The InkZone concept for presetting the ink keys on offset printing press is making life easier for printers: they are saving money and gaining time; at the same time, they are achieving considerable increases in quality and productivity.
InkZone smoothes the way into a future with JDF: JDF files supplied from the workflow or bitmap or CIP3 data that has been converted by DI-Plot into the Job Definition Format are then converted by InkZone into the required preset control commands for the specific machine. As a direct continuation of the preset function, the Closed Loop technology is responsible for non-stop control of the press and compliance with print production standards.
Small gap, big opportunity
In many printing houses, the digital process chain stops with plate imaging. The option to transfer prepress output data to press for presetting ink zones remains unused. And because proprietary available CIP3/4 connections come with relatively high investment costs, there is often little incentive to close this gap in the flow of data. Which is why Digital Information has developed InkZone: InkZone is an intelligent, flexible concept that can be adapted to requirements. With little expenditure and the simplest equipment, full use can be made of existing potential for the sake of increased efficiency.
An alternative to plate scanners
In many printing houses, preset values for ink zones are still generated using plate scanners. Apart from the laborious handling of the printing plates, the scanning of plates will also result in a relatively imprecise ink profile due to weak contrast between the aluminium and ink-bearing layer, while subsequent precise adjustment of the zones costs time and paper. Through the online transfer of bitmap files, on the one hand a work-intensive detour via the plate scanner is eliminated, while on the other, InkZone will always refer back to first-generation data. That means: shorter set-up times and minimum start-up waste. In view of shrinking print runs and frequent job changes, this means a significant increase in productivity.
Digital presetting of the ink keys
InkZone extends DI-Plot, the Rip-independent formproof solution, by a new component and brings manufacture-independent workflow all the way to the press. Now, bitmap data calculated by DI-Plot and used for the formproof can be simultaneously used for presetting the ink zones on the press. InkZone can be used with all popular press types. Existing offset machines without digitally preset ink zones can be upgraded with InkZone simply and economically
JDF technology
InkZone supports the transfer of preset data - also JDF based - between prepress and press. Bitmap or CIP3 files accepted from RIP and converted by DI-Plot into the Job Definition Format are then converted by InkZone into specific press signals for presetting the ink zones. The conversion function is fulfilled by inkZone also in the case of direct transfer of CIP4/JDF files from any JDF prepress workflow.
More productivity, greater efficiency
Data calculated for film and plate imaging provide the printer with reliable information for digitally presetting the ink zones. Numerous advantages are the result, which go to boost the productivity and quality of the printing process: much quicker attainment of the correct ink feed, shorter start-up times, drastic savings in waste and 100% reproducibility with repeat orders, because the same digital data are referenced all the time.
Quality assurance thanks to Closed Loop
The calculated preset data can be written to the Closed Loop software package by InkZone. After start-up, the press also prints measuring fields for each print zone, which are measured and compared with the saved reference values for CYMK plus spot colours. InkZone transmits the necessary correction values to the press control console online. The printer decides on the use of these corrections and retains the option to intervene manually at any time. The console then writes the relevant settings back into the InkZone software package.
The Closed Loop functionality of InkZone is the simplest possible way to achieve continuous monitoring and control of all zones in the offset press. When it comes to maintaining and logging a stable printing process as required by all international standards, Closed Loop is indispensable!
What is InkZone?
The InkZone concept for presetting the ink keys on offset printing press is making life easier for printers: they are saving money and gaining time; at the same time, they are achieving considerable increases in quality and productivity.
InkZone smoothes the way into a future with JDF: JDF files supplied from the workflow or bitmap or CIP3 data that has been converted by DI-Plot into the Job Definition Format are then converted by InkZone into the required preset control commands for the specific machine. As a direct continuation of the preset function, the Closed Loop technology is responsible for non-stop control of the press and compliance with print production standards.
Small gap, big opportunity
In many printing houses, the digital process chain stops with plate imaging. The option to transfer prepress output data to press for presetting ink zones remains unused. And because proprietary available CIP3/4 connections come with relatively high investment costs, there is often little incentive to close this gap in the flow of data. Which is why Digital Information has developed InkZone: InkZone is an intelligent, flexible concept that can be adapted to requirements. With little expenditure and the simplest equipment, full use can be made of existing potential for the sake of increased efficiency.
An alternative to plate scanners
In many printing houses, preset values for ink zones are still generated using plate scanners. Apart from the laborious handling of the printing plates, the scanning of plates will also result in a relatively imprecise ink profile due to weak contrast between the aluminium and ink-bearing layer, while subsequent precise adjustment of the zones costs time and paper. Through the online transfer of bitmap files, on the one hand a work-intensive detour via the plate scanner is eliminated, while on the other, InkZone will always refer back to first-generation data. That means: shorter set-up times and minimum start-up waste. In view of shrinking print runs and frequent job changes, this means a significant increase in productivity.
Digital presetting of the ink keys
InkZone extends DI-Plot, the Rip-independent formproof solution, by a new component and brings manufacture-independent workflow all the way to the press. Now, bitmap data calculated by DI-Plot and used for the formproof can be simultaneously used for presetting the ink zones on the press. InkZone can be used with all popular press types. Existing offset machines without digitally preset ink zones can be upgraded with InkZone simply and economically
JDF technology
InkZone supports the transfer of preset data - also JDF based - between prepress and press. Bitmap or CIP3 files accepted from RIP and converted by DI-Plot into the Job Definition Format are then converted by InkZone into specific press signals for presetting the ink zones. The conversion function is fulfilled by inkZone also in the case of direct transfer of CIP4/JDF files from any JDF prepress workflow.
More productivity, greater efficiency
Data calculated for film and plate imaging provide the printer with reliable information for digitally presetting the ink zones. Numerous advantages are the result, which go to boost the productivity and quality of the printing process: much quicker attainment of the correct ink feed, shorter start-up times, drastic savings in waste and 100% reproducibility with repeat orders, because the same digital data are referenced all the time.
Quality assurance thanks to Closed Loop
The calculated preset data can be written to the Closed Loop software package by InkZone. After start-up, the press also prints measuring fields for each print zone, which are measured and compared with the saved reference values for CYMK plus spot colours. InkZone transmits the necessary correction values to the press control console online. The printer decides on the use of these corrections and retains the option to intervene manually at any time. The console then writes the relevant settings back into the InkZone software package.
The Closed Loop functionality of InkZone is the simplest possible way to achieve continuous monitoring and control of all zones in the offset press. When it comes to maintaining and logging a stable printing process as required by all international standards, Closed Loop is indispensable!
InkZone Move Software
It Starts with Fast Color Measurement
The on-screen display of the InkZone Press solution makes it easy and quick for the press operator to interpret the measurement results.
InkZone Move Press has at it's foundation an unique software solution which makes clever use of automation to gather color measurements quickly from a color bar positioned at each press sheet. To ensure accurate alignment, the measuring device rides upon a precision guide which is included with the IZM Press package. This allows smooth and steady movement of the Eye-One and results in dependable, repeatable data – every time. When compared to slower manual color measurements, IZM Press completes a comprehensive evaluation of the entire press sheet in just a few seconds.
Press operators have the benefit of applying any necessary corrections faster, and can focus their attention on decision-making and press adjustments instead of on data collection. With such a simple color evaluation process, operators can always have access to an up-to-date look at any deviations from target values or customer-approved samples. And since the entire system operates uses a full-fledged spectrophotometer, it is equally well-suited for controlling both process color and spot-color work.
True and Consistent Color Results
Press operators will appreciate how easy and quick it is to interpret the graphic display of the IZM Press solution. The software depicts the ink-key zones for each unit of the press, and provides the option to view either absolute color and density results, or measurements relative to target values. With the functions of density, dot area/dot gain (tone value/TVI) and colorimetry (CIELAB/Delta-E), InkZone Move Press is the basis for process stability, color consistency and adherence to recognized standards or specifications. And since IZM Press keeps a running history of your color results, you can easily use it to provide proof of quality records, or import the data from its native ASCII/XML format into analysis or statistical software for further evaluation.
InkZone Move Press supports all makes and models of printing presses, allowing operators to review measurements and make manual adjustments to the ink key settings. However, for prompt and consistent ink adjustments, IZM Press can be upgraded to a full, closed-loop control system (InkZone Loop), providing automatic, simultaneous regulation of ink key openings across all press units.
Complete, Uniform, Color Results
InkZone Move Press: the measurement parameters for all ink zones are displayed on-screen within seconds.
InkZone Move offers a comprehensive set of tools for color consistency and uniformity across the entire imaging process. With objective, measurement-based evaluation of the press-sheet color bar, InkZone Move provides a comprehensive approach to controlling all of the factors relating to quality sheetfed offset printing.
And as the industry's first, integrated aftermarket solution, InkZone Move has the capability to unite otherwise incongruent solutions from multiple system providers at each stage of the process.
