Print 01 Technology Takes A Stand

Print 01 featured numerous innovations in prepress, offset and bindery technologies. Find out all about them in part two of our show report.

&002;by Bob Neubauer

Walking the show floor at Print 01 was a printer's dream. Presses were churning out color posters, software was being demonstrated on large screens for small crowds, books were being folded, stitched and trimmed—wherever you looked, something was happening.

Though the September 11 attacks brought the show to a halt, show management said about 66,300 people attended overall. Vendors reported a number of sales. Heidelberg's NexPress subsidiary sold more than 70 NexPress 2100 presses, part of Heidelberg's $345 million in orders at the show. MAN Roland reported $20 million in sales. Indigo said it sold at least one of most of the products it was showing. Baum said it sold more than 30 pieces of equipment.

In part two of our Print 01 report, learn more about the technologies on display at the show.

Offset Printing

The short-run color market is booming. To help it flourish, A.B.Dick brought its QP25/QP25II offset presses to the show. Their Constant Contact Register System allows close register printing from a direct feed press. A micro-set ink fountain means easy setup of variable ink coverage for first-time jobs, and repeat printing with little or no fountain setup. An ink cleanup attachment reduces ink roller cleaning to 90 seconds. A.B.Dick also debuted the E-Ink system for the QP25. E-Ink lets operators manually set ink keys on a non-automated ink fountain.

Hamada of America introduced a new heavy-weight press—the Impulse 266/266P. It has a maximum sheet size of 20x26˝, producing up to 12,000 iph. Features include auto-plate loader and plate cylinder cocking on-the-fly, plus optional perfecting. Perfector changeover takes only 59 seconds from two-over-zero to one-over-one jobs, or vice versa. The press has continuous dampening and 18 ink rollers, including four different diameter form rollers.

Hamada also showed the new two-color B252, four-color B452 and five-color B552 presses. Features include Easy Plate Setter, blanket washers, running register, swing gripper in-feed, and landscape feeding.

Heidelberg unveiled the Printmaster PM 74 four-color press, with options including a remote ink control and semi-automatic sheet reversing device. Other features include the EasyPlate clamping device with automatic positioning run and new control panels with clear user guidance. It prints 12,000 sph.

Print 01 marked the North American debut of the Komori Lithrone 40SP super perfector press, which combines sheetfed quality with web-fed productivity. The design of the Lithrone 40 SP allows for one-pass, double-sided printing. Because sheets are not reversed, multi-color printing yields unmatched front-to-back registration accuracy. The space-saving Lithrone 40 SP is available in four-, five- and six-color configurations and comes with automatic plate changing on top and bottom units and automatic paper size and thickness adjustments.

MAN Roland was printing 4/2 perfecting jobs at its booth using the 15,000-sph MAN Roland 300 commercial perfecting press. This high-speed, short makeready press offers the 23-1⁄4x29-1⁄8˝ format, which allows a substantial boost in productivity over smaller 20x29˝ presses.

Muller Martini showed off its A-74 variable web press. Designed for mid-range sheetfed printers, it can print 300,000 sph and can be reconfigured to different sizes in minutes. It is easy to operate, usually requiring just two employees. The A-74 allows sheetfed printers to handle jobs more economically, leading to reduced overhead, increased productivity and profitability.

Sakurai USA introduced its new 26˝ press series. The 466SIP Series is an automatic, four-color convertible perfector press, which features a compact design and maximum running speed of 15,000 iph. Sakurai re-engineered this model from the ground up, incorporating automation and profit-enhancing features.

At the xpedx Import Group booth, the Ryobi Model 684 P was on display. This 20x27˝ press is a convertible perfector based on the 680 series press. The change-over between straight printing and perfecting is done in about one minute. The maximum printing speed is 15,000 sph.

For envelope printers, Halm showed its Envelopemaster Series EM5315, a four-color process perfector that prints 30,000 envelopes per hour. Its microprocessor motor control eliminates electromechanical problems. Chillers are standard and the press has a retractable table that allows easy access to the perfecting unit. Its cold UV system lets you ship envelopes as soon as they are printed.

Elsewhere, FAE-USA exhibited its ColorPrint V52 narrow web press and its 14x20˝ Plus Print E1 automated sheetfed press.

As an add-on, Townsend Industries displayed the Anniversary Edition T-51 for A.B.Dick 9800/9900 series presses, featuring total plate positioning on the fly. All vertical, horizontal and twist adjustments are made with the press running, resulting in reduced makeready time, precise registration and increased productivity.

