Offset: the big fight back
Clearly, there has been no resting on laurels when it comes to developments in offset over the last 20 years, but because offset litho is the most prolific form of printing, it also finds itself under increasing attack, mainly from digital processes that have now matured beyond measure. The last ten years have seen the digital process go from mere photocopy colour and output standards, to a process that without doubt threatens the quality, speed and versatility of litho printing. And, digital machine manufacturers have been very quick to play any advantages they have.
But it is ‘hats off all round’ to the offset machine manufacturers who have pulled out all the stops when it comes to innovation, even totally changing the way litho actually work. All manufacturers have been concentrating on the key elements such as speed, automation and quality output, but two in particular, Heidelberg and manroland, with the Anicolor and DirectDrive respectively, have in recent times brought out new concepts that really do keep the litho press at the forefront of technology for printing’s future.
Anicolor
Heidelberg has taken the fight back to the digital manufacturers with multi-colour small format machines. Even before the implementation of the Anicolor concept, it was having some success with 10 colour SM52s, a B3 size press with perfecting. This little workhorse can be plated up in 10 minutes, (one minute per unit) and can be up and running in at 15 000 sheets an hour in perfect mode on most stocks. It is linked to Heidelberg’s own CP2000, which handles all the colour control.
But it is when the Anicolor principles are applied that real differences are seen, and this is where the fight lands directly at digital’s door. Anicolor has a format size inking from roller that applies exactly the right amount of ink to the image area on the plate. Using temperature control means that changes and adaption to colour can be almost instantaneous (within 10 to 12 sheets) which heralds in very fast make readies and 90% less start up waste. Heidelberg reckons that the Anicolor concept increases press capacity by 25%.
Customers with the Anicolor in the UK include Alderson Brothers Print Griup and Healeys of Ipswich who have installed them to tackle short run colour brochures and leaflet work, which digital printers are fighting for. The Anicolor has the advantage of being able to produce work at a much more efficient and economical rate than digital machines. Comments so far on the newly installed presses include, ‘We are achieving extremely fast make ready times and getting colour consistency right across the sheet from the first to the last’.
DirectDrive
Manroland’s DirectDrive concept first saw the light of day in April 2007. At first it sounded as if we were going to be shown ‘just another new long perfector’. How wrong we were. The DirectDrive concept is in many industry experts’ opinion, one of the most dynamic and conclusive developments in B1 technology to come along for some time.
At the demonstration in Germany was a very quiet ten colour B1 press (5 back 5) running at full tilt printing colour on both sides of the sheet. The minder then stopped the feeder, and presses a few buttons on his console. The machine then automatically made 10 plate changes, washed 10 blankets and cylinders was back on the run in less than 4.5 minutes on a completely different job.
The technology on the manroland 700 press means that a ‘normal’ B1 perfector is turned into a master of simultaneous multi tasking, which speed up the changing and make ready of jobs to such an extent that it leaves all completion in its dust – at least for now. Other plate loading on machines currently is linked to the other processes, for instance blanket washing, which means that jobs have to be done in sequence opposed to simultaneously.
Manroland states that the press will consistently deliver four minute make readies on basic change over on an eight colour 700 and in six minutes on jobs that require roller wash ups. The machine also hit the record books recently by achieving a rare world record in print with 412 plate changes whilst printing a catalogue of 1000 run, equating to a plate change every 14 minutes over a 24 hour period.
The future – challenges and threats
The offset lithographic market has no more or less to worry about than any other process and as long as innovations of the like we have seen over the last 20 years continue there is no reason that the lithographic process will not be as dominant in the next 100 years. It is the perfect low cost ways of producing print en masse, and the quality is simply the best out of all the processes. Yes, digital is nibbling away at the smaller shorter run area of business, but without that small threat, surely the dynamic and wide changes that have been made would not have happened? There is nothing wrong with a bit of competition to help you get your house in order.
One area it would be perhaps wise to watch is the ticket price of litho presses. In the demanding era we are about to enter with a recession just about to move into full swing, printers are going to find is much easier to buy lesser priced digital machines. What must be taken into account is that digital is still more expensive per sheet to produce, and its environmental credentials are yet to be truly proved.
One glimmer of hope is the packaging market, which has not been covered to any extent in this article. The rush to purchase products online is producing a whole new opportunity for packaging printing, and all the big offset manufacturers are already well down the line of producing machines that can take the packaging world by storm, complete with on line foiling and stamping, flexo units and an array of on line finishing including die cutting.
There is one threat looming that is beginning to affect the whole of the print on paper arena, and that is the one of the electronic media. We are already seeing a rash of magazines titles going online and out of print, and this should be of concern to all the processes, not just offset litho. One of the main reasons the publishers are stating fro dropping printed media, is the environmental unfriendliness of using print and paper. A combined effort from all areas of the print and paper business fraternity needs to unite and promote the power and environmentally friendliness of print, much like the National Association of Paper Merchant’s Two Sides campaign has started recently. Now is the time for unity across all of the processes in this dynamic and diverse industry.
Peter Harrison is Joint Managing Director of The Printing House Ltd of Crewe, Cheshire, UK.
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