In this way, the full process can be controlled using a single, comprehensive approach. When paired with the automation and affordability of InkZone Move, it's hard to envision a packaging or commercial printing environment where it wouldn't be relevant.
InkZone Move Hardware
Techkon: SpectroDrive, SpectroJet, RS400 and RS800
The Techkon SpectroDrive is a very fast means to measure color bars from the edge of press sheets. It delivers precise results regardless of the print substrate’s thickness.
The SpectroDrive, with its automatic color and density measurement capabilities substantially increases press productivity by ensuring consistent print-to-print color accuracy throughout the press run.
The motorized measurement system scans the complete color bar on a printed sheet within seconds and simultaneously sends the spectral measurement data wirelessly to InkZone Move where all relevant information for controlling the printing press is displayed.
SpectroJet is a „spectrophotometer on wheels“ which automatically measures the densities and color values of process- and spot-colors and simultaneously transfers the measurement data to a PC within seconds.
Of course InkZone is fully compatible with the legacy Techkon measuring instruments RS400 and RS800.
Semi-automated color scanning system with the X-Rite Easytrax.
IntelliTrax is X-Rite’s advanced, automated color management scanning for press-side color control. Ultra-fast, IntelliTrax automatically scans the color bar of a typical press sheet in less than 15 seconds. InkZone Move reports these results on-screen instantly. IntelliTrax is the ideal color management solution for high-end, high speed printing operations.
EasyTrax is X-Rite’s semi-automated color scanning system for producing accurate CMYK and spot color jobs. Available in multiple press sizes from 20” to 40”, EasyTrax comes on a measurement board for easy installation and can be adapted to other after-market consoles. EasyTrax has the ability to take a scan measurement or spot measurement anywhere on the sheet making EasyTrax the perfect solution for press-side color control for smaller format color presses.
Of course InkZone is fully compatible with the legacy X-Rite measuring instruments ATS and ATD.
Drag & drop: straightforward operating with mouse or touch screen
With InkZone Perfect, Digital Information offers an interface between prepress and press that's equally powerful and economical.
First, the solution provides networked ink key presetting, so color start-up is accomplished in a fraction of the previous time, bringing a clear increase in productivity. What's more, InkZone generates a database of your settings, allowing corrections and continuous improvement in results over time. This makes InkZone Perfect a component that's indispensable on the road to a standardized printing process.
Consider the following: As you use InkZone Perfect, it compares the computed preset data with the corrected values during each press run. By reading back the values measured throughout the print run, the calibration curve for a given set of printing conditions can be continuously corrected and will gradually approach an optimum. When it comes to repeat orders, that means a further boost to the speed of set-up sequences, significant savings in paper, and a permanently stable, high-quality printing process.
InkZone Perfect: automatic adjustment of the linearization curves to specific printing conditions
Using the appropriate hardware components IZ Card, IZ Strip, IZ Tape, IZ eFloppy and IZ Wire, ink key presetting with Ink-Zone Perfect can be realized on almost all offset presses.
An investment in extending your workflow to the pressroom with InkZone Perfect from Digital Information is worthwhile. From the hundreds of printers using InkZone worldwide, experience shows the ROI horizon to be only a few months away.
A detailed description of the supported presses and consoles can be obtained here as a PDF file.
InkZone Loop
Online printing
The launch of InkZone Loop puts a manufacturer-independent online solution for digital control of offset presses onto the market for the first time ever. Supported by measurement technology, InkZone Loop enables the automatic measurement and evaluation of control strips, as well as the continuous transmission of computed correction values directly to the printing press. InkZone Loop is based on tried-and-tested IZ Card, IZ Tape, IZ Strip and IZ Perfect preset solutions.
Measure...
Input: Direct connection to prepress
InkZone Loop supports measuring systems from a wide range of manufacturers. Density values on the sheet containing the printing control strip are measured in a matter of seconds, and can be visualized in IZ Loop.
Using saved data, the printer immediately recognizes the ink zone where the color is wrong. In addition to density, InkZone Loop evaluates other factors like dot gain, slur, etc.
Naturally, as well as functioning with CMYK, InkZone Loop supports any spot color. All these functions combine several production steps that so far have mostly been carried out manually. InkZone Loop thus comes with a huge increase in efficiency. Streamlined sequences are extremely important, especially at a time when print runs are shrinking.
InkZone Loop generates a record of the measured color data and thus assists with repeat runs. Naturally, the record also aids compliance with international quality standards.
...and regulate
Output: Transmitting correction values to the press
By comparing actual measured values with reference data, IZ Loop computes correction values for the press. Transmission of the data to the console can be via IZ Card, IZ Strip, IZ Tape, or IZ Perfect. If necessary, the operator checks the preset values and, at the press of a key, releases them to the press. The effect is clear: a huge reduction in workload, higher quality, and a stable production run.
Preset & proof
The preset products IZ Card, IZ Strip, IZ Tape and IZ Perfect are extremely important if IZ Loop is to be used successfully. The better the preset, the more efficient the closed loop! While InkZone solutions secure the connection to the press, the DI-Plot software package looks after the transfer of prepress data. DI-Plot reads both CIP3/4 and proprietary bitmap formats from almost all prepress workflows and passes the computed ink zone values on to InkZone for digital presetting of the press.
At the same time, DI-Plot can produce accurate form proofs from the ripped bitmap data of almost all workflow systems.
Ready for the print run in record time
The combination of control, measurement technology and workflow interface is unique. With InkZone Loop, the printing house saves time and cuts down on waste. Reference values are attained faster, and it's easier to keep them within narrow limits. InkZone Loop enables set-ups in record time, even with offset machines from the previous millennium. It's the perfect way to protect investments in existing installations. InkZone Loop - the latest update for your offset press!
A detailed description of the supported presses and consoles can be obtained here as a PDF file.
InkZone Connect
InkZone Card: direct connection
InkZone Card for online connection of MAN roland and Heidelberg printing machines
As an online system, InkZone Card augments InkZone Box, the globally successful offline solution. InkZone Card is used with machines from Heidelberg and MAN Roland. As an online system, it is the obvious choice when production is on one printing machine only, or when the online principle is preferred for technological reasons.
InkZone Card takes on the function of e.g. Heidelberg's Job Memory Card or MAN Roland's Chipcard and connects the machine control station via Ethernet to prepress. Ink zone values are brought into line with individual printing conditions by the software package supplied, converted to the specific machine format, and saved online to the machine control system via InkZone Card. InkZone Card also accepts CIP4/JDF files from the prepress workflow and converts them into the specific machine format for presetting the ink zones. InkZone Card supports JDF-based ink zone presetting in all heterogeneous machine environments.
InkZone Strip: preset in Japanese
Control unit for InkZone Strip and InkZone Tape
With InkZone Strip, the winning strengths of InkZone technology can now be put to full use on offset machines from manufacturers Akiyama, Komori and Mitsubishi. InkZone Strip replaces the magnetic strip readers normally used on these machines. Tedious handling of sensitive magnetic strips and the associated risk of errors are now a thing of the past. Thanks to InkZone Strip, the preset data can be transmitted - online and secure – from prepress to the machine control station.
InkZone Tape: Planeta machines live longer with
Drag & Drop:
simple operation for every user
Planeta machines are used untiringly in many operations. But although their mechanical components guarantee excellent printing quality, the Fuji and WPC consoles used on these machines are not state-of-the-art. InkZone Tape achieves the same high-quality printing results, but faster and cheaper. The magnetic strip reader is simply replaced by InkZone Tape. After the transfer of preset data online, the ink slides travel into position automatically and precisely.
All InkZone connect products also accepting CIP4/JDF files from the prepress workflow and convert them into the specific machine format for controlling the ink keys. InkZone Connect supports JDF-based ink zone presetting in all heterogeneous machine environments.
Adjustment of the calculated preset data to the actual ink key values set on the printing machine enables continuous process optimisation, while the associated set-up times approach the absolute minimum. Naturally, individual jobs can be copied from the control station back to the computer and will be readily available for repeat orders.
A detailed description of the supported presses and consoles can be obtained here as a PDF file.
InkZone Report
Instrument independent, web-based color reporting
Real-time information about the difference between color standards and current print job quality
Now, color quality information can be accessed not only through local intranet network topology, but also by using a state of the art web server. InkZone Report has the ability to deliver print quality reports worldwide to different types of computer platforms by using a common web browser.
Measure and compare
In leading-edge print production, the ability to monitor daily output to meet international standards is imperative. InkZone Report enables the collation of color data on each job and verifies if current and post print run conditions are within the defined quality operating zone.
By automating the process of reading spectrophotometric and/or densitometric data, InkZone Report can store job quality information in a centralized SQL database. From this data pool, both single sheet and complete production reports can be generated in HTML file format. By clicking on the automatically created index file, the desired report can be selected and viewed on an unlimited number of workstations running a standard web browser (e.g. Google’s Chrome).