Proofing

Agfa introduced a duplex digital proofing system, the SherpaMatic. The 43˝ system has a built-in alignment mechanism to automatically turn paper over in exact alignment for precise, unattended two-sided proofing. It prints at 720x720 dpi and uses six colors. Its sensor system prevents the media from telescoping.

Also new was the Grand Sherpa, with 1,440x1,440 dpi resolution, variable dot size, eight-color capacity and a two-minute print speed. It's available in 50˝, 64˝ and 87˝ sizes.

Hewlett-Packard introduced a trio of graphics printers: the HP Designjet 10ps, 20ps and 50ps. The printers allow designers and printers to share files over the Internet and print them with the assurance of consistent color. They boast six-color printing at 2,400x1,200 dpi. An 11x17˝ full-bleed glossy image prints in four minutes.

Imation introduced proofing technology that provides accurate CMYK colors on a monitor. The Matchprint Virtual Proofing System features proprietary CMYK proofing software and high-end CRT monitors. Special calibration methods accurately render color consistently across multiple monitors. This, coupled with a suite of Web-based tools from RealTimeImage, enables users to collaborate with colleagues and clients.

Also new from Imation: the Matchprint Digital Halftone DtP proofing system. It images digital halftone proofs onto four different stocks.

Kodak Polychrome Graphics unveiled its First Check Desktop Proofing System. It prints at 10˝ per second with a thermal dry proofing technology using pigmented ribbons and can print 600x600 dpi. The maximum image area is 12.69x17.95˝. The proofer prints to a variety of substrates, and colors do not smudge.

For proofing without the paper, Océ Printing Systems USA introduced the TrueProof electronic viewing system, which allows dot-to-dot comparisons of pages exactly as they would print on high-end digital printers. TrueProof lets users verify that pages will run correctly when ported to different platforms, providing an accurate representation of how fonts and other resources will appear in print.

E-commerce

There are not many e-commerce providers left compared to the plethora just two years ago at Graph Expo. One of the survivors, Printable Technologies, recently acquired Printplanet.com, after buying Collabria not long before. At Print 01, Printable announced PrintSite Web Builder, a tool that simplifies Web site creation. Printable has replaced its existing Web site building application with the Trellix browser-based platform, Trellix Web Express, and will provide customized designs, services and content.

Elsewhere, printChannel.com launched its print I/O procurement solution. Features include online content proofing, inventory management, multi-supplier order routing, output-ready PDF imposition and order activity reporting. printChannel.com teamed up with Indigo to show how its online print procurement system can work with Indigo's digital presses to control every phase of the print production cycle, from ordering and scheduling to proofing and delivery.

RIPs

Fujifilm's Celebrant Extreme V4.2 is an upgrade from the CelebraNT RIP V3.21. Developed in collaboration with Adobe, Celebrant Extreme uses the latest Adobe PDF and trapping modules, and encompasses a suite of productivity-enhancing options. It enables late-page editing and replacement without re-RIPing an entire job, in addition to providing remote client access to RIP setup and full OPI compliance.

RIPit showed its new OpenRIP 2000, featuring the Adobe PostScript 3 Interpreter. It drives a variety of imagesetters, plotters and color proofing devices. OpenRIP 2000 makes it easy to RIP and output PostScript, EPS and PDF files from Mac and PC applications. It includes such high-end features such as monitor preview, Agfa balanced screening, custom plate templates with page information and color bars, linearization and dot gain compensation, advanced color proofing and custom job queue editor with drag-and-drop.

Platesetters

Escher-Grad Technologies demonstrated its ability to image both photopolymer and silver-based plates on a single computer-to-plate system, the Cobalt-8. Both plate types were imaged at 2,540 dpi/200 lpi, processed and printed. The Cobalt-8 violet CtP system can image a range of plate sizes and thicknesses; from two-up (GTO) formats to full eight-up plates (32x42˝). It can be operated in bright yellow safe light environments and runs from a standard office power outlet.

Consumables

Flint Ink announced three additions to its Arrowjet line of DOD inks. The trio comprises water-based, solvent-based and UV curable inks—Arrowjet UV DOD 3000 series, SV DOD 2270 series and AQ DOD 1200 series. Each of the performance-driven inks is intended for industrial piezo DOD print heads and is specifically engineered for wide-format printing, direct mail/addressing, packaging and other emerging digital applications.

Kodak Polychrome Graphics introduced its Kodak Premier Recording Film, with improved image quality, faster processing and lower chemistry usage. The film incorporates a new Enhanced Booster Technology (EBT) that reduces the process cycle time by as much as 33 percent. EBT is said to ensure the development of all exposed silver-halide crystals, thereby yielding a high-density image with superior edge definition.

