All About Newspapers

Innovations that drupa 2016 brought
to the newspaper industry
Digital presses crack a new dawn of prospects and possibilities

The atmosphere at drupa is always like ‘an experience for all’ as this world’s largest printing expo covers everything that comes under the print universe in which publishing sector is an imperative. A group of companies from this niche cluster exhibited a spectrum of innovations spanning machines, materials and technologies designed for newspaper, magazine and book productions during drupa 2016 organised from May 31 – June 10 at Dusseldorf in Germany. Jyaneswar Laishram from ALL ABOUT NEWSPAPERS explored the entire show floor to witness a glimpse of new trends or updates the expo introduced to the publishing industry.

It has been seen as sweeping a new wave across the industry; and drupa 2016 showed it as a big trend. That’s ‘digital’ revolution! And it’s the publishing industry, now literally following this trend. Look at the way editions of almost every newspaper now available digitally online; short-run copies getting produced on digital presses; demands keep increasing for digital in-line finishing machines among publishers—all seem to be the crack of a new dawn of digitisation, signaling a new paradigm shift in the publishing industry, including newspaper production.

At drupa 2016, an array of versatile machines and technologies designed for newspaper publishing were announced, with physical showcases of traditional web offset presses, modern mailroom systems, digital presses, press chemicals, software, workflow solutions and many other allied equipments and materials. The expo presented added values and concepts that are truly trending to ‘touch the future’ of newspaper production in the printing and cross-media industry.

Key showcases

A select group of exhibitors, a few out of the total 1,837 from 54 countries at drupa 2016, we discovered being the latest innovators pushing the newspaper production industry to a new height. Have a closer look at the key exhibitors showing latest presses, technologies and materials, setting a new momentum of innovative expansion in the publishing industry.

R Arun Kumar, Sudeep Bhattacharjee and Eric Wagner

manroland web systems: Showing appropriate solutions to cover any requirement, whether it could be for pressroom, new machines, tailor-made retrofits, digital finishing solutions or cutting-edge network systems, manroland web systems at the expo carved a new pathway in newspaper printing leading to a fresh advancement. As per Sudeep Bhattacharjee, MD, manroland web systems India, the company’s focus at the expo was to offer real added value to customers with respect to productivity, quality, flexibility and cost reduction.

Innovations revolved around a complete product portfolio, comprising solutions for web offset presses as well as digital printing. Each solution from the company has been developed with an aim to provide their customers a fresh innovation. For those going for digital with certain print jobs, but seeking industrial solutions, manroland web systems offered cutting-edge FoldLine and FormerLine systems, demonstrated live at their stall. Fully integrated with any digital OEM press, FoldLine, which is configured for 300 m/min, could meet high-speed inkjet technology pagination and book-structure change on the fly. It is designed to take up to 96-page tabloid or 48-page broadsheet newspapers.

A complete digital printing workflow with FoldLine variable inline finishing uses Kodak Prosper 6000S press installed at manroland web systems’ stall to woo trade visitors about the comprehensive, customer-oriented production machine. On other hand, FormerLine could process all book formats in signatures and compatible with high flexibility, maximised use for digital production, lines in shift operation. Above all, the company also presented its competence as a single source provider for the print sector. ‘Print 4.0’, or networked production as it is known from the company, has been a lot more than just a vision for more than a decade, but now rather as a respected and highly innovative reality brought about through the development of essential linked elements. In addition, under the theme ‘Radical Changes in Newspaper Publishing’, ppi Media – as a co-exhibitor of manroland – presented its latest products and developments for cross-media use in print, online and mobile.

Vijay Pandya and Sascha Eschweiler

Q.I. Press Controls: Following the asset acquisition of INTRO International, the first collaborative product from Q.I. Press Controls, which marked a global launch at the expo, was IBS-100 (Intelligent Bar Sensor – 100 percent full inspection). IBS-100 is a unique innovative system that enables 100 percent full inspection and can be combined with existing register and density measurement and control software from Q.I. Press Controls. Talking about the new launch, Sascha Eschweiler, senior product developer, QIPC-INTRO, said the IBS-100 is designed to inspect (100 percent) image-based density control, colour register control and perforation, cut-off control or side-lay control of the complete image. IBS-100 is first-of-its-kind system ever introduced in the newspaper world, which is engineered combining multiple functionalities in a single bar sensor. Vijay Pandya, managing director, QIPC-EAE India Pvt Ltd, mentioned the full inspection system is all set to hit the Indian market soon.