InkZone Report shows job target values and compares them against printed job data in the solids, (Lab and delta E), dot gains, mid-tone spread and substrate. The result is an onscreen “pass” or “fail” report for each print job. InkZone Report manages process colors (CMYK), as well as spot colors.
Printing to intranet or web
Based on HTML, InkZone Report
delivers print color information
as charts and numbers.
Graphics in InkZone Report are calculated from scanned color bar data and converted to HTML format. By clicking on specific spots inside the report chart, the user can immediately see the scanned color data information as mathematical figures.
By adding an Apache HTML web server, the availability of InkZone Report can be moved from local, directory-based intranet to the World Wide Web. This allows authorized users to have worldwide access to InkZone Report. InkZone Report measures the stability of color printouts and detects impact variations on print product quality.
A detailed description of the supported scanning devices and technical requirements can be downloaded here as a PDF file.
IZ Vacuum for the Techkon SpectroDrive
IZ Vacuum for Techkon’s SpectroDrive allows a
safe fixation of any substrates. Its suction plate
is fitted with a powerful suction pump, with a
double-row hole system allowing the SpectroDrive
to glide smoothly across the sheet. The sheet
rests firmly fixed for the entire scan, eliminating
substrate warping. This stable sheet positioning
drastically reduces substrate related measurement
errors so target colors can be attained far more
quickly, guaranteeing a stable print run with less
waste – job after job.
IZ Vacuum's powerful suction grip locks the sheet firmly into position, keeping the sheet perfectly flat.
Technical details of IZ Vacuum
The double-row vacuum hole
system.!
All Techkon SpectroDrive systems currently on the market including the
original SpectroDrive (supplied from 2012–2016), as well as the current
SpectroDrive NG (supplied from 2016–present), can be retrofitted with IZ
Vacuum.
IZ Vacuum is software-independent and can be used with any scanning
software (i.e., Techkon Expresso, IZ Move, and other products from known
manufacturers).
IZ Vacuum is available in any measurement length required – according to
the SpectroDrive’s measuring bar already fitted or to be ordered.
The SpectroDrive’s flexible mount uses magnetic adhesion with proven
reliability.
IZ Vacuum’s bottom side with its magnetic attachment.
A powerful suction pump firmly grips the paper.
Specifications
IZ Vacuum
• Supports all Techkon’s SpectroDrive systems currently available on the market.
• Software-independent.
• Sturdy, reliable unit available in any length required.
• Compatible with Techkon’s magnetic mounting system.
Vacuum pump
• Power supply 110/220 Volt, 0,45 kW.
• Weight 28.6 lb /13 kgs.
• Maximum vacuum 120 Mbar.
Configuration
DI-Plot
Software package for conversion and printout of bitmap files. Automatic reading and writing of CIP3 and InkZone files for presetting offset printing machines.
DI-Plot can read CIP3/4 files or proprietary bitmap files from which it calculates the percent dot area according to the printing machine used. In many cases, the reading of bitmap files (1 Bit Tiff, Delta lists, page buffer, etc.) can save the investment in expensive CIP3 extensions for the respective Rip/Workflow.
We recommend installing the DI-Plot software on a dedicated PC running Microsoft Windows XP Professional or Windows 7 Professional. The perfect hardware is an CPU Intel Core 2 Duo, 3.x GHz, 2 GB RAM, 80 GB hard disk, 10,000 RPM, 19-inch TFT monitor (touch screen recommended), USB. There are two important special hardware requirements: the PC should contain two Ethernet boards. One Ethernet line is connected to the customer's network (hub or switch), the other one is using a crossover cable and drives the InkZone Box/Card. This kind of installation ensures a clear separation between the box and the customer's network. And the PC should contain a free serial connetion (RS232) to drive the InkZone Tape and Strip solution.
InkZone
According to your needs our solutions InkZone Box, InkZone Card, InkZone Strip, InkZone Tape, or InkZone Perfect are being used.
Our distribution partners will be pleased to help you configuring the appropriate system for you.
A detailed description of the supported presses and consoles can be obtained here as a PDF file.
This list does not claim to be complete. Please contact us or any of our distribution partners if you require more information. A detailed description of the supported presses and consoles can be obtained here as a PDF file.
Conzett+Walter
Schlieren/Zurich, Switzerland. Offline Preset, Müller Martini web.
Bruhin AG
Freienbach, Switzerland. Offline Preset, Heidelberg sheetfed.
Schellenberg Druck
Pfäffikon, Switzerland. Offline Preset, MAN Roland and Heidelberg sheetfed.
Acorn Press
Lancaster (Pennsylvania) USA. Online Preset, Heidelberg sheetfed.
Koprint AG.
Alpnach Dorf, Switzerland. Online Preset and Preproofer, Komori and Ryobi sheetfed.
RR Donnelley Plant in Menasha, Wisconsin, USA
RR Donnelley Plant in Menasha, Wisconsin
Company Profile
RR Donnelley (Nasdaq:RRD) a global provider of integrated communications works collaboratively with more than 60,000 customers worldwide to develop customized communications solutions that reduce cost, increase pro- ductivity, enhance ROI and increase compliance. Drawing on a range of proprietary and commercially available digital and conventional technologies, RR Donnelley provides premedia, printing, logistics and business process outsourcing services to clients in virtually every private and public sector.
The RR Donnelley printing facility in Menasha, WI is G7 certified and employs approximately 400 people. With unmatched manufacturing capabilities and the latest tech- nology, RR Donnelley produces accurate, RR Donnelley Plant in Menasha Wisconsin high-quality, color printed materials including POP printing, corporate collateral, annual reports, books, business forms, catalogues, direct mail, packaging, labels, magazines, etc.
Technical Situation
Eight web presses and one sheetfed Komori 40" press anchor the RR Donnelley plant in Menasha, WI. RR Donnelley is an existing customer of Digital Information’s InkZone Ink- Presets and Closed Loop technology, having invested in the solution for their sheetfed press, along with the X-Rite IntelliTrax scanning instrumentation, a few years ago through CMYK Distributors. As an existing customer, RR Donnelley understands the value that InkZone brings to the pressroom in terms of automation, reducing waste, and increasing productivity. Featuring the ability to monitor trends and track job history, utilization of a rollback feature to revert ink key positioning, and the creation of ink key preset line- arization curves based on measurement data, running InkZone on their sheetfed Komori 40" press enables RR Donnelley to realize substantially shorter makeready time and a remarkable reduction in paper waste, paired with considerably-improved color quality.
Kirk Schmidt, RR Donnelley Technical Specialist
While they were extremely satisfied with the InkZone solution, the leadership team at RR Donnelley in Menasha, WI was interested in taking comprehensive quality color control to the next level and CMYK Distributors was there to deliver the solution. CMYK Distributors introduced RR Donnelley to InkZone Instrument Flight® by System Brunner for their Komori 40" press. InkZone Instrument Flight® by System Brunner is the premium upgraded product solution for InkZone for color verification, process diagnosis, and quality assessment, allowing users to harness the power of the world’s leading closed-loop instrumentation with the most sophisticated technology in standardization and printing process verification.
«At RR Donnelley, we are committed to providing our customers with the highest standard of quality and unpar- alleled service,» said Kirk Schmidt, Technical Specialist with RR Donnelley in Menasha. «By investing in InkZone and InkZone Instrument Flight® by System Brunner – technology that has breathed new life into our legacy printing equipment – RR Donnelley is realizing substantial savings in terms of time and materials on a monthly basis. InkZone Instrument Flight® by System Brunner is an invaluable tool for troubleshooting the press and helping us maintain our G7 certification.»
Solution
InkZone Instrument Flight® by System Brunner brings RR Donnelley color control with the priority on color/gray balance, leading to optimal color consistency with a high level of automation. The solution safeguards print results in accordance with international standardization concepts (Globalstandard®, ISO/PSO, worldwide standards) and rates print quality based on System Brunner’s 5-Star quality rating system. Moreover, the system permits extensive print process diag- nosis in real time that enables problems with the process or materials to be recognized and resolved by RR Donnelley’s press crew at an early stage.
(L to R) Randy Docta, 2nd press operator; Toralph Franz,System Brunner; Shawn Buelow, 1st press operator
Prior to installing InkZone Instrument Flight® by System Brunner, RR Donnelley noticed that even when measuring consistent solid densities and LAB values, it was still possible for disturbing color variations to appear in the image during a print run. A number of factors were responsible for these variations including ink; substrate; blanket; fountain solution composition, balance, and conductivity; press settings, etc. These color variations in the image were influenced by tonal value increases, gray balance, the three-color overprint behavior of the inks, trapping, the relationship of the solids to the tonal value, LAB deviations of the inks, etc. InkZone Instrument Flight® by System Brunner controls and regulates these technical parameters.
