had several new products on display, including the Pony II friction-feed, floor-model paper folder. It can fold up to 30,000 sheets per hour. Sheets can be up to 11˝ long and can be folded into letter, half, double-parallel or Z-fold configurations.

The company also showed off the new BaumBinder 1500, a perfect binder capable of 1,500 cycles per hour and book thicknesses up to 1.77˝. The Robofeeder was also new. It feeds sets into a booklet maker from a 1,300-sheet bin.

A.B.Dick introduced the Watkiss Auto SpineMaster. It gives stitched booklets the appearance of perfect binding by producing a square spine. It processes up to 1,400 booklets per hour with a single pass, and is adjustable for thicknesses up to 1⁄4˝. Booklet sizes range from 31⁄2x43⁄4˝ to 91⁄2x133⁄4˝.

New at the Spiel Associates booth was the Sterling Digibinder, an automated perfect binder. The book size is entered on the keypad and the pneumatic clamp adjusts for thickness. The blade notches and roughs the spine for deeper glue penetration and a stronger book. Two glue rollers ensure an even glue application. Users can bind up to 360 books per hour up to 11⁄2˝ thick.

James Burn International introduced the PB3300 Electric Tabletop Wire-O Finisher, a punch and bind machine that finishes documents from two to 210 sheets. The punch handles up to 25 sheets per lift. Another product, the new Semi-Automatic Wire-O Binder, handles 500 to 1,000 books per hour. Automatic functions cut, feed and position the wire for insertion. A closing unit accurately positions the document.

ISP Stitching & Bindery Products said its M-2000 stitching head has been a hot seller in recent months. The replacement head, with hardened steel parts for extended life, has been optimized to reduce operating forces. Its magnetic rotator has no moving parts to bind or jam.

Collating, Punching, Wrapping

GBR Systems showed off a brand new feeder/collector, the FPF 35. The new model collates up to 35 20-lb. flat sheets at a time at 40,000 sheets per hour. Using touch-screen controls, operators can handle line code and bar code job setups and recalls. Additionally, the FPF 35 boasts continuous loading.

GBC showed the Fusion Punch II in-line punching system, validated for color output. It handles a variety of stocks, including slick and lighter stocks. The device can be configured to take up output directly from a Xerox DocuColor and offers an offset stacker that prepares each document for further finishing.

The new BS Multi 450/750 from MBO America offers automatic cutting, hole-punching and perforating, and can work in-line or stand alone. The company's new Pick & Place tip-on machine allows users to stick a variety of three-dimensional objects (e.g. cards, coins, CDs) onto a passing substrate at up to 20,000 products per hour.

The 218 Bobcat tabletop perforator from Rosback Co. is a new device that can handle a variety of perforating styles at speeds up to 15,000 feet per hour. It can perforate, score, micro perf and slit, and has a lateral guide adjustment.

Böwe Bell & Howell was eager to walk its customers through the DemandWorks Compact Polywrapping System, which handles 8,000 pieces per hour. The company says the new machine is priced 40 percent lower than comparable devices and offers an internal film unwinder, a compact, heavy-duty shuttle feeder and heavy-duty rotary feeders with double-sheet and misfeed detectors. The DemandWorks system comes with a touch-screen interface.

Laminating

Banner American Products was excited to show its new Entry 4500 laminating/mounting machine. The device can mount, laminate and encapsulate output from 36˝, 42˝ and 44˝ ink-jet printers. To make the laminator more affordable, Banner installed one heat control instead of two and removed the slitter and sliding cutoff. Still, the 4500 boasts top and bottom heat, variable speed, a forward/reverse switch, a clear polycarbonate safety shield and more.

D&K Group showcased the System 2760, a 27˝-wide laminator that runs at 60 feet per minute. It has a compact, easy loading feeder, one-sided laminator and an automatic sheet separator. D&K also showed off its Expression Professional 42˝ laminator, which can accommodate substrates up to 1⁄4˝ thick. It features variable speed, heated rollers and a pressure sensitive rewind.

GBC showed a new scuff-free polypropylene film for one-sided lamination. Intended for book covers and dust jackets, the film has a hardcoat, matte surface that has low reflective properties. Another film, the GBC HI-TAC LAY-FLAT Film, was designed to eliminate curl and provide adhesion to color copies and prints from print engines using fuser oils.

Mailing Performance

On the envelope imaging end, Rena Systems showed its XPS-90 and XPS-80 tabletop/console ink-jet addressers. Both systems handle a maximum of 34,000 post cards per hour (26,000 envelopes per hour) at 150/200 dpi; at slower speeds 600 dpi is possible. The XPS-90 has an automatic cartridge maintenance system that features digital robotic positioning, an integrated cleaning unit and an integrated capping station. The XPS-90 also offers a 3˝ print area, fixed-head design, a synchronized friction feeder, a tri-channel Accutrak high-pressure vacuum transport system and precision height adjustment.

Videojet showed its PrintPro digital printing system, which can be configured with nine 2˝ print heads to produce a print band of 19x18˝. Each print head can print a different color. The printer can print more than 50,000 mail pieces per hour with inline automatic mail sorting. It uses fast-drying inks and prints on an array of substrates, including plastics, coated stocks and varnished surfaces.

Ink And Paper

Mohawk Paper Mills debuted its Mohawk Color Copy paper, designed exclusively for use with digital printing devices. The company showed four products—Color Copy Premium, Color Copy 96, Color Copy 100% Recycled and Color Copy Gloss—that featured Mohawk's new Digital Imaging Surface, which creates an even, uniform, smooth paper with improved toner adhesion for better color copies. The papers were demonstrated on Canon's CLC 3900+ printer. The Color Copy Premium line offers 100 brightness, a feature the company says is so far unavailable for any digital paper.

Each morning, reps from Massachusetts-based InteliCoat Technologies rolled out a full range of Magic brand products designed specifically for the Epson water-based piezo ink-jet printers. The product line included products engineered for producing durable fine art, high-resolution photorealistic images, trade show displays, indoor and outdoor signage, vehicle graphics digital wall coverings and murals. InteliCoat also introduced PTRANSFER, an ink-jet image transfer media. Package prototypes can be printed on ink-jet printers, then transferred to packaging substrates.

Flint Ink presented ARROWMAX 1000 inks, the company's newest stay-open system, specially formulated for use in sheetfed printing applications. Also, Flint's DURACURE UV-curable inks made their debut at the show. The high-performance ink system is formulated specifically for use on a variety of non-porous substrates including plastics, films, laminated boards, and foils. The company also showcased its OPTIMISER Ink Dispensing System.

Printing professionals from around the globe swarmed into the McCormick Center in Chicago for this year's Graph Expo and Converting Expo.