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Drupa developments 3

May 1, 2004 12:00 AM

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JDF-enabled workflow, press innovations

Heidelberger Druckmaschinen AG (Heidelberg) (Heidelberg, Germany) will offer more than 50 innovations at Drupa. Its modular, JDF-enabled Prinect workflow components reportedly integrate business-management and technical functions into one comprehensive data and workflow. Said to be adaptable to each printing company's individual requirements, the Prinect family is categorized into three areas: management, production and color solutions. Prinect Management Solutions integrate business-management processes into the production workflow. Prinect Production Solutions provide a direct connection between prepress, press and postpress, enabling data generated at prepress to be used online for presetting the press, as well as equipment in the bindery. Prinect Color Solutions help automate color management and calibrates production systems. Specific products in the Prinect line include:

  • Prinect Printready 2.0, a fully automated, JDF- and PDF-based workflow for the generation of print-ready PDF files. Operators can automate the production process, from creating the job and retrieving specific customer, job and production data from the MIS to outputting the plate and forwarding the preset data to the pressroom. PDF approval and remote access integrate the end customer in the production workflow.

  • Prinect Signa Station 1.0 imposition software based on folding sheets. Information from the MIS can automatically flow into a job-assistant function, which then guides the user through the impositioning process. Signa Station adapts to production changes, displaying all job parts — such as a cover and contents — as corresponding folding and print sheets.

  • Prinect Profile Toolbox, for the accurate management of color from original to press. Prinect Profile Toolbox contains PrintOpen V5, which measures actual spectral values on the test form and creates ICC output files. A new iterative proof correction enables precise profile calculation for the proof, reportedly minimizing midrange color inaccuracies from proof to print. Quality Monitor then enables comprehensive comparisons of two measuring data sets, such as between proof and print.

  • Prinect Calibration Toolbox, which allows the generation and management of calibration data for the entire printing process.

On the press front, Heidelberg will offer the Speedmaster SM 52 in an eight-color version also capable of printing four over four. The 35 × 50-cm format Speedmaster SM 52-8-P-H features a new sheet-transfer system, consisting of TransferJacket Plus ink-repellent cylinder jackets for the transfer cylinders and PerfectJacket Plus for the impression cylinders downstream from the perfecting device. Other developments include:

  • The Quickmaster DI 46-4 Pro digital offset press with new Presstek ProSpot imaging technology

  • Workflow integration from the Printmaster PM 52 with the Prinect Online Kit and Prinect Classic Center remote inking and register-control system

  • A new feeder for the Printmaster PM 74, featuring a central suction tape and pneumatic pull lay for short makereadies, as well as a new feeder and high-pile delivery for the Speedmaster SM 74

  • New models in the Speedmaster CD 74 line that include a coating unit and short, space-saving delivery.

Heidelberg will also display several postpress innovations.

Waterless and keyless offset presses

KBA (Williston, VT) is targeting short-run production applications where its waterless and keyless offset systems reportedly offer reduced waste, less dot gain, simplified handling and reduced variables. KBA's 74 Karat, with its waterless features, will be adapted to the new 46 Karat and an 18-inch version of the digital press. New applications for the 74 Karat include 3-D photographic printing on plastic and foil using oxidative inks and HumanEyes software.

In addition, a 20½-inch waterless, keyless sheetfed press makes its commercial debut in the Genius 52. This five-color press also features keyless inking units and a compact design to fit tight spaces. A single operator can run the press using a touchscreen console. The entry-level Genius 52 features automatic plate infeed, automatic circumferential register for handling various substrates and automatic blanket washing (optional).

KBA will unveil Rapida 74G, a waterless offset press featuring the same keyless inking system as the 74 Karat. The press is equipped with a Technotrans temperature-control system, automatic plate changing, remote format and register control. The 15,000-sph G version can be configured with up to eight printing units plus perfectors, coaters and other inline finishing options.

