Short runs that pay off

 
Printing At its Open House 2007, Heidelberg Switzerland presented how the offset printing process can also economically master short runs in high-quality design. 
Heidelberg Switzerland describes cost-effectiveness, productivity and quality as the cornerstones for the success of graphic arts companies. With the three pillars of workflow integration, production technology and service, Heidelberg offers holistic solutions aimed at minimizing costs and achieving the best possible cost-effectiveness. The concept begins with the customer inquiry and extends to post-calculation for a reliable target/actual comparison. Previously decoupled processes thus mutate into an integrated, cohesive system which, in addition to its purpose of producing printed matter, takes on the role of an orientation and management tool for the strategic orientation of the company and for securing its future. Despite the good economic situation at the moment, cost pressure in the printing industry remains. Print shops must therefore work towards reducing the large cost blocks in the production chain. At the same time, it is important to tap into niche markets, create additional added value within the company and offer customers added value.
Approaches to minimizing makeready timesThe degree of efficiency, productivity and quality that the offset process is capable of achieving, even in the lower print run range, was demonstrated by Heidelberg Switzerland at Open House 2007 with a specific job. A brochure with works by British artist Heather Bishop went through all stages from plate exposure to the perfect bound product. The work was produced in several sheets using 90, 150, 250 and 300 g/m2 papers.
In the offset printing process, register and ink feed are the two setting variables with the greatest impact on productivity. Heidelberg is pursuing two different approaches to minimizing the time from press start-up to production and the associated paper savings: The Inpress Controll inline measuring and control system was developed for presses with conventional ink control via ink zones. The second approach is called Anicolor with the zoneless short inking unit. Both solutions celebrated their Swiss premiere in Bern.
Efficient short runsInpress Controll was in operation in Berne on a Speedmaster CD 74-5+LX of the 18,000-unit generation. The measuring system, which is located in the last inking unit, really comes into its own during the critical phase of register and color setup. While the manual measuring process outside the press requires repeated stopping and starting, Inpress Controll adjusts the ink feed and circumferential, lateral and diagonal register fully automatically in a continuous and rapidly rising curve.
In practice, makeready times are reduced by half. Massively shorter makeready times and a significantly reduced number of start-up sheets allow the production of short runs of 100 copies or more with Anicolor short inking unit technology. The Speedmastser SM 52-5+L Anicolor, which has been in production at Fotorotar AG for several months, proves that the good economic and quality results do not require "clean room conditions". "Printing costs are reduced by 30 percent for runs of less than 1000 copies," confirms Commercial Director Jürg Konrad, adding: "Thanks to shorter makeready times and low waste, even very short runs of 50 to 60 copies now pay off."
Solutions for postpress operationsThe KAMA ProCut 74 from Heidelberg is an automatic embossing and die-cutting machine whose applications make it ideal for use in commercial print shops. In addition to punching, creasing, perforating, hot and cold stamping foil printing and blind embossing, the system is also suitable for hot-cutting processes (punching plastic and foils with heated tools). The option for hologram applications is also interesting. Just how quickly the KAMA ProCut 74 can be converted was demonstrated in Bern with a changeover from hot stamping foil printing to a die with contour stamping and blind embossing.
Heidelberg Switzerland also offers a comprehensive range of finishing solutions. The automatically convertible Stahlfolder TH 66/6-66/4 folding machine was used to demonstrate how the system can be converted from a simple cross-fold to a gatefold in the shortest possible time. The Polar 92 XT high-speed cutter operated via touch screen and three modular collating machines completed the impressive presentation in Berne.
 
Sabine Flaxman