For QIPCEAE, the first week of the expo had been phenomenal with the close of multiple order intakes and tremendous response to the newly launched IBS-100 and EAE Desk 7. A new press command centre, EAE Desk 7 unites a clear, light and dynamic design with exceptional robustness in a web offset press. Amongst the big deals closed during the expo included the one with Israel Today, which ordered IDS-3D for colour and dampening control and mRC-3D for controlling cut-off and side lay register to equip on two of their KBA Colora presses (8 print units).

Kawal Arora

Ferag: Latest from Ferag at the expo were the landmark introductions of its EasySert and Navigator, designed to individualise and personalise in-line inserts in newspapers. At the same time, the systems allow advertising brochures to be personalised at the same speed as conventional inserting processes, running at the speed of 30,000 individualised copies per hour. “This can save both time and manpower; with such in-line inserting systems, a retailer can target its customers with personalised ads based on purchasing preferences,” explained Kawal Arora, managing director, Wrl Global India (Ferag).

He mentioned that the systems will be arrived in India soon.

Yet another novelty from Ferag at the expo was One2Out, a smart pre-collecting process for advertising brochures of all kinds. Production mode 1 of the system involves two different production runs, running parallel enabling an output of up to 40,000 copies per hour. And in production mode 2, both pre-collecting streams are merged, increasing the number of hoppers to 41. The system folds advertising brochures with JacketFix and then wraps around the collections as a jacket; and finally, PostStack processes the collections into stable bundles. With these innovations, Ferag attracted huge crowd at the expo, enhancing post-press insertion systems to a new standard.

SAKATA INX: Presenting a diverse range of inks for offset, flexography, gravure, metal decorations and, of course, for web offset presses, SAKATA INX impressed the crowd buzzing around at the expo. The company’s advanced game-changing printing solutions and chemistry are designed for everyone involved in today’s printing world. The combo of inks offering at the company’s stall consisted of a portfolio of diverse applications, such as flexible packaging, corrugated boards (for which high-colour water inks are used) and digital inkjet inks. Identifying the inks manufactured especially for cold set presses, Navin Singh, manager-QC&QA, SAKATA INX (India) Ltd, pointed out the News Web Master HLOW, FL00, WF HS and CH00HS as the ones that have been used by a number of leading newspaper production houses in India.

“Big newspapers like The Times of India, Hindustan Times, Ananda Bazar Patrika (ABP), Malayala Manorama and others are our regular clients that go for SAKATA INX products for years,” mentioned Navin, adding that for brand owners, designers and printers concerned with colour management and print quality, they also have solutions for proofing and quality inspection shown at the expo. The company unfolded solutions even for those looking for digital printing; it included direct-to-object printing inks as well as modular single-pass automation inks; helix rotary inkjet technology and software for straight-walled and tapered cylinders; a multi-pass conveyor belt scanning platform, among others.

SM Ramprasad

FUJIFILM: The massive stall of FUJIFILM was divided into different zones for different lines of printing applications and products, which turned out as through everything about printing came under a common roof. In the Zone 4, solely allotted to inkjet, a key learning area was set up for anyone wanting to glimpse the future of printing. “Basically being a consumable expert, we always show how inkjet ink technologies can contribute to the expansion and development of new printing applications and opportunities. Of equal importance, however, we also show our traditional technologies and solutions which are designed to optimise existing print processes, including offset print production, at the expo,” informed SM Ramprasad, assistant vice president, Graphics Arts Division, FUJIFILM India Private Limited. Highlighted at the print zone of the company were premium quality and productivity of FUJIFILM solutions, in the realms of short-run book and newspaper productions.