«With InkZone Instrument Flight® by System Brunner, RR Donnelley makes great strides in taking color control to a whole new level,» said Kirk Schmidt, Technical Specialist at RR Donnelley in Menasha. «First with InkZone and now with InkZone Instrument Flight® by System Brunner, RR Donnelley is poised to keep pace with the international printing industry by employing this cutting edge new technology.»
Offset Büttner GmbH, Westerngrund, Germany
InkZone Instrument Flight®: Efficiency in Color
In the Heart of Europe: Quality, Environmental Sustainability and Economy with InkZone Instrument Flight®. The recent admittance of Croatia into the European Union has shifted its geographical center to the German country town of Westerngrund, in the district of Aschaffenburg, at the northwestern corner of Bavaria. Defined by the «Institut de Geographie» of Paris, the location has been officially confirmed by the Bavarian Agency for Surveying and Geoinformation.
52 Years of Progress
In the more than half-century since Herbert Büttner founded Offset Büttner GmbH, the company has grown exponentially from a small copy shop to a commercial printing plant committed to delivering the highest quality printed materials and featuring the latest technology. Located in the small Franconian country town of Westerngrund, Offset Büttner GmbH is an important mainstay in the local business community.
Their choice to go with InkZone Instrument Flight® is reaffirmed daily: Harry and Michael Büttner (from left).
After growing and refining Offset Büttner GmbH for more than 30 years, Herbert Büttner passed the torch to his sons, Harry and Michael Büttner, who have been capably running the family business since 1993. Honoring the standard of excellence set by their father, Harry and Michael Büttner have taken the company to new heights, positioning Offset Büttner GmbH as the industry’s premier innovation partner for print and media services. In addition to local advertising agencies and direct print customers, Offset Büttner GmbH’s reach extends beyond regional bound- aries, encompassing the entire federal state of Bavaria, and serving well-known companies in industries including medical goods, organic food delivery services, tourism, etc.
Commitment to Environmental Sustainability
Offset Büttner GmbH is committed to investing in technology that enhances the efficiency and cost-effectiveness of their business, as well as minimizes their environmental footprint. Under Harry and Michael Büttner’s leadership, Offset Büttner GmbH has become a best practice model for environmental protection and stewardship in the printing industry. For plate imaging, Offset Büttner GmbH uses chemistry-free materials in which the moistening solution has an alcohol content of zero percent. In addition, they print with mineral oil-free inks and their paper supply originates from sustainably managed forests. They also use «green» energy to power their facility.
Why InkZone Instrument Flight®?
Advancing the company’s overall strategy and commitment to technology and solutions that promote sustainability, Offset Büttner GmbH recently investigated and selected a new ink preset and color control system for their sheetfed offset printing press. The company sought a solution that would enable them to reach target color values quickly, thereby reducing paper waste and makeready time.
Upon learning that Offset Büttner GmbH was evaluating this type of technology, their graphic products supplier, Heinrich Baumann Grafisches Centrum, introduced Harry and Michael Büttner to InkZone Instrument Flight®, the world’s leading universal solution for color control developed in partnership by Digital Information and System Brunner.
At a large-size monitor, Michael Büttner monitors all of the parameters of safe color control.
We wanted a system that measures not just the densities in the solids, but also considers how screened halftones and color balance influence the settings,» said Michael Büttner. «InkZone Instrument Flight® is exactly what we were looking for. It is a multi-channel solution that takes into account the L*a*b* values, dot gain, and the gray balances in the midtones and shadows – according to control priority chosen. InkZone Instrument Flight® gives us the tools we need to achieve optimal comprehensive industry standards.»
High color consistency during the print run
Offset Büttner GmbH uses different control priorities depending on the requirements of each print job (density balance in the solids, ISO/PSO, or gray balance). InkZone Instrument Flight® safeguards the print results in accordance with international stan- dardization concepts (Globalstandard®, ISO/PSO, wolrdwide standards) and rates print quality based on System Brunner’s 5-Star quality rating system. Moreover, the system permits extensive print process diagnosis in real time that enables prob- lems with the process or materials to be recognized and resolved at an early stage. Or, as Michael Büttner put it, «One sheet is like the others.»
Harry Büttner expressed his satisfaction with InkZone Instrument Flight® and noted the fact that the presetting system does not necessarily require CIP3 data transmission from prepress. It is capable of optimizing the preset calibration from saved press data. «InkZone Instrument Flight’s® simple and straightforward user interface – especially the concept of working with “image zones,” – has enabled our team to get up to speed quickly and to harness the color verification, process diagnosis, and quality assessment capabilities of InkZone Instrument Flight,» explained Harry Büttner. «We are very pleased with the comfortable way that color casts can deliberately be set. The fact that color balance is regulated not only by solid density but also by several other variables took some getting used to. But it was extremely helpful in getting a better understanding of how the solids and dot gain depend on each other.»
nkZone Instrument Flight® contributes to a higher awareness of quality, indicated by the fact that more and more proofs are produced in order to define the target point visually. «During the production run, we are able to reach the required standards without any problem and we can also adhere to them,» confirms Michael Büttner. «In this context, I would like to highlight that InkZone Instrument Flight® is capable of maintaining the visual appearance alongside the sheet mar- gins in case the densities change (e.g. unstable ink/water balance).»
Thanks to InkZone Instrument Flight®, Offset Büttner GmbH has gained considerably better control over the offset process. «This is of particular importance when working without alcohol in the moistening solution because the ink/water equi- librium tends to lose stability/balance more quickly» says Michael Büttner.
Important component: the PrintCurve Checker
Further enhancing the functionality and success of their installation of InkZone Instrument Flight®, Offset Büttner GmbH took the recommendation of Digital Information’s German distributor, go4color, and added PrintCurve Checker by System Brunner to their overall solution. The PrintCurve Checker measuring system integrates Techkon’s SpectroDrive scanning device to collect the measuring data within seconds. The Software calculates the mean Tone Value curve from serveral readings, from which the RIP correction curve for each color is then extracted. Printing characteristics are produced within seconds and measurements are curves across the entire print run. With these checks, process variations can be detected which may occasionally occur due to the materials used.
The PrintCurve Checker by System Brunner enables the creation of reliable tone value curves in just a few seconds. From several readings, the mean curve is calculated and a RIP correction curve is deduced.
For example, thanks to the PrintCurve Checker, Offset Büttner GmbH recently discovered that their printing plates were prematurely wearing during long print runs and were able to resolve this problem, saving time, money, and resources. «Without the tools we now have with our com- prehensive InkZone Instrument Flight® solution, we would never have been able to monitor such fluctuations or to resolve issues so expeditiously,» said Michael Büttner.
Objective achieved
The Büttner brothers and their team at Offset Büttner GmbH are very pleased with the InkZone Instrument Flight® solution. Thanks to an initial introduction from Heinrich Baumann Grafisches Centrum and further recommendations, support, and professional assistance from the team at go4color and System Brunner, Offset Büttner GmbH is now a best practice InkZone Instrument Flight® operation, equipped to handle color control far more consciously. «We are delighted with our decision to install the InkZone Instrument Flight® solution on our offset press. The quality of the sup- port that we get is incomparable and the value and wis- dom of the decision to go with InkZone Instrument Flight® is reinforced daily by the quality of our work and the meas- urable savings we are seeing in terms of our resources and time,» said the Büttner brothers.
Key benefits of InkZone Instrument Flight by System Brunner include:
Optimal color consistency
Better harmony between human color perception and control software
The most comprehensive industry standards
Quality rating with the System Brunner 5-Star Score
The most comprehensive printing process diagnosis
Permanent training tool, optimized communication between the prepress and printing operations
Grafimedia AG
Contented faces after successful PSO certification (from left): Peter Breu, Grafimedia AG; Roland Gisler, Digistuff AG, Andreas Breu, Grafimedia AG, the printing technician Adela Kujovic; Erwin Widmer, UGRA St. Gallen; Martin Breu, Grafimedia AG.
The All-In-One Package
In opting for the InkZone solution from Digital Information, Grafimedia AG acquired a complete system for working at a consistent printing quality. The key components of their system are: InkZone Perfect for presetting ink keys prior to press makeready; InkZone Loop - a closed-loop color solution which helps maintain on-press results within the tightest of tolerances; and InkZone Move Press for automatic scanning with the affordable X-Rite EyeOne (i1) spectrophotometer. InkZone Move Press has been approved by UGRA, the Swiss standards institute for the graphics industry, as a solution to obtain certification to ISO 12647-2 (sheetfed offset printing). A color bar developed by UGRA is an official part of the InkZone Move package.
Dreaming About PSO Certification
Grafimedia AG has long been aware of the importance of standards as a means not only for promoting internal efficiency, but also for delivering quality to customers and for differentiating their printing services in the marketplace. Although Grafimedia's working practices have always been organized with standards in mind, they were never officially recognized as such. One reason for this is that PSO certification requires the use of a scanning measuring instrument - and for a company of Grafimedia's size, that's a considerable investment, especially considering the large price tag associated with press manufacturer's solutions.
