Offset Presses Medium & Small Have It All

Large-press automation is now available on almost every model of medium- and small-format offset press.

By Chris Bauer

When it comes to automation, small- and medium-format sheetfed presses (up to 23x29˝) have just as many bells and whistles as the large presses—but for a lot less money.

"The main features required by today's press buyer [are based on] automation," notes Mike Dighton, vice president of Hamada of America. "Auto plate loading, blanket washers, color consoles, including CIP3/4, are almost always asked for by our customers. The automation carries into prepress, as well."

Hamada's new Impulse 452P is a 14x20˝ perfector. The Impulse runs at 13,000 iph and will perfect at 12,000 iph. Standard features include a color console with remote running register, ink sweep and on-the-fly cylinder cocking. Semi-automatic plate mounting, vacuum tape register board and many other time-saving features are also standard equipment.

"Automation and higher quality are the trends," agrees Ken Newton, senior vice president and COO at A.B.Dick. The company's 4995A-ICS with ink control system offers the benefits of a four-tower portrait press for in-plants looking to step up to four-color process work. Digitally compatible with CTP systems, this automated press, with a maximum sheet size of 13.4x17.75˝, reportedly increases short- and long-run productivity and accommodates polyester or metal plates.

The smaller-format market will continue to play an important role in the overall production chain for printing, declares Chris Curran, Heidelberg's manager of marketing communications.

"CTP systems sized around the [small] format continue to evolve and get more affordable, both in terms of hardware and plate materials," he remarks. "Increased use of digital information, better networking, and machines with high automation will let printers with this equipment compete and win jobs with low run lengths. And with the high speed of these smaller presses, and productivity of options like perfecting and in-line coating, they can still be competitive with the larger presses at surprisingly long runs."

The Heidelberg Speedmaster CD 74 can be supplied with four, five, six and eight printing units and a coating system in both the standard and UV versions. These models have double-width impression cylinders and air transfer to ensure the reliable transport of a range of printing stock. The preset feeder with central suction tape, high-speed inking units, Alcolor Vario dampening system and the CP2000 Center are further key features of this series.

New Three-quarter Format

The big news in smaller offset presses, according to Christian Cerfontaine, director of marketing for MAN Roland, is what he calls the 3⁄4 format—a half-size machine that's been increased to a six-up configuration.

"That allows printers to get 50 percent more productivity—in the form of two extra pages—on every impression they make," he says. "MAN Roland literally invented this format, and we continue to be the leader in this growing segment. For instance, we now offer two completely unique 29˝ press lines—the ROLAND 300 and the ROLAND 500. Each offers a set of special features and capabilities designed to help printers go after and win new printing projects."

Because increasingly more printers realize the benefit of integrated automation, increasingly more presses are ordered with options that improve quality control and allow "printing by the numbers," Cerfontaine observes.

"For example, Computer Controlled Inking (CCI), which provides closed-loop color control, is an option that is ordered with more than 80 percent of our presses. Our automation features are in such high demand because we can offer a clear return on investment for almost any option we offer. The result: our customers gladly invest 10 percent more up front because they realize it gives them a 20-percent potential productivity increase on every job they print."

With a six-up format, the ROLAND 300 is equipped with perfecting and offers a top speed of 16,000 sph. Its PECOM operating system connects directly to prepress, automatically setting the press' ink fountains, ink rollers, size, folder, sheeter, angle bars and slitters. This cuts makeready times tremendously.

University of Oklahoma Printing Services recently installed a five-color MAN Roland 305 double perfector, and Administrator John Sarantakos says the six-page, 23x29˝ press has opened up new opportunities for the 72-employee in-plant.

"The speed and the makeready times...are going to let us be much more competitive than we were," he says.

Keeping It Simple

Simplified processes and easier-to-operate equipment that can produce high-quality printing day in and out are what Eric Frank, vice president of marketing for KBA North America, sees for the future of the small- and medium-format sheetfed press market.

"Manufacturers also need to increase overall training on everything—from the product to the surrounding components that influence it," Frank says.

To that end, he points to the KBA Karat press as a good option—especially in a market where qualified labor is difficult to find. As a result, KBA offers a 20x29˝ model, a dedicated direct imaging press. The 74 Karat can image plates and do a complete makeready in just 15 minutes and then deliver the first sellable sheet in under 10 sheets.

At Graph Expo, KBA North America announced the new Genius 52 sheetfed offset press. The 20˝ keyless, waterless press is designed for in-plants. The maximum sheet size is 20-1⁄2x13˝, available with four or five printing units.

Don Trytten of xpedx/Import Group feels manufacturing is headed toward increased productivity—which requires more productive and versatile equipment.

"We are also seeing these presses being considered in areas that previously were reserved for only larger machines, such as labels, packaging and thicker paper stock printing."

His company offers the Ryobi 750 series of B2-size multi-color offset presses. The 750 series boasts advanced automation, a digital quality-control system and CIP4 prepress compatibility.

All of the quality and automation demands made by printers are for good reason, points out Ernie Bardocz, president of Grafitec America. Quality and color sells.

"The savvy print purchaser and product marketer understands this and demands that they get the most for their print dollar," Bardocz explains. "Color allows printing to compete with all other advertising media."

Grafitec America recently introduced the 29˝ Polly Prestige 74, with semi-automatic plate changing and automatic plate cocking. The 19-roller inking train and 23-zone ink fountain react rapidly to ink adjustments and provide stability of ink feed. The press is rated at 13,000 sph.

"The small- and medium-format sheetfed press is not just an entry-level machine any more—not just used to fit a niche," stresses Randy Siver, business development manger, sheetfed presses, for Mitsubishi Lithographic Presses. "Some printers with 40˝ presses are supplementing what they do with half-size machines. Those presses are fully automated—just as automated as anything else we sell."

In addition, Siver reveals that the ability to connect to JDF and CIP4 is now a key requirement.

The Mitsubishi Diamond 1000LS is a fit for printers looking to extend their capabilities on a range of multi-color products. This 28˝ press offers speeds up to 15,000 sph. Capable of producing direct mail work, publications, sales collateral, point-of-purchase displays and software packaging, the Diamond 1000LS opens up opportunities in the mid-size format.

In today's competitive market, minimal makeready waste is mandatory, adds Wally Chmura, Komori America's national accounts product manager.

"The margins on every piece a printer produces are getting smaller, and run lengths are getting shorter," he says. "Printers need to maximize the performance of their press by utilizing all of the automation available."

Komori America recently debuted the redesigned Lithrone 28P half-size perfector. It features improved inking and dampening systems for reduced ghosting and better print quality. Sheet reversing is handled by a high-performance mechanism employing Komori's double diameter, three-cylinder configuration. The sheetfed press runs at 15,000 sph in straight and perfecting mode, and can print on substrates from onion skin to 18-pt. board for maximum versatility.

Also on the equipment front, Sakurai USA has announced the expansion of its 26˝ press series. The 556SI, an automatic, five-color press, is available with a coating unit and extended delivery. The compact design and a maximum running speed of 15,000 iph increases productivity while reducing makeready times. Sakurai's automatic plate changers can remove and load a plate in less than one minute.

Another option, available from Akiyama, is the Bestech P28. It offers speeds of up to 13,000 sph and a maximum sheet size of 20-1⁄2x28-3⁄8˝. The Akiyama ACC (Akiyama Color Control) console provides the operator with precise ink controls, lateral/circumferential register, storage of job information and interface with other systems. Bestech also offers the versatility and efficiency of aqueous or UV coating.