For flexo, the company demonstrated in a big way how its recently launched SUPERIA and FLENEX solutions could optimise production, help printers improve their profitability and ultimately provide the foundation for a strong print business. Over the past few years, FUJIFILM has been engaging in developing its inkjet arena. As a result, the company presented a milestone plate for water-based flexo printing, designed specifically for the flexible package printing market.

GOSS International: A major revelation from GOSS International at the expo was the company’s new collaboration with offset printing experts and equipment manufacturer, Presstek LLC. The two companies have teamed up to deliver a powerful combination of CtP imaging systems, eco-friendly plates, presses, service and support, specifically targeting for the commercial and newspaper printing markets. In addition, Presstek is introducing a range of new prepress and plate products that align perfectly with GOSS’ commercial and newspaper printing systems. “We (Presstek and GOSS International) strive for continuous advancement in our products and in the way we deliver them to our customers,” said Sparsh Bhargava, CEO, Presstek. The partnership shows yet another demonstration that, under the new ownership, GOSS International is undergoing a major transformation to become even more customer-focused as well as a financially strong company, committed to long-term partnership.

Mohit Uberoi, CEO, GOSS, remarked that the industry is changing and innovative thinking is needed from both customers and suppliers. “In order to meet the evolving needs of our customers and remain at the forefront of this industry, we need to think outside of the traditional box and ensure our product portfolio and service offerings continue to provide dynamic, pioneering solutions. However, we’re not looking to reinvent the wheel. We want to utilise the strengths and expertise of those companies that we can see a partnership approach would be mutually beneficial, and most importantly, provide our customers with the best solution,” he exclaimed. Also, GOSS International announced the launch of its game-changing Embedded Color Bar Control technology, a new innovation that enables packaging converters to embed the colour bar, at the expo.

KBA: With a focus on diversity in print with vast highlights of digital and packaging activities, Koenig & Bauer Group (KBA) exhibited on its 3,000 sq m stall a line of unmatched solutions—Rapida sheetfed offset presses, Rapida 106 RDC rotary die-cutter, re-designed high-volume digital RotaJET L series in a flexible modular design and its popular NEO XD LR web press and others related to service, workflow and KBA 4.0. Claus Bolza-Schünemann, KBA president and CEO, referred to the activities of subsidiaries KBA-MetalPrint and KBA-Kammann in packaging segments metal and glass container direct decoration which are represented on their stall with print samples.

Christoph Müller, CEO of KBA-Digital & Web, mentioning the successful alliance with HP in the digital corrugated printing, he unfolded the company’s new success story, which tells that the KBA’s digital & web continued to build web offset presses for commercial and newspaper printing. Though KBA is one of the market leaders for newspaper presses in the mid and top performance classes, the growth prospect is seen predominantly in digital printing and industrial markets, new to KBA, such as decor printing, and in expanding services for own and third-party web presses. KBA RotaJET L, shown at the company’s stall, is individually configurable for many digital print markets and designed with web widths of up to 2.25m implemented as a 4/0 press for industrial applications, such as decor printing. And the machine with web widths of 77 to 138 cm in 4/4 configuration printing appeals primarily to establish digital print markets for books, mailings or publications, but it can also be implemented in other industrial markets as a 4/0 press.

Muller Martini: Leading post-press major Muller Martini unpacked a bunch of new finishing solutions viably designed for those presses engaged in magazine, book and newspaper productions. The overall showcase of the company at the show gave a clean spotlight on magazine printing on offset and digital printers on one side and efficient print finishing of hybrid products on another, Muller Martini demonstrated how signatures from both printing systems could process according to a smart workflow on day-to-day basis. Every single day of the expo, a number of copies of over 20 different print products were produced live using no fewer than nine connected systems, demonstrating competence of smart automation and workflows, at the company’s stall.