Unbeatable in price and performance
With the recent introduction of InkZone Move Press to the market, however, the situation at Grafimedia changed. The affordability, quality and adaptability of this new solution from Digital Information makes it ideal for this type of situation.
The measuring system relies upon the EyeOne, a commercially available, open-ended and accurate spectrophotometer. On the price/performance side, this measuring device is unequaled. Grafimedia saw the benefits, equipped their Heidelberg Speedmaster SM 52-6 with InkZone Move Press, and also installed the optional DC2 (Digital Control) electrical drive to ensure ease of use and more reproducible measurement results. With this arrangement, the press operator triggers the fully-automatic measurement sequence via a graphical, touch-screen interface.
An Excellent Foundation in Pre-Media
With products from Digital Information, Grafimedia has always been sure of sound and economical investments. Like thousands of others in the printing industry, they have relied upon DI-Plot software to output imposed proofs prior to making plates for the press, in this case via a Harlequin RIP. In terms of workflow, DI-Plot simply sends the zone coverage values as JDF files to InkZone Perfect, which then converts the data into calibrated values for presetting the ink keys and duct rollers on the six-color Heidelberg. So with only a small capital outlay, the full package including DI-Plot, InkZone Perfect, InkZone Loop and InkZone Move Press brings the sheetfed press at Grafimedia AG up to the very latest specification, while also making their operation more efficient.
Theissen Druck GmbH
Compared with previous systems, for each job, InkZone saves between five and ten minutes between introducing the plate and resuming production.
At Theissen Druck GmbH, Process Standard Offset (PSO) is the way of life. An indispensable quality assurance tool for this printing process is the Techkon RS-400 with closed loop color control software. Using InkZone Perfect for presetting the ink keys and InkZone Loop for color control, the life cycle of the printing presses have been extended at a small fraction of the cost of adding new presses. The presses printed well, they just needed an infusion of technology. The result: press operators embraced the system for the benefits the equipment has brought into the pressroom.
Theissen Druck GmbH operates the InkZone Loop control system with Techkon measuring technology.
1000 hours saved each year
At Theissen Druck GmbH in Monheim am Rhein, production in 8/up format runs on two Speedmaster SM 102s (with four and six printing units respectively), and in 2/up format on a Speedmaster SM 52. All printing presses are connected online to prepress via InkZone Card and receive the JDF files from the workflow via DI-Plot for precise presetting of the ink zones.
Production is a three-shift operation, with the number of makereadies stated as 6000 to 7000 per year. "Compared with the previous "sneaker-netted" offline presetting system, the InkZone Perfect presetting solution from Digital Information saves us between five and ten additional minutes between introducing the plate information and resuming production", says Thomas Arenz, who as Managing Director is responsible for production. Based on the total number of makereadies, the extra capacity amounts to 1000 hours a year. Theissen Druck receives additional added benefit by being able to modify curves easily at each press for various stocks and inks.
InkZone Loop fills important gaps in the marketplace
"When we decided to make our printing house fit for the PSO certificate, closed loop color control finally became the topic of discussion", says Thomas Arenz. Accordingly, at the end of 2006, Theissen Druck GmbH equipped the CPC consoles on both its approximately eight-year-old printing machines with a Techkon measuring system plus Digital Information's InkZone Loop ink control software. For the measuring procedure, the printer runs the densitometer over the measuring strip manually with the aid of a magnetic rail. A motorized scanning track is also available as an option.
"On the road to more efficient utilisation of capacity and improved quality assurance, InkZone fills an important gap in the marketplace", Thomas Arenz claims. "The really big boost to productivity in the printing process came in the 1990s with automatic plate changes and washers for the blanket and ink fountain/damping rollers and the printing cylinder. Since then, any improvements have tended to be marginal. In contrast, at a comparitively low price, we now have the InkZone solution, which gives a fresh boost to automation and definitely brings us a lot further - from the points of view of efficiency and also achievable stability at a high level of quality."
Thomas Arenz, Managing Director at Theissen Druck GmbH: "Thanks to the InkZone solutions, we are extending the service life of our eight-year-old printing machines by a further three years."
Service life extended by three years
Before the installation of InkZone Perfect and InkZone Loop, Theissen Druck GmbH would have been looking at the replacement of a Speedmaster SM 102 by a state-of-the-art printing machine. "Naturally, InkZone presetting and closed loop color control would be part of the overall package with any new investment, but we would have paid an incomparably higher price for it. With the InkZone solutions from Digital Information, we get exactly the same performance, but at a much lower cost", says Thomas Arenz, who points to the efficiency aspect in particular. "Our two Speedmaster SM 102s are now eight years old and have paid for themselves in full. When it comes to printing quality, they are the equal of any new machine. Now, thanks to InkZone Perfect and InkZone Loop, we can run production on the existing technology for at least three more years. Here, we profit from genuine added value."
Imprimerie LVRI
The printers at Imprimerie LVRI rate InkZone Perfect and InkZone Loop as reliable and very easy to use.
Imprimerie LVRI has equipped its KBA Rapida 105 with Ink Zone Loop interfaced with the IntelliTrax scanning system from X-Rite to provide closed loop ink control. In addition, ink preset data for each ink zone is delivered to the press by DI-Plot in conjunction with InkZone Perfect ink preset software. According to the customer, the high data quality means that InkZone gives printers maximum security when operating the system.
State-of-the-art technology behind an old facade
"We think the InkZone solution is a winner." With this short statement, Fabrice Houillon expresses his enthusiasm for InkZone Perfect and InkZone Loop. Together with his wife Mathilde, he runs Imprimerie LVRI, based in Corbeil-Essonnes to the south of Paris with some 20 employees. Although housed in an old building, this printing company can point to state-of-the-art equipment throughout. In the press room, there is a Rapida 74 with four printing units plus a KBA varnishing unit, and a four-color Rapida 105.
The X-Rite IntelliTrax is one of the fastest scanning systems. The colour-bar on a 105 cm press-sheet is scanned in just 15 seconds.
InkZone exceeds expectations
Imprimerie LVRI has been using X-Rite' ATD scanning technology for color control for the last seven years. Adjustment of the ink keys were not interfaced from the X-Rite ATD directly to the ink console. Make-readies were slower and waste was higher than necessary without the benefit of ink key presetting. The systems installed at LVRI before either lacked the required precision or were unsatisfactory from an operating point of view. Fabrice Houillon eventually found the solution he was looking for in the form of InkZone Perfect for presetting the ink zones and InkZone Loop for closed-loop ink control. When asked about the reasons behind his enthusiasm for this product, Fabrice Houillon's answer is clear and concise: "The InkZone solution from Digital Information is completely reliable and very easy to operate. Immediately after it was installed, we were able to use the software productively". Fabrice Houillon can also confirm that the system is stable, and that so far there's been no need for support.
Reliability brings high security
The data for the ink zone preset is calculated by DI-Plot on the basis of a bitmap generated in the RIP imaging device. It is sent direct to the printing press console via Ethernet. Fabrice Houillon points to the high data quality in particular. "We can depend on the JDF files. The values create the required print-job color profile with above-average precision. Our press operators have become very confident with the system, and feel secure when using it. With reduced doctor/ sweep movement, the ink keys can be opened wide. The result is greater latitude when setting the keys with fine adjustments of the correction options."
Having replaced the ATD with the new IntelliTrax scanner, Imprimerie LVRI also benefits from a high measuring speed. It scans the colour bar on a 105 cm press-sheet in just 15 seconds. InkZone Loop shows the measurement values for each ink unit on the screen's graphic interface. The press operators themselves will decide on the extent to which they should accept the corrections that the system recommends.
Mathilde and Fabrice Houillon are the second generation to run the company, which was founded by father Georges Houillon in 1954.
Commitment and quality stay the same
The foundations of Imprimerie LVRI were laid in 1954 by Georges Houillon. His brother and son Fabrice joined the company some twenty years later, which from then on operated under the name LVR (Lithographie des Vignes Rouges). The printing operation experienced strong growth in the following decade, and in 1985 LVR became LVR International (LVRI). In the fifty or so years of its existence, Imprimerie LVRI has kept one thing the same: the fulfilment of high quality demands by a committed and professional team of employees.
Stern Druck GmbH
On the Speedmaster SM 52, presetting the ink zones using Ink Zone Card saves about 15 minutes per job.
At Stern Druck GmbH, the complete InkZone solution, with ink zone ink presetting and closed loop color control, is being used on a Speedmaster SM 52. The system configuration uses an X-Rite i1 spectrophotometer as the measuring device, for a low-cost, high-performance solution for press sheets up to 29 inches in width.
