Print At its "home game" in Augsburg, German printing press manufacturer MAN Roland focused on the supersize format.
Printing press manufacturer MAN Roland invited customers and the trade press to the plant in
Augsburg for a two-day event called "Heimspiel".
What was explained is not necessarily obvious at first glance:
Larger machines also produce short runs more economically.
To this end, the topic of XXL (super-large format) was discussed at the customer event.
in sheetfed, illustration and newspaper printing in the truest sense of the word
written in capital letters.
Misjudgement in the arc area corrected
Jens Gebel, Head of Large Format Sheetfed Printing Systems at MAN
Roland, conceded that the company's large-format sheetfed printing
errors in assessing the market and left the field open for a long time.
to a competitor. Likewise, the
Development costs underestimated. The Group, which is active in the sheetfed
is in a restructuring phase, recognizes today especially in the
trend towards larger formats and larger packaging printing.
machines. But that's not the only place where the XXL super-large format - plus
include format 7 (1,120 ¥ 1,620 mm), 7B (1,200 ¥
1.620 mm) and 8 (1.300 ¥ 1.850 mm) - makes sense. On the large print sheets
can 64
pages of DIN A4 can be printed at once, which means that XXL
also suitable for book production. The problem of the initially scarce
selection of printing plate imagesetters (CtP) and for
print finishing machines has now been largely resolved. So
today there are several suppliers of CtP imagesetters - in addition to Agfa,
Basysprint and Creo also offers the
Swiss supplier Lüscher offers corresponding systems - and there are also
corresponding folding machines (T1420 from MBO and TD 142 Topline from
Heidelberg) for folding these huge, up to a maximum of just under 2.5
square meter sheet available on the market. Also for companies that
not equipped for the further processing of XXL format sheets
are available with the last impression cylinder, which can be mounted on the last
InlineSlitter, a tool that can be used to control the arc of the
inline and with high precision into two sheet sections. This also allows
smaller folding machines can be used without sacrificing the advantages of the
XXL format (including higher productivity, less waste)
must be dispensed with. Paper manufacturers have also focused on the
large formats. From M-real, Sappi, Stora Enso and UPM
there is now a fairly good selection of papers for the XXL format
available. However, it must be added here that the
paper producers can neither offer all grades nor all grammages of a
grade. As it is well known that roll paper is cheaper than
sheet papers, MAN Roland took this opportunity to provide information about this,
that the company will launch an inline sheeter next year together with a
roll-to-sheet feeder, which also takes into account the format 8
carries. This means that roll paper can be used in sheet-fed offset printing.
72 pages from the roll
Although web printing ticks a little differently to sheetfed printing - the
Machines are not classified according to their maximum print formats (e.g.
Speedmaster 74, Rapida 74, Roland 700 = printing presses of various types
manufacturer in "50 ¥ 70 cm [net] format"), but according to the per
cylinder revolution - according to the
Sales Manager Peter Kuisle also in commercial web offset the
XXL concept makes sense. Kuisle justifies this with trends such as
Target group splitting, regionalization/localization,
Preliminary/test runs, just-in-time production and cross-media
Publishing. "If you look at these trends, the most striking ones are
the associated smaller print runs. But the
Conclusion that smaller print runs are better combined with smaller
machines is the wrong one." Why this conclusion is not
Kuisle explains that this is because larger machines in the
role area, a production with fewer signatures (one of the
print format corresponding to the web section) is permitted. Fewer signatures
mean shorter set-up times, which also leads to a significant reduction in
of waste - which the company is able to minimize with a "closed loop".
quality assurance solution with various measurement and
control systems are also supported. The XXL recipe for success
illustration printing leads to a reduction in copy costs (see
box on page 22), not least the automation of the
printing system. The possibilities range from automatic roll handling
via an automatic web infeed and plate change up to
machine diagnostic systems. The world market for commercial web offset
(24 to 72 pages), one of the leading machine suppliers in the
72-page Lithoman machine (2.06 m web width) is the world's largest
(XXL) rotation in the portfolio.
XXL concept can also be transferred to newspaper printing
In newspaper printing, the additions to the machine names are limited to the
maximum printable pages in width and size. One
2/1 press therefore has a printing cylinder size that can accommodate two
(Broadsheet)-pages wide (Broadsheet = collective term for various
newspaper formats; see issue 37, page 24) and is one page high;
A 4/2 machine can therefore produce 4 ¥ 2
sheet = 16 (broadsheet) pages - in four colors, mind you.
But although newspaper presses are already "extra-large" by nature,
MAN Roland first calls the new Colorman 6/2 newspaper press
XXL machine. Anton Hamm, Business Unit Manager Newspaper Machines, is
realize that technology does not determine the market.
"But," he explains, "the Colorman XXL manages 50 percent more
printing capacity than comparable 4/2 machines - per web with the same
speed. This allows a significantly greater output at
At the same time, less maintenance, energy and building costs
achieve." A newspaper rotation in the
past, first more options in terms of color, then a
simpler operation, followed by the desire for a more flexible
production, then the highest quality - and finally, today the
highest productivity is a priority. The current demand for a
maximum productivity, according to Hamm, were just
XXL newspaper presses in an ideal way. In demand in newspaper printing are
increasingly also upstream concepts (paper roll logistics) and
Solutions after the ramp. Hamm also points out that the
investment in the machine is only part of the total investment
and that, especially when investing in rotating equipment, the "whole
life cycle" of the machine must be taken into account. The fact that MAN Roland
is obviously right with the XXL concept in the newspaper sector too,
The success of the company, which is also a leader in newspaper
machine manufacturer. Production at the Augsburg plant is
The company works to capacity in three shifts, producing six days a week.
The world's first largest Colorman 6/2, also known as the XXL machine, is
delivered and produced, the second is currently being built - at
Pressedruck in Augsburg. The customer event was also organized with this in mind
to the home game.
Integrated production
As was repeatedly heard at the event, the
actual production is only part of the overall production chain.
Especially in the XXL range, it is not least due to the large
investment costs, it is particularly important to take a closer look at these.
Norbert Ohl, Managing Director of MAN Roland subsidiary ppi Media GmbH,
explained the importance of networking for publishers and
printing houses. "The networking of production resources is
XXL machines are particularly important." He speaks of electronic
pockets and digital planning boards, which are based on the newer, so-called
JDF standard, which enables end-to-end networking.
This makes it at least technically possible to merge previous production islands into a larger whole.
Conclusion: The biggest hurdles are still in the bow area
The overall advantages of XXL cannot be denied if
The topic must of course be viewed in a differentiated manner.
There are still hurdles in the bow area. Although the
production and folding have been solved, there are still
no punching machine that can punch sheets printed with the Roland 900
is possible. The limited availability of papers in the
sheet area. One of the users addressed
MAN Roland is responding to this need: Inline measurement (automatic
quality check of the sheet) is under development. "We are working
because we know that handling the large formats is naturally very difficult," explains CEO
Gerd Finkbeiner, who opened the event with a summary
has completed.
Jürgen Franck