Kodak Polychrome also introduced Thermal Gold Printing Plates, which require less energy from the laser.

A different type of film came from GBC Films Group, which introduced a new thermal laminating film called the 8800 GBC Diamond Film. It is a high-quality, heat-activated film used on graphic applications that require a notable finish. Available in a gloss and matte finish with a 1.2mil thickness, the film boasts excellent foil stamping, folding, gluing, cutting, separating and diecutting properties. The film is also scuff- and scratch-resistant.

Stitching, Binding

Baum introduced the BaumBinder 300 perfect binder. Its automatic, self-centering clamping station comes with an automatic opening and closing mechanism, a jogging system and three timed programs for cover nipping. Binding is carried out either with hot melt or dispersion gluing. Easy exchange of glue tanks reduces setup times. Glue is applied via a rotating drum equipped with an adjustable glue-metering device. The BaumBinder 300 processes individual sheets and folded sheets with a book thickness of up to 1.58˝ with and without cover.

Best Graphics showed the Best Osako 368AS AutoSet saddle stitcher, boasting fast, easy setup. It features a touch screen control unit that controls key stitcher operations and allows chain timing and stitch head positioning to be set in 15 seconds. The Best Osako 368 family of 12,000/hour saddle stitchers includes the 368 High Folio design, featuring versatile Tilt-Back Feeders, the automated 368AS High/Lo Folio, for maximum production, and the 368MP Moveable Pocket design, ideal for long-run publishing.

The Brackett TM series of high-speed, adhesive binding equipment was on display, boasting quick makeready, operator-friendly interfaces, reduced downtime and heavy-duty construction. Binders are available with 16, 18 and 21 clamps, which can be configured to fit available factory floor space. Production speeds of up to 10,000 units per hour are available depending on the model. All binders feature TSK's computer automation system, which allows makeready and on-the-fly adjustments to be made centrally at each station or simultaneously from a job title data bank.

Duplo USA showed its System 4000, a complete finishing solution designed to maximize productivity. The heavy-duty System 4000 consists of up to six collator towers (60 bins), a dynamic bookletmaker, face trimmer and precision stacker. Together the system produces up to 4,200 booklets or 10,000 collated sets per hour. It can handle a variety of paper types, sizes and weights. Setup and changeover are automatic, with no manual adjustments required. Eight programmable settings allow operators to store frequently used jobs and change from one to another by pushing a button.

Graphic Whizard had its floor model KB60-S perfect book binder on hand. The German-engineered product offers many features not usually available on machines in its price range, like slitting knives for notching that provide better glue adhesion, spine preheating and side gluing. Also at the show was the PL60 bookletmaker, a quiet, compact device that provides automatic stapling and folding of up to 11x17˝ paper. Finished booklet sizes are 8-1⁄2x11˝ and 5-1⁄2x8-1⁄2˝

Océ Printing Systems announced general availability of its new Digi-Stitcher system for in-line finishing of print-on-demand applications. The finishing unit keeps pace with the fastest of Océ's DemandStream and PageStream systems, even the PageStream 1060 with an outspeed of 1,060 images per minute. The system delivers up to 8,220 saddle-stitched books per hour.

Océ-USA also showed some new binding equipment, the Océ DFS10. It is an on-demand cover binder that binds up to 240 pages with a perfect bound cover. The two cover input trays can be refilled on the fly. The DFS10 runs at the full production speed of the 6,000-pph DPS400 digital printing system.

The Rosback 318 'Lynx' four- or eight-pocket SaddleBinder automatically collates, saddle stitches and three-side trims—delivering professionally finished books at production speeds between 3,200 to 4,200 bph. The newly featured 'Lynx' 724 is a heavy-duty, all ball-bearing, four-pocket feeder that handles individual signatures or pre-inserted signatures. The stations hold approximately 8˝ to 9˝ of stock that can be loaded on the run. It handles multiple signatures ranging from four to 32 pages for a finished book of approximately 120 pages (3⁄8˝).

Standard Finishing Systems introduced the Standard Horizon CABS (computer aided binding system) 5000. This perfect binding system includes the MG-60H gatherer, the SB-15 perfect binder and the HT-100 three-knife trimmer. It boasts quick setup and advanced control technology. The SB-15 binder cycles up to 5,200 books per hour, and the HT-100 features auto setup and operation through a touch-screen color console.