15 minutes faster per job
Stern Druck GmbH runs its production on a Roland 706 with varnishing unit and a Speedmaster SM 52-6. This press operates from a CPC console and receives the ink zone preset values from DI-Plot through InkZone Perfect via InkZone Card. The DI-Plot proof software was installed seven years ago for generating proofs from a bitmap created by a Harlequin RIP. Since then, the operation has changed over to the Prinergy workflow system with computer-to-plate. DI-Plot has taken on an additional role in the workflow and now also delivers the JDF files for precision ink zone presetting to the Speedmaster SM 52-6.
"We gain about 15 minutes per job when presetting the ink zones", says printing technician Andreas Pfister. With most print runs varying between 2500 and 10,000 printed sheets, much faster makereadies are going to make all the difference.
With Ink Zone Loop control software, the i1 spectrophotometer from X-Rite is a professional, low-priced solution for use on 2up and 4up format printing machines.
Simple operation, high process security
Equipping the press with InkZone Loop was the next logical step. In addition to presetting the ink zones, the closed loop color control software provides press operators practical support and is effective in lightening the load when monitoring quality control thereby improving print reproduction consistency. Connection of the i1 spectrophotometer with the Ink Zone Loop control software results in a professional and low-cost solution, the use of which is fully justified on the Speedmaster SM 52 from the operational efficiency viewpoint.
"InkZone Loop has proven to be a very efficient aid to quality assurance", says Andreas Pfister. "Even with smaller print-runs, we obtain much more stable print results. The user interface is clear and concise. So working with the system is very straightforward. As printers, we get a very secure feeling when monitoring production".
Company founder Jörg Höllwarth (to the right) and his son Michael
Commitment and quality stay the same
Stern Druck GmbH has been based in Fügen (Zillertal, Austria) since its foundation by Jörg Höllwarth in 1980. Today, the family-owned company has 35 employees, with ten working creatively in the company's photographic/graphics studios, or in layout and copywriting. It is a full-blown operation, offering services that extend all the way through to perfect-bound finished products. Last year, some 1400 tons of paper left the premises.
"We see ourselves as part of the upper quality segment", says Jörg Höllwarth, underlining his statement with a cross-section of the printwork that is processed in-house from A to Z. Often, UV and emulsion varnishes are used. Hybrid technology is also a frequent enhancement for Stern Druck's clients. "We do not actively look for orders. For us, advertising is work that's executed both well and on time. No job is too small for us", says Jörg Höllwarth, and points to print-on-demand as a further strength at Stern Druck GmbH.
Lagoprint GmbH
Printing is on a total of ten printing units in formats 70 x 100 and 50 x 70 cm.
At Lagoprint GmbH, in Rielasingen, Germany, six ink units on a Heidelberg Speedmaster CD 102 as well as four on a SM 74 are controlled online via InkZone Card. InkZone Card redirects the data transferred from prepress to the separate printing units for precision setting of the ink zones.
Quicker set-up, better quality
Each day, Lagoprint, a specialist in display, packaging and commercial work, is confronted with difficult forms and increasingly short print runs. So, in order to reduce set-up times to a minimum and achieve production-quality printing quickly, a direct connection for online transfer of the ink zone values was extremely welcome. Both the Heidelberg printing machines are connected via Ethernet (TCP/IP) and InkZone Card to the existing Prinergy Workflow. The versatile DI-Plot proof software converts bitmap data into ink zone values that are then accessed directly from the printing machine and transmitted online to the control console. The control software included in the InkZone package automatically accepts the conversion and linearisation of the bitmap calculated by DI-Plot in the specific Heidelberg machine format.
A milestone in networked production
The preset data for the ink zones are transmitted online to the control console of the Heidelberg CD 102 and SM 74 via InkZone Card (below right).
According to Metin Sentürk, Managing Director of Lagoprint, InkZone Card is nothing short of a milestone on the road to complete process networking. With the open InkZone concept, software developer Digital Information has succeeded where the manufacturers of prepress systems and printing machines have thus far failed: namely, the network-based transfer of data between systems of different origins. "A printing house we know in Switzerland drew our attention to InkZone", says Metin Sentürk. "The online solution promised by Digital Information at Drupa 2004 with InkZone Card was exactly what we had in mind to finally replace the so-called sneaker net with modern process networking. A half year later, and both our machines were equipped with InkZone Card."
Ancient House Press Plc.
A year ago, Ancient House Plc invested in an eight-colour KBA Rapida with CIP3 interface to the Agfa output workflow. With immediate recognition of the benefits of CIP3, Ancient House was looking for ways to transfer the ink zone presetting values to an existing Speedmaster 102 with eight printing units (adjustable after the fourth unit).
At the same time, the company became aware of InkZone Box from Digital Information A comparison of cost versus performance led the customer to view an existing InkZone system at Drukkerij Schuttersmagazijn BV in the Netherlands. where the ink zones on three Heidelberg machines - two SM 102s and an SM 74 - were being preset on a central InkZone Box. Immediately after the visit, Digital Information received an order to supply and install an InkZone Box with InkZone-Perfect. InkZone-Perfect puts Ancient House Press in a position to assign the values calculated for a job to any printing unit regardless of production type (recto/verso or recto only).
There is also web offset production in the Ipswich printing house. Only a few months after commissioning InkZone Box in the sheet-fed area, the old tape drive on the web-fed press was replaced by the Heidelberg Jobcard. By adding the appropriate format to DI-Plot, at no extra cost the customer acquired the option to select ink zones directly from DI-Plot in web offset, too, and write them to the Jobcard directly via InkZone Box.
Ancient House Press Plc. in Ipswich uses InkZone Box for presetting the ink zones on a recto-verso machine (InkZone-Perfect) and a commercial web press.
De Vries Communications Centre
At De Vries Print Work in Zierikzee (The Netherlands) a reduction in make-ready times of 15 minutes per job is achieved with InkZone.
A full range of services from creation through to production lie behind the success of the DeVries Communications Centre, founded by Dannie de Vries in 1980. Accordingly, the company is divided into De Vries Advertising and De Vries Print Work.
At De Vries Print Work, production comes off a four-colour KBA-Rapida (Format 52 x 72 cm). In 2002, the company invested in state-of-the-art CtP technology. The digital workflow via direct plate imaging was, however, insufficient; the ink feed profile on the four printing units still had to be set manually at the control consule.
Noting the products on offer from Digital Information Ltd, in January 2003 De Vries Communications Centre decided to fill the gap between the two key prepress and press sectors with DI-Plot and InkZone Box. The company thus scored twice over: with DI-Plot, form proofs can be created from data off an RIP imaging device that is 100% definitive with regard to content and status. At the same time, the imaging data is used to calculate the ink zone values which are then written to a data carrier in the specific KBA format and entered at the control console.
Dannie De Vries: "With DI-Plot and InkZone we reduce the make-ready times on the printing machine by 15 minutes per job. And we also gain from a considerable reduction in paper costs".
The ink zone values converted to the corresponding format in InkZone Box are entered at the control console via data carrier.
Conzett+Walter
At Conzett+Walter, InkZone production delivers the zone values for the BST Monigraf ink zone control system on an A52 (pictured) and a GMI Microcolor system on a Müller Martini Concept.
Conzett+Walter AG has existed in its present form since 1997. Prepress, printing, finishing and the personalisation of mailings, leaflets, flyers, brochures and forms are accommodated on several floors.
In endless web offset, capacity comprises a total of 23 Müller Martini printing units. A six-colour A52 and an eight-colour Concept use open, PC-based BST Monigraf and GMI Microcolor systems for remote ink control. Up to the spring of this year, calculation of the ink zone presetting values was done on a plate scanner. "We had long been on the lookout for a solution for entering zone values into the control system via CIP3 directly from prepress", says Production Manager and Director Peter Buri. "Thanks to the simple concept and low investment cost, it was the Digital Information solution that finally convinced us."
The connection between the prepress workflow and the two printing machines is formed by a DI-Plot station that calculates the amount of surface coverage from the RIP bitmap and writes the corresponding zone values to a data carrier. The target ink control system (BST Monigraf or GMI Mircocolor) is simply selected from the menu, and the system will then automatically choose the correct format. Peter Buri: "Per job, our machines are now productive an hour earlier compared with the roundabout route with the plate scanner".
Compared to the plate scanner previously used, endless web offset machines are productive one hour sooner for each job.
Bruhin AG
Bruhin AG in Freienbach exploit the synergies of DI-Plot and InkZone Box. The bitmap files calculated in the CREO-Impact-Workflow are accepted by DI-Plot and passed on to the InkZone Box as InkZone files via Ethernet. In InkZone Box, the files are converted to the special Heidelberg format and written onto the Job Memory Card. This card is used by the CPC control console of a Heidelberg Speedmaster 102. At the same time, DI-Plot uses the same bitmap data for content- and status-specific formproof output on an HP Designjet 2500 and for the generation of CIP3 files for online presetting of the ink zones on a Komori Lithrone 540.
Schellenberg Druck
At Schellenberg Druck AG InkZone is used as the link between prepress and press on Heidelberg and MAN Roland machines.