KBA's booth also will highlight:

  • Rapida 105 running at 18,000 sph in straight printing or 15,000 sph in perfecting mode
  • Rapida 205 with a sheet size of 59½ × 80¾ inches
  • Compacta 217, a 70,000 cph heatset web press for the high end of the 16-page market
  • Cortina waterless newspaper press.

Fifth imaging unit; digital front-ends

NexPress Solutions LLC (Rochester, NY) offers the new IntelliColor and IntelliCoat solutions for a fifth imaging module NexPress 2100 digital color press. IntelliCoat lets users add a clear DryInk coating for flood or spot coating. With IntelliColor, users have the option of adding a DryInk red, blue or green as a fifth color. The result is said to be a color gamut that is 80 percent richer than standard offset process printing. Other innovations include:

  • An upgraded NexStation III front end with JDF support and enhanced color management

  • The NexTreme OneFlow+ workflow tool that reportedly automates prepress on a centralized platform

  • The more entry-level NexTreme Exchange is a Web-based order-management tool that offers online job submission and automates the fulfillment of static, short-run print jobs. NexTreme Media Producer is a Web-creation tool: Users can access predesigned templates of versioned jobs, and preview the proof in real-time. NexPress also introduces new versions of its NexTreme DL-100 and DL-1000 variable-data software.

Printers can purchase one of three pre-bundled digital-print packages, as well as digital-printing consulting services.

New perfectors; JDF production management

Komori (Rolling Meadows, IL) will exhibit eight presses, including a redesigned perfector mechanism offered on all full- and halfsize Lithrone presses. Look for its eight-color Lithrone S40 perfector and small-format Spica 28 convertible perfector press to make their North American debut at Graph Expo.

Visitors will see the following special exhibit areas:

  • DoNet with JDF production management
  • Magazine and commercial
  • Perfecting theater
  • General printing
  • Carton printing
  • Chambon packaging printing
  • Currency and security printing.

New generation of cutters

Polar (Hofheim, Germany), whose products are distributed in the U.S. by Heidelberg USA (Kennesaw, GA), offers the XS, X and XT generation of its cutters, featuring an optimized machine frame for greater stabilization; improved operating height and centralized operator panel; 15-inch color display for the XT touchscreen models; a uniform knife change feature, Optiknife, said to enable fine knife adjustment from the front; greater cutting capability, even for tougher materials more suited for industrial printing applications; and greater safety features. Longer front tables for the Polar 78 and 92 models also offer more working space in front of the knife.

A new option is the P-Net Ethernet-compatible networking concept. P-Net, which operates as an interface between prepress, order preparation and production, organizes and manages the data flow between all Polar components.

A new naming convention allows Polar system components to be more easily identified. For example, a system consisting of the Transomat loading, Polar cutter 137 and Transomat unloading models will be called T-137-T.

JDF-enabled workflows, soft proofing and production management

Dalim Software (New Orleans) will feature:

  • DALiM TWiST 5.0, automated workflow software with built-in system failover; advanced load balancing; native PDF 1.4 and 1.5 file support; a new graphical user interface; PDF/X-1a: 2003, PDF/X-3: 2003, Pass4Press, (V4) and PDF/X Plus file output; and preflight and color-separation mapping tools.

  • DALiM DiALOGUE 3.0, a standalone application. It is compatible with the Macintosh OS X operating system and enables remote and collaborative viewing and soft proofing of high-resolution files via the Internet

  • DALiM PRiNTEMPO 2.0, a Web browser-based, JDF-enabled print production system that monitors the status of the production of pages and trigger actions such as the generation of plates or proofs. Using JDF, PRiNTEMPO can also automate production of imposed pages.

  • DALiM MiSTRAL, a Web-based production management system. It serves as the common electronic submission interface for production assembly as well as the interface for subsequent production tracking, administration, correction, approval and printing. JDF compliance enables advanced job ticketing, imposition and preflighting.