Parthasarathy S from Muller Martini (India) Private Limited briefly mentioned about the new developments in the finishing segments, which the company showcased at the expo, consisting of saddle stitches, perfect binders, thread sewing machines and booklines as well as other including an all-new solutions for the three-sided trimming of softcover books in ultra-short runs. The company, also at the stalls of partner digital printing press manufacturers, Canon Océ and Xerox, presented two identically configured Presto II Digital saddle stitchers, each with an unwinding system, cross cutting unit (both from Hunkeler) and pocket fold unit (from Heidelberg). Muller Martini underwent these innovations not only to prove their leading market position, but also to provide visitors a glimpse of the ‘future of finishing’.

Bottcher Systems:
‘Everything from one source’— this was the slogan that Bottcher Systems coined to herald the company’s combo of products that includes rubber rollers, printing blankets, fountain solutions, printing aids, cleaning webs and others made for offset and web offset printing systems, shown during the expo. Among the complete array of solutions, Bottcher UV dryers, which the company demonstrated at its stall, was one of the impressive innovations ever introduced in the newspaper industry. The added advantage of the UV drying system lies in unrivalled print quality and brilliance as well as options of printing on glossy and coated papers on a web offset press.

Apart from the solutions for UV newspaper printing and semi-commercial printing on web offset presses, Bottcher Systems also presented all allied products, which a host of printers including those engaged in flexography can adopt, such as Flex Sleeves. DLE Sleeves, DLE Plates, Plate Mounting Sleeves, etc. Besides that, formulations of the company’s printing chemicals and blankets for the newest generation of compact newspaper presses have been the outcome of collaborative discussions and developments with press manufacturers’ engineering design departments and those were what Bottcher Systems highlighted during the expo.

Saurabh Gupta alongside SG-50

PRAKASH Web Offset: One of the 41 Indian companies that participated in the global expo, PRAKASH Web Offset impressed a number of overseas trade visitors swarming around the company’s stall where they displayed their ever acclaimed SG-50 automatic splicer, which is compatible with any brand of web offset press. Saurabh Gupta, director, Prakash Web Offset, said that the global launch of their SG-50 automatic splicing machine received a good response from visitors from different continents. There is a specific reason why SG-50 became an object of attraction at drupa 2016—that’s its cost effectiveness. SG-50 was spotted as one of the world’s most economical flying splicers by drupadaily, an official daily newspaper circulated during the expo. SG-50 is a shaftless reel changer with a maximum splicing speed of 460 m/min, priced at €35,192.

In addition to SG-50, PRAKASH Web Offset showcased its portfolio of versatile web offset presses, engineered for newspaper, book, and semi-commercial prints, which are indigenously manufactured in India. Right from boring to cylinder grinding, the company’s technologies allow them to produce parts that meet the exacting standard required to build a precision printing press. PRAKASH web offset presses, which start from production speed of 36,000 impressions per hour and a multitude of state-of-the-art features, aimed at reducing waste and make-ready time and all of them are proven ideal for many applications. Such attributes of the company’s machines drew crowd during drupa 2016.

Krause: Under the motto ‘Process Automation in Ctp Platemaking – No Touch from Pallet to Sorter!’ Krause marked new solutions in Ctp area, boosting experience of newspaper production with fully automated plate production technology. Released during the expo was the Krause Imposition Manager (KIM), version 7.5, which is a core part of many printers. KIM user interface is based on a known prepress workflow and it allows the import and export of JDF job tickets plus the effective integration of leading MIS and workflow systems. KIM accepts PDF files plus CSV and XML data, offering libraries for imposition, folded sheets, print sheet templates, print marks and machine parameters. KIM production profiles enable a fully automatic imposition, so that it saves time and reduces human error.

Particularly for newspaper applications, Krause presented PlateStream, a new platesetter concept with violet laser. This platesetter has become a benchmark in plate handling, capable to run at the speed of 400+ plates at 1270 dpi, the integration of industry 4.0 and 3D printing components and operating efficiency. A source from the company mentioned that the main goal of the company is to integrate its proven technology from various platesetters with the latest developments in the field of electronics, sensors and actuators to bring the networking of humans with machines to a new level. The new platesetter was demonstrated alongside the BlueFin LowChem with Clean Process Kit for clean and sustainable LowChem applications. Krause proved once again the innovation power of the Ctp at the expo.