With over 200 employees, Schellenberg Druck AG with headquarters Pfäffikon is one of the region's key graphic industry companies. Together with various subsidiaries, the company is active in all areas of visual communication.
Printing machines operated in Pfäffikon comprise two-, four-, five- and ten-colour machines by Heidelberg and MAN Roland. For all sheet-fed machines equipped with remote ink control, zone setting values are calculated centrally with a DI-Plot station and InkZone Box.
Last-moment changes from the administrative department do not represent a problem for InkZone Box. InkZone Box is equipped with a number slots that correspond to the different machine data carriers. By simply selecting the machine on the integrated touch screen, the zone values will be converted into the correct format.
InkZone Box (centre) writes the ink zone preset data in all familiar printing machine formats to the corresponding data carriers. To the left of the picture is the user interface to the DI-Plot form proof software; the screen on the right shows a preview of the imposed print form.
Acorn Press
InkZone Card has been a time-saver at Acorn Press where three Heidelberg Speedmasters are now up to production speed much quicker.
Acorn Press is a mid-sized commercial printer who is striking a profitable balance between servicing their local customers well and investing in new technologies to drive efficiency. Their 100-employee facility in Central Pennsylvania was started in 1956, and today has revenues exceeding $10 million based on their full service capabilities including prepress, digital and offset printing, die cutting, bindery capabilities, mailing and fulfillment.
The workhorses at Acorn Press are their two 6-color Heidelberg SM102 presses. Despite their age, these solid machines are well maintained to deliver quality color results, and recently have been upgraded to deliver increased efficiencies that rival the capabilities of the latest press technology thanks to new InkZone Card systems.
In reviewing the technology landscape, the management team didn't want to take-on the burden of entirely new presses in order to leverage the latest press features like ink-key presetting. Their recent investments focused on expanding prepress capabilities with a Creo CTP installation and the addition of Indigo digital printing capability, so further investment in new sheetfed equipment would have been a stretch. Instead, Acorn Press contacted Digital Information about the InkZone Card, a unique system that leverages their existing prepress investments in CTP to significantly reduce on-press makeready time on their legacy sheetfed printing equipment.
Acorn has taken advantage of existing CTP investment with InkZone Card; it simply plugs in to the job-card reader of their Speedmaster consoles.
The performance of InkZone on the 40 inch presses, and the low incremental cost of adding another press, easily justified Acorn Press to add their SM74 6-color into the digital ink preset workflow. Management is now evaluating the addition of Closed Loop Color Control Software using an X-Rite Scanning Densitometer.
Scott Reighard, President Acorn Press admits that the amount of makeready waste depends on the prior print run, but like the seasoned presses at many commercial print shops, those at Acorn now boast makeready times that are up to 25% more efficient, saving thousands in monthly time and materials. Operators are not only getting to color faster on each run, there is also increased consistency between presses and crews, making the entire pressroom more efficient.
Koprint AG: Printing is better double
With Digital Information's Preproofer 740, double-sided formproof production at Koprint AG is efficient and economical. The output process is controlled by the DI-Plot software package. Linked with InkZone Perfect, DI-Plot also delivers JDF files for presetting ink-zones automatically on two printing machines of different manufacture.
Preproofer 740 runs at up to 16 double-sided printed formproofs per hour
Koprint AG has been working with DI-Plot from Zurich-based software developer Digital Information since 1998. Located in Alpnach Dorf, the family-owned company is one of the early users of this versatile proof software, which can be integrated into any prepress environment. The company continues to work with a delta workflow, with DI-Plot sampling the ripped bitmaps down to the required resolution to produce a formproof that is absolutely accurate as far as layout and content are concerned.
After nearly ten years and with more than 2000 licences granted worldwide, DI-Plot is still holding its own as a future-proofed solution that can keep pace with the latest developments in the different prepress workflow solutions. Which is why Koprint has recently gone over to double-sided proof outputting with a Preproofer 740 from Digital Information. In a further efficiency measure with InkZone Perfect, the company has now made the connection for presetting the ink zones on two offset machines from Komori (52 x 72 cm) and Ryobi (52 x 36 cm), each equipped with five printing units. DI-Plot is used as the data source and control platform for proof outputting on Preproofer 740, and also for InkZone Perfect. For Managing Director Jochen Konrath, who is in charge of operations, the value of the proof software is confirmed over the long term because it can continue in use with Koprint's upcoming investment in a new workflow system.
DI-Plot is the control platform and data source for Preproofer 740 and at the same time calculates the JDF data for ink zone presetting via InkZone Perfect.
Lower costs, higher performance
In Alpnach Dorf, the annual consumption of print plates is around 13,200. Then there are 6,500 plates for Gersag Druck AG in Emmenbrücke, which was acquired by Koprint AG in 1989. At Gersag Druck, production runs on a convertible Speedmaster 74 with five printing units.
With the installation of the Preproofer 740 four-page system, Jochen Konrath can confirm that expenditure on proof production is down by almost a half: "Thanks to Digital Information and Preproofer, we achieve clear savings from several points of view. Compared to earlier methods where we could only output single-sided proofs, we now use both sides of the sheet and consume correspondingly less paper. Also, by dispensing with gluing, we are much faster and more accurate. We gain time, make considerable savings in the cost of materials, and attain a very appealing proof quality that comes close to the actual printing result." And that's not all. With the CMS capability of DI-Plot, when it delivers the formproof Koprint is at the same time giving customers an "OK-to-Print" that goes a long way to resembling the final print result from the colour point of view, as well.
Quality with Piezo technology
Preproofer 740 is based on two Epson Stylus Pro 7400 printers - currently the fastest inkjet system on the market. Depending on the chosen resolution, speeds reach up to 16 double-sided proofs per hour, while a new screening method allows excellent reproduction quality down to even the finest details and with low resolutions, too. Micro Piezo technology functions on the drop-on-demand principle and enables precision control of the ink droplets as far as size, shape and positioning on the substrate is concerned. In addition to brilliant printing results, the outputting process can be accelerated while saving on ink consumption by varying the droplet size according to the subject.
Front and back without turning
Double-sided formproofs can be produced in one pass without turning the paper thanks to the offset configuration of the vertically displaced printers. Preproofer works on the roll-sheet print principle where output of the front is off the roll and output of the back is on the cut sheet. For outputting the back, the sheet is moved by gravity alone and scanned for precision register printing by the system before DI-Plot releases the data. With no mechanism required for turning the sheet, the result is reduced maintenance and fewer spare parts.
At Koprint, ink zones on a Komori and a Ryobi are automatically preset using InkZone Perfect.
With JDF to the ink-zone preset
Print shop production at Koprint is in a heterogeneous environment. A five-colour from Komori in 52 x 72 cm format, a five-colour from Ryobi in 36 x 52 cm format, plus two A3 Ryobi models, each equipped with two units, add up to a total of 14 printing units.
The installation of InkZone Perfect for online ink-zone presetting on the five-colour machines makes for an economical solution with a high streamlining effect. With InkZone Perfect, both systems can be supplied with presetting data, thus avoiding the need for relatively expensive proprietary CIP3/4 connections for printing machines from two different manufacturers. DI-Plot calculates the JDF files with the zone values from the bitmap data delivered by the imager RIP and then transfers them to InkZone Perfect. The software is not dependent on the type of printing machine and offers functions like linearization to individual printing conditions, the display of ink-zone values, visualisation of the printing job with the separate imposed composite forms, and ductor control. Thanks to a simple drag-and-drop function, the press-man can allocate the individual separations with the preset values for CMYK and special colours to the printing units.
With a simple drag-and-drop function, the press-man assigns the preset values to the separate ink zones on the printing machine.
"One thing is clear: the preset solution from Digital Information makes things much simpler and speeds up the process", says Jochen Konrath. "Previously, we needed between 30 and 45 minutes per printing job for setting the ink zones manually. Thanks to InZone Perfect, we are ready for the production run after fifteen minutes. Also, the software allows us to adapt the calculated preset data to the effective ink-zone values and thus further optimise set-up times. A further productivity bonus comes from the option to save job data for repeat jobs."
Buoyant growth
The satisfaction shows (from left to right): Gregor Keiser, Manager PrepressJochen Konrath, Managing Director Koprint AG, Michael Haenni, Digital Information
Koprint AG was founded in 1984 when Austrian Werner Konrath acquired former book printers Ehrli Druck AG in Sarnen. Eleven years later came the move into modern premises in Alpnach Dorf, the present-day location, and the change of name to Koprint AG. Since 1989, Emmenbrücke-based Gersag Druck AG, a company that is well established in the region, has also been owned by Koprint AG. Recently, Kneuss Print AG of Lenzburg was taken over by the service provider, which has now grown to employ more than 40 staff. The customer base is mainly manufacturing companies, banks, insurance organisations and firms in the IT sector. Because Koprint remains largely independent from agencies, the services are not restricted to tasks relating to printwork production but range from the development of graphic design concepts through artwork production and printing to the finished product.