A unique binding technology was on display at the Unibind booth. The Unibind S 425, like the S 625 and S 225, has no moving parts. It consists of a heating element and a row of metal arches. The user places loose pages into a cover and then places the "book" between the arch supports. The spine is immediately heated, softening the glue. A green light tells the operator to place the book on a drying rack. Each book takes just 90 seconds, and many books can be bound consecutively, with just three seconds of setup time.

Spiral Binding

The latest spiral binding technology was on display at the Gateway Bookbinding Systems booth. The company unveiled the Plastikoil Concept III. It combines the Plastikoil New Concept Former with the PBS 3000 Auto Coil Inserter. Plastic spiral binding is formed in the diameter and length needed then immediately conveyed into position on the PBS 3000 Auto Inserter, with the operator simply activating the foot pedal to complete the coil insertion into the book with a simultaneous cut and bend of both coil ends.

Spiel Associates also had coil binding on display. The new Sterling Coilmaster II plastic binding system creates coil from plastic filament and automatically inserts it into the book from the first hole onwards. It then cuts and crimps automatically. This machine abolishes the need to store plastic coil. The cost savings of producing 12˝ lengths of coil from filament is over 50 percent. The Coilmaster II allows the speedy binding of books with healthy margins of up to 3⁄16˝. You can bind books automatically at speeds of up to 700 books per hour.

Spiral Binding Co. offered its new AnyBind multiple punch and bind machine, which can manually punch and bind both Double-O wire and plastic comb binding, all in one unit. This machine can bind up to 130 sheets (9⁄16˝) for wire binding and up to 150 sheets (5⁄8˝) for plastic binding. AnyBind punches 32 square holes for 3:1 pitch wire and 19 rectangular holes for plastic comb, and can also punch A4 size. One handle does it all, including reopening the closed wire binding if necessary.

Cutting, Folding

Baum unveiled its 15GSL floor-model folding machine with GSL automatic fold roller tensioning and the new HDN gear drive system. Maintenance free, the gear-drive design produces a constant drive without slippage and reduces gear noise to a whisper. Spring tensioning automatically adjusts for the paper. The Baum 15GSL handles 8-1⁄2x11˝ to 14x20˝ sheet sizes to perform letter, Z, double parallel, half and other parallel folds at up to 8,200˝ per minute.

From Challenge Machinery came the new CMT 330 digitally controlled three-knife trimmer. It trims soft cover, perfect-bound books at a rate exceeding 400 books per hour. Designed for on-demand applications, it can be used in-line with most new perfect binders, or off-line in a manual-feed mode. Trimmed book sizes range from 4x6˝ to 9x12˝, and up to 2˝ thick.

For cutting small dimensions precisely, quickly and reliably, MBM showed the new, improved Triumph 5550-EP programmable, hydraulic cutter. Its adjustable clamping pressure provides mark-free cutting of carbonless and specialty papers, even cast-coated stock. Its hydraulic clamping pressure is adjustable between 446 and 2,454 pounds, while the electronically driven backgauge adjusts at 1.65˝ per second. The 5550-EP cuts 18 to 26 units per minute, cuts paper widths up to 21-21⁄32˝ and stacks up to 3-5⁄8˝ high.

For smaller-format folding, GBR Systems introduced the Mathias Bäuerle Multimaster CAS 35 computer-controlled folder. Most fold settings are possible by just touching a button. The fold plate stops automatically to move to the correct position according to the computer data entered, so manual settings of fold length are not required. The delivery rollers are also positioned automatically. The CAS 35 is equipped with two fold plates for the production of all standard parallel folds. Cross folds can be made too, because the bottom-feed, top-loading air feeder also separates pre-folded sheets.

Graphic Whizard showed its new FoldMaster 250 folding, perforating and scoring system. It can handle 25,000 sheets per hour, with sheet widths as wide as17.5˝. It boasts entrance and exit perf and score capabilities, and lets you score 11x17˝ sheets on the same machine that you fold on.

MBO displayed its Perfection folder with Rapidset, which enables more automation via motorized buckle plates; a microprocessor displays full setup instructions, such as slitter shafts and sidelays. Rapidset is preprogrammed with 65 standard folding impositions and is able to store an additional 250 programs. Operator setup time is minimized.

Also used on the Perfection marble-less folder was the Navigator, digitally controlled technology that unites and integrates a new operating system in concert with production monitoring and assorted machine controls. Navigator technology with a 15˝ touch screen has a menu of selections to optimize efficiency.

Standard Finishing Systems introduced a floor-model folder, the Standard Horizon AFC-504AKT. It includes advanced setup automation through a user-friendly color touch screen control panel that displays fold formats and sheet sizes for easy selection. Up to 50 different job settings can be stored in memory, and automated setup can be accomplished in as little as 15 seconds.