NELA: ‘Pre-press to Press Automation’— loudly pronouncing this motto at the expo, NELA presented a complete line of products and technologies that close the gap between CtP-room and press while ensuring absolute quality control. Jochen Glaser from NELA expressed that visitors could experience live demonstrations of how the company’s total automation of pre-press area has truly become reality: imaged, punched and bent plates are delivered at the right time directly to the right press cylinder. In the process, paper waste and delays caused by wrongly mounted printing plates or difficult to adjust colour register on press are eliminated.

With the VCPEVOLUTION Flexx, NELA showed the most flexible model of its newest generation of punch/benders. Integrated into the system, NELA highlighted the fully automatic quality measuring system PQM+. And the company’s LogiStack System with PlateFlow Software is designed for continuous automation from pre-press to press. The LogiStack plate manager makes delivery of offset plates to the press more efficient. NELA’s new On-Press Register Control System, shown for the first time at the expo, completes the automation cycle from pre-press to press.

Manugraph: Iconic Indian manufacturer of web offset presses, Manugraph, known for its versatile and cost-effective newspaper presses worldwide, had a persuasive presence at the expo. Testimonials from printers and publishers across the globe that have been using Manugraph presses confirm the company’s outstanding contribution to the printing industry. Showing the latest developments in its product line, the manufacturer made debut of its latest

ECOLINE systems in the overseas market. According to PK Bhalla, general manager, Manugraph India Ltd (MIL), ECOLINE is a 2x1 press designed in combination of high-end technology with minimum floor space.

Since presses from Manugraph, including ECOLINE range, have been gaining popularity in the overseas market, the company’s participation in drupa 2016 was essential as the expo provided them a rare chance to interact face-to-face with their offshore customers. In addition, at the expo, Manugaraph also highlighted its commitment to refurbishing and retrofitting services with upgraded technologies. In addition to the showcase of the company’s cutting edge machines, PK Bhalla felt that their presence at drupa would always turn out to be an opportunity to spread footprints of Manugraph in the offshore markets.

NBG: NBG Printographic Machinery, yet another Indian web offset manufacturer at the expo, marked its presence with the introduction of the company’s range of web presses designed for various configurations. Known for two brands, Star and Newsprint web offset presses for newspaper, NBG pulled a crowd taking interest in the economical and resourceful presses they offered. “Some of our existing overseas players turn up at our stall; in addition, we are pleased to see new trade visitors from different countries showing interest in out presses,” said Rahul Gupta, general manager-International Business, NBG Printographic Machinery Co Pvt Ltd. NBG boasts its popular web offset press, Star, which is available as Star-16 model to churn out 16,000 copies per hour and Star-30 for 30,000 copies per hour. In addition to the web offset presses, NBG also presented its all round solutions for corrugated and duplex boxes at the expo.

The Printers House (TPH): When it comes to counting oldest web offset manufacturers in the Indian newspaper printing market, The Printers House (TPH) might come on top as the establishment of the company could trace down to the country’s pre-independent era and they have been participating at drupa since the 1986 edition of the expo. The web offset manufacturer is proud of its globally acclaimed Orient series presses, which they have presented at drupa 2016 with upgraded features, with a focused highlight of the machine’s new automations including auto reel changer, auto registration and cut-off control, auto inking and digital preset, ink-water balance preset, auto ink pumping, footprint shaft less and compensating stacker and more.

Just recently the company delivered two fully automated presses to Africa and the Middle East. “Our participation in drupa 2016 is to proclaim our achievements and experiences in the overseas market,” said Pawan Tyagi, general manager (International Business), TPH. He added that the upgraded automated presses from TPH always leave good impression among the offshore buyers, for the fact that the machines are up-to-date and cost effective. Some of the distinct features of Orient presses include ease of operation, reduced initial waste and consistent print quality and automation. Orient X-Cel, one of the popular among the Orient family, has been adopted by a number of newspapers in the overseas and domestic markets—Punch in Nigeria and Lokmat, Amar Ujala, to name a few, in the domestic market.