Digital and offset finishing

Duplo Corp. (Santa Ana, CA) will launch the slit/cut/crease (SCC) bookletmaker and the DC-645, a second-generation digital slitting, creasing and trimming machine. Duplo will also show the System 5000 and Duetto bookletmaking and collating systems.


The SCC bookletmaking system includes a DSF-2000 sheet feeder, the SCC unit, a DBM-500 bookletmaker and a DBM-500 trimmer. The SCC unit side-slits and trims the head and foot of each sheet. A CCD camera registers the resulting full-bleed trim to the image, rather than to the physical dimensions of the sheet facilitating image drift correction.


The DC-645 can read printed images and automatically adjust and compensate for image shift. It offers a high duty cycle, accepts heavier substrates (up to 310 gsm) and larger sheet sizes, and can produce a six-page brochure.

Two-knife trimmer

An optional unit to the DBM 500T face trimmer, the DBM 500 2KT trims the head and foot of completed booklets, delivering them on a shingled belt delivery back to the operator station. The initial settings are programmed from a user interface on the trimmer and are then transferred to the main memory of the finishing modules.

Bookletmaking and collating system

Based on the System 5000, the Duetto bookletmaking and collating solution incorporates up to three DC-10/60 collating towers, a DSF-2000 dynamic sheetfeeder and DBM-500 bookletmaker.

Variable-data printing for mailers

Domino Printing Sciences (Gurnee, IL) will showcase Domino On Demand, a 1,200-fpm variable-data platform that combines printer, ink and control systems and can use corporate/spot and Pantone colors.

Domino will also display its JetArray eight-line printer for the magazine wrapping market, as well as its Bitjet 212 binary printer, said to offer 2.13-inch band heights on a wide variety of substrates.

Inline binding; online job submission

Innovations from Canon U.S.A. (Lake Success, NY) for its imageRunner 110 and Pro150+ include a Coverbind/Bindomatic inline binder and Smartboard 3.0 digital prepress software. The Coverbind 301 automatically jogs, binds and delivers the document. The two cassette trays can hold 300 covers, and the second feed drawer can be loaded while the machine is running.

Canon is one of two national distributors for Heidelberg Digital's SmartBoard 3.0 software (formerly called Imagesmart Document Mastering). Appropriate for both digital color and black-and-white document assembly, the Smartboard PDF workflow enables an array of expanded capabilities for complex production jobs.

The company also announced it will distribute EFI's job-submission and ordering software, Digital StoreFront Express. The Web-based system allows print customers to submit digital files, view and approve PDF proofs, and enter their own job specs for production and finishing. Once that information is entered, Digital StoreFront Express creates a job ticket and the file is automatically submitted into the print provider's workflow, billing systems, print servers and output devices.

UV lamps for faster curing

Prime UV's (Carol Stream, IL) UV lamp systems are said to cure UV inks at speeds up to 2,400 fpm on commercial web, publication and newspaper presses.

The Prime UV Perfection air-cooled UV dryers are intended to replace hot-air gas-fired ovens on commercial web presses. An end-of-press Prime UV dryer can be installed after the last print unit to cure top and bottom sides of the web. Commercial printers can install Prime UV dryers after each print unit. Interstation UV drying for high-speed perfector presses instantly cures UV inks, eliminating dot gain.

Stitchers; on-demand book production

At the PrintCity display, Muller Martini's (Hauppauge, NY) PrimaPlus Amrys saddlestitcher will be networked into a JDF workflow via a production planning and management tool developed by ppi Media. With the aid of JDF networking, data generated in prepress and the pressroom will be used to pre-program the finishing operations. The information will be exchanged in real-time mode, and will be linked to a master production control system.

Saddlestitching highlights include the enhanced entry-level Valore. Improvements include tilt-back feeders and new stitching heads.

A new stitcher, Supra, targets high-volume magazine and catalog applications, as do the Perfetto and Robusto stackers, which will be demonstrated under production conditions. The Robusto stacker is rated at 30,000 copies per hour, enabling it to keep pace with the new Supra stitcher.