To control its folders, Heidelberg introduced the ACC 2.4 digital controller. It controls the peripheral devices used for gate folding, gluing and timed perforations. It simultaneously controls two gatefold buckle plates or two spot gluing guns.

Feeders

The new Multi-Flo envelope feeder from A.B.Dick is compatible with all A.B.Dick models (including the PowerPro 34S), plus with other manufacturers (Adast, Hamada, Komori, Ryobi, Shinohara and Toko) since there are no mechanical or electrical hook-ups. Designed for high-volume applications, it holds 500 envelopes in a feeder and has a five-foot variable-speed receiving conveyor. Some press models running this unit feed at speeds up to 15,000 iph.

Spartanics introduced the Spartanics M96 Auto Sheet Feeder at Print 01. It provides new flexibility and automation capabilities to printers using Spartanics' M500 Die Cutting Systems. The M96 Auto Sheet Feeder uses sophisticated optical sensor technology to automatically feed sheets up to 29x30˝ into the automated Spartanics M500 Decorated Material Die Cutting Systems. This helps printers expand into large-format jobs that require more versatile die cut tooling.

On the heels of Hunkeler's announcement that Standard Finishing Systems will now be the sole agent for all its products in the U.S., Standard showed off an intelligent feeding and offset stacking line for continuous printers. It comprises the Standard Hunkeler UW4 Unwinder, CS4 pinless cutter/stacker, DD4 Document Delivery Module, the Standard Horizon VAC-100 collator, ST-40 stacker and SPF/FC-20A automated bookletmaker.

Laminators

Banner American Products showed some of its laminators at Print 01, including the OmniSystem 2700. Comprising a precision feeder, a laminator and a microprocessor-controlled trimmer, it is designed to laminate manuals, directories, books, menus and more. Set on casters, the system can be easily moved or pushed out of the way when not being used. The in-line track system keeps the feeder, laminator and trimmer completely square with each other.

Another laminator on display was the Seal Image 6500 XT, from Hunt Corp., capable of mounting, laminating, encapsulation and low temperature transfer. It has swing-out auto grip shafts for easy material handling. It can do single-pass electrostatic transfer and lamination. A rear-heated top roller allows greater speed and efficiency.

Other Products

The Marconi Data Systems Videojet PrintPro is a non-contact system capable of printing fixed or variable text, logos, bar codes or graphics on direct mail, catalogs, magazines, business forms, tickets, tags, labels, mailers, plastic cards or specialty printing. Each PrintPro unit contains two print heads and two ink management systems, enabling one PrintPro unit to print two spot colors from one cabinet, or four spot colors from one system.

Designed for high-speed batch counting, the Streamfeeder XT Starwheel Dropper attains feed rates up to 900 pieces per minute. Designed for use in single-feeder applications and as a collator system component, the XT Starwheel Dropper is equipped with an intelligent system control featuring a high-performance CPU. Compatible with Universal Collator Systems, this easy-to-use feeder is for any application requiring trouble-free, high speed feeding.

Graphic Whizard showed its HFS 7000 hot foil stamp system for the first time. With a maximum speed of 7,000 sph, it makes in-house foil stamping easy. It can stamp up to 10 impressions on a sheet and boasts a 12x4˝ impression area.

On Support Products' Chiller Recirculator, all controls are encased in a stainless steel cabinet for a clean appearance. Units can be supplied with air-cooled or water-cooled chilling units. The size of the cooling unit is determined by the press size. Safety devices for flow control and automatic fill and liquid level controls ensure a properly maintained system. The system automatically maintains set temperatures while supplying the press with chilled solution.

Dynaric showed the new D-2100 and D-2300 strapping machines. Capable of throughput of 50 straps per minute, the machines are designed without sharp edges to protect the user. Both machines are equipped with an internal strap dispenser, stainless steel tension roller and an automatic strap feed system.

Buhrs Americas has updated its 4000 paper and film wrapping system with redesigned guide rails, allowing easier movement of production accessories such as product guides, brushes and hold-down straps. Individual belt tensioners for quality control eject gate provide consistent tensioning, faster repairs and eliminate the need for equal-length belts. Cross seal bar improvements include new electrical connections and quick-releases for cooling tubes for easier removal and reassembly. New coiling plates improve adjustment accuracy and sealing quality.

GBC introduced the Quick Color binder, a full color, insert and seal, three-ring binder. The binders are available in either black or white, in a variety of sizes and include two pockets. Custom digitally produced artwork is inserted and sealed on the front, spine and even on the back, if desired.