ABB: Modular press-control retrofit systems, production management systems and support services were the latest that ABB announced during the expo. According to Damian Staedeli from ABB (Switzerland), the retrofit systems are capable to control and drive web offset presses of any brand, configuration and size.

“The systems allow a part of web press to be retrofitted, thereby freeing up spare parts for the rest of the press and minimising the cost,” he explained. Further, he added that the retrofit systems allow to process ergonomic control consoles and advanced production management. Trade visitors moving around on the isles of ABB stall at the expo were elated about the features of the systems that support customers with its long-term availability of spare parts, even after 10 years of installation. And the company’s production management systems improve the efficiency in newspaper production and make complex demands more manageable.

Hunkeler: Those looking for ways to streamline newspapers, books or transpromo workflow were jammed at the stall of Hunkeler. In this, Heinrich Marfurt from Hunkeler AG, Switzerland also mentioned that they aimed at providing trade visitors at the expo a complete solution. He further mentioned the integrity and tracking solutions the company showcased attracting a huge crowd that consisted of a number of visitors from various countries. During the expo, Hunkeler announced a string of updated solutions, which included flexible, high performance book-on-demand system as well as dynamic book block feeding for various perfect binders.

For the newspaper sector, shown at the stall of the company comprised highly dynamic newspaper and glued booklet production with Folder Collator FC7, which Heinrich said was getting a resounding response from visitors. Other solutions the company highlighted at their stall included the systems for web inspection and tracking with ‘huncontrol’; laser cutting/engraving for security applications with Hunkeler finishing; highly dynamic perforating and punching with new DP8 module, and others.

Tesa: A well-known tape manufacturer Tesa unpacked its latest range of Flexographic tapes, namely: Softprint 72522 FE-X, 72524 FE-X, 72526 and 72528 FE-X. These tapes are designed for foam plate mounting in the pre-press process in newspaper production houses. Print experts at the Tesa stall during the expo demonstrated the benefits of the new Softprint range and addressed enquiries on the company’s existing range of tapes. “With its unique structured PP-liner to prevent formation of air pockets during plate mounting, the new Softprint FE-X range offers more flexible product design to compensate thin sleeve expansions and best bonding on scratched sleeve surfaces for excellent print results and optimum handing properties,” explained David Watson, regional market manager, print & web processing, Asia Pacific, Tesa.

Further, David talked about the new Softprint tapes, which he explained as one designed to meet the increasing requirement in the newspaper and allied printing activities in the industry for fast mounting, best print quality and demounting tape performance. About drupa 2016, he marked the expo as an ideal platform for them to introduce the new products, taking printing into the new future.

Digital short-runs

For short-run newspapers and book productions, what leading digital press manufacturers staged at drupa 2016 included those lines from Canon, HP Inc, RICOH, Kodak, Konica Minolta, to mention some of the top players. Canon showed its Océ ColorStream 6000, configured as a completely integrated system with the Zero Speed Splicer u40 and Libra One book block solution from the finishing partner Tecnau, offering a unique configuration for books-on-demand production at a new level. HP Inc presented its line of inkjet web presses designed for varied productions, including on-demand books and newspapers. In addition to ELECTRA MAX Thermal Plates and LIBRA VP Digital Plates for commercial and newspaper presses, Kodak held live demo of its PROSPER 6000C with inline finishing and Kodak NEXPRESS ZX3900 digital production colour press, an enhanced version of Kodak NEXPRESS SX platform, among others, for short run printing.

Konica Minolta presented its KM-1 prototype, a landmark press that the company defined to be a perfect system for short-run book production. Opening a new world, RICOH unveiled seamlessly manageable workflows, maximised productivity, increased profitability and ways to access additional markets. The company’s Publishing Zone was where they would showcase digital print technologies and workflows for short-run colour trade book and journal production with samples from leading publishers, including HarperCollins and Reed Elsevier Group.

Here the bottom line is that drupa 2016 conclusively indicated that the printing industry is re-inventing itself, offering a wealth of potential facets, even in the publishing sectors like books and newspapers.