The BravoPlus Amrys saddlestitcher features updated Asir3 controls and new stitching heads. It is reportedly the only fully automatic stitcher in its class that provides JDF networking/CIP4 compliance.

For on-demand applications, the firm will unveil the SigmaLine. The system starts with prepress data and goes through digital printing to produce a finished perfectbound or saddlestitched product.

Muller's new Alprinta variable-size offset web press is available in two widths (20.4 inches and 29.1 inches) and can be equipped with fixed- or variable-size insert modules for special applications. At the Kodak exhibit, visitors will see Muller's Concepta press demonstrating inline personalization.

Preflight tools; opening proprietary files

Markzware (Santa Ana, CA) highlights include FlightCheck Professional 5.0, FlightCheck Workflow and FlightCheck Online.

The server-based FlightCheck Workflow V3.1 (formerly MarkzScout) is a management workflow tool for prepress operations. It is a user-definable, crossplatform, open application that inspects digital files to sort, filter and categorize them.

Vio Ltd. and ROI Distribution will showcase their solutions based on Markzware's FlightCheck Online technology (formerly MarkzNet). FlightCheck Online is a server-based solution that enables companies with a high volume of digital files from external or internal sources to check these files against a customized set of preflight rules defined by the recipient. The sender is automatically notified of errors and required corrections before the job is submitted into the prepress workflow.

Markzware will demonstrate XMLazarus, a standalone plug-in that enables content creators and their manufacturing partners to tap into proprietary digital documents. Data can be extracted into a new, XML-rich document with the original content, design, styles and layout preserved.

Color management; ink software

GretagMacbeth (New Windsor, NY) announcements include:

  • Enhancements to its Eye-One solutions, which combine the Eye-One Pro measurement device with software to calculate profiles

  • Three ProfileMaker 5 software packages (PM5 Publish for prepress/publishing, PM5 Packaging for multicolor packaging-textile printing and PM5 Photostudio Pro for professional studio photography)

  • DensiEye densitometers for CMYK and spot-color measurements

  • InkFormulation 5.0 software with enhancements for batch processing, formulation of additional substrates such as metallic foils and transparent films, customizable printing for labels and reports, and simplified communication between pressroom and ink laboratory

  • An Ink Formulation software package for small and midsize printers. Configured with either a Spectrolino or SpectroEye spectrophotometer, users can measure color and obtain the ink recipe.

  • A Web-based ink-formulation solution that lets ink manufacturers and suppliers offer a centralized database of ink formulation data

  • An entry-level iCPlate plate reader for conventional and CTP plates.

Drupa Tidbits…

  • Bobst Group will premiere five machines for flexo printers/converters and showcase products from the recently acquired Metso Corp. as well as Atlas, General, Midi, Rotomec Titan and Schiavi machines.

  • MAN Roland will show DirectDrive, a sheetfed press with direct drive technology. It powers a printing unit's plate cylinder with a high torque motor, controlled by MAN Roland's PECOM system. All of the plates on a Roland 700 with DirectDrive can be changed simultaneously. The mechanical isolation of the plate cylinder also gives a sheetfed press 360 degree circumferential register, expanding the range of plates that can be used.

  • Flint Ink offers UV inks and hardware for digital printing, active packaging, and brand protection, and conductive inks for radio frequency identification (RFID) applications. With Day International, MAN Roland and X-Rite, Flint Ink will also host a tour demonstrating RFID technology.

  • Xitron will launch versions of its Navigator Harlequin RIP, XiFlow workflow, and Xenith Extreme Adobe RIP. All include JDF functionality. Dynagram's Dynastrip imposition solution has been integrated into XiFlow and Xenith Extreme via JDF, reportedly providing the benefits of workflow/imposition automation to high-end production environments as well as entry-level two- to four-page printers.

  • IST Metz will demonstrate special UV effects on a six-color Heidelberg CD 74. Four different applications will be showcased.