InkZone Fountain: The Clear Choice
Ast & Fischer Ltd. is committed to superior performance and precision. To help achieve the level of excellence that their customers expect, Ast & Fischer Ltd. became the first European company to install InkZone Fountain. With IZ Fountain, Ast & Fischer Ltd. realized remarkable gains in the stability and security of their print production process.
First installation in Europe
Efficient production with InkZone Fountain: One of Ast & Fischer’s two KBA 106 at Bern.
InkZone Fountain is an innovative four-step fountain solution filtration system designed to purify the fountain solution of sheet-fed presses by any manufacturer. InkZone Fountain is manufactured by Swiss company Digital Information and is distributed in Switzerland through Digistuff Ltd. in Zurich.
Recently, Ast & Fischer Ltd. at Wabern (on the outskirts of Bern) became the first European company to install InkZone Fountain. Ast & Fischer Ltd.’s offset division has two sheet-fed, KBA Rapida 106 presses which were put into operation in 2008 and 2010. Both presses run without alcohol in their fountain solution. At the beginning of 2013, InkZone Fountain was installed into the fountain tank of the newer of the two presses.
Quality and efficiency
Ast & Fischer Ltd. chose to install InkZone Fountain because they were dissatisfied with the performance of their original fountain solution filtering system. Calcium, paper dust, fillers, coatings, and other residue from paper were not being filtered out sufficiently and were causing ongoing, severe contami contamination of their fountain solution. The result was consistently unstable print runs as the ink/water balance was extremely difficult to maintain. The amount of fountain solution on the printing plates was reaching unacceptable limits leading to drying problems and delays in further processing, which in turn put delivery deadlines at risk. Only by changing the fountain solution several times per week could the print product’s quality standards be met. These frequent press downtimes significantly reduced productivity.
Martin Schütz (Ast & Fischer, right) and Michael Haenni (Digital Information, left) both agree: InkZone Fountain stands the test on a daily basis.
Clean water within three hours
The InkZone Fountain Filtration Solution was installed at Ast & Fischer Ltd. in just two hours without interruption to the print run. Their fountain solution filtration situation improved within only three hours after putting InkZone Fountain to work. Samples taken became visibly clearer by the hour. By the third hour, the water in the tank was completely clear without evidence of any contaminating particulates. «Almost immediately, we were able to realize a decrease in our consumption of fountain solution, our ink drying was accelerated, and the entire printing process became considerably more stable with InkZone Fountain,» said Martin Schuetz, Head of Printing & Post-Press Processing for Ast & Fischer Ltd. «We are also pleased that the InkZone Fountain filtration system was able to eliminate the unpleasant odors associated with dirty tank water. Since installing InkZone Fountain three months ago, we have not had to change our tank water». While Mr. Schuetz notes that it is too early, yet, to comment on the effectiveness of InkZone Fountain in being able to extend the time between changes of tank water to up to one year or more, Ast & Fischer Ltd. is very pleased with the increased reliability of their printing process, to date.
ROI within six months
Easy-to-read information on filter condition via green/yellow/red indicator.
With InkZone Fountain, fountain solution circulates through a four-step filtration system. Utilizing the same powerful, advanced nanofiber technology used in medical technology featuring ceramic nanofibers on a micro-glass matrix, InkZone Fountain filters are graduated in fineness to retain dirt particles down to 2 nanometers.
InkZone Fountain’s easy-to-read Smart Gauge indicators refer operators to the degree of filter contamination. The intervals between filter changes depend on the degree of printing press use, as well as on shift operation. «When making the decision to equip our first KBA Rapida 106 with InkZone Fountain, we were very impressed with the system’s purification efficiency and with the promised gains in productivity through improved stability and security of the production process. This played a crucial role in our decision,» said Mr. Schuetz. «With a return on our investment on the horizon at the six month mark, we are already preparing to upgrade our second KBA Rapida with InkZone Fountain.»
The Princely Printers: Gutenberg Ltd., Schaan
Recently, Gutenberg Ltd. at Schaan (Principality of Liechtenstein) partnered with Switzerland-based powerhouses Digital Information and System Brunner to become the world’s first printing company to install the all new InkZone Instrument Flightcolor control software on the control center of their Heidelberg Speedmaster® SM 74-5-P. By joining System Brunner's leading Instrument Flight Gray Balance color control software with Digital Information's InkZone ink-presets and closed-loop product line, InkZone Instrument Flight by System Brunner allows users to harness the power of the world's leading closed-loop instrumentation with the most sophisticated technology in color control, standardization and printing process verification. Since installing InkZone Instrument Flight, Gutenberg Ltd.'s productivity has increased exponentially, exceeding company expectations - and breaking world records.
The Story Begins with InkZone Loop
Managing Director, Remi Nescher, rates the gains in quality and cost reduction through InkZone Instrument Flight® on the Speedmaster SM 74-5-P as remarkable
Gutenberg Ltd. at Schaan (Principality of Liechtenstein) is a true pioneer in the printing industry. Whenever a new product promises to add value and increase productivity, the Gutenberg Ltd. team is ready to take a step ahead of the curve. Four years ago, Gutenberg Ltd. invested in Digital Information’s InkZone ink-preset and closed loop technology to bring their then 6 year old legacy Speedmaster SM 74-5-P press up-to-date with the latest technical level of color control. Equipping their 5-color press with the fast, motor-driven SpectroDrive scanning measurement tool by Techkon and the InkZone ink-preset and closed-loop software, Gutenberg Ltd. was able to considerably decrease set-up time and waste production. According to Remi Nescher, Director of Gutenberg Ltd. at Schaan, the gains in quality and the cost reduction witnessed with InkZone were remarkable.
Moving Forward
Four years later, the sheet-fed, offset press from Heidelberg was still mechanically flawless, but ready for the next step in its evolution to remain competitive with the latest printing technology. When Digital Information and System Brunner announced their strategic alliance and introduced InkZone Instrument Flight, Remi Nescher and Gutenberg Ltd. Production Manager, Fabio Wellenzohn knew they were ready to harness the power of the world’s leading closed-loop instrumentation with the most sophisticated technology in Gray Balance control, standardization and printing process verification for their Speedmaster SM 74-5-P. Remaining true to Gutenberg Ltd.’s pioneering spirit, their Speedmaster SM 74-5-P became the world’s first Heidelberg printing press to be equipped with the InkZone Instrument Flight solution after a short testing period of just a few months.
InkZone ink-preset and closed loop technology remains the framework for this new system. The DI-Plot software transcribes bitmap files generated by the prepress workflow into ink coverage values and feeds them as JDF files to the InkZone Perfect presetting software. The initial key values are then transmitted to the CP2000® control console where they are constantly re-calculated by InkZone Instrument Flight during the print run. From this point, InkZone Loop takes over the operation.
The Process Viewed as a Whole
Until the installation of InkZone Instrument Flight, Gutenberg Ltd. was conducting color control according to the densities in the solids. However, many of the variables that can affect the quality of a printed product were being ignored. With InkZone Instrument Flight, they are now able to take automatically into account an entire range of additional factors, which are essential to maintaining stable color consistency within narrow limits including: dot gain and mid-tone spread, gray balance in the overprint of the three chromatic colors Cyan, Magenta and Yellow (CMY); color balance of the primary colors CMY in mid-tones (50%) and solids (100%); trapping of the three chromatic colors CMY in the solids (100%); and color balance in the solids according to the L*a*b* standard (best match).
Production Manager, Fabio Wellenzohn, keeps track of all process parameters. By means of the Hexagon diagram he can easily assess gray and color balances, solid densities and dot gains for each ink zone.
The multi-dimensional color control performed by InkZone Instrument Flight handles the full spectrum of process dynamics in offset printing. The heart of the application is innovative and sophisticated software that is the result of more than thirty years of practical experience. InkZone Instrument Flight maintains control by continually taking into account the extent to which the deviation of one parameter influences all of the others. For example, the tendency towards a drift in the reds can be compensated for by either reducing the densities in Magenta and Yellow or by increasing the amount of Cyan. But, before InkZone Instrument Flight implements such a correction, the system considers other parameters such as dot gain and color and gray balances. The analysis encompasses all of the interactions among the four process colors CMYK with their differing tonal values and their overprint as halftone dots. This procedure ensures that for every adjustment and each ink zone, the best possible setting is found and executed in line with the pressman’s color perception.
InkZone Instrument Flight provides a variety of adjustment priorities for differing process balancing situations. The pressman can choose them according to the printing form. In addition to giving priority to the gray balance, to ISO 12647-2 (PSO) or to other worldwide specifications, it is also possible to lay the main focus on GCR/Gray Stabilization - in other words, stabilizing the image gray balance through achromatic structures - or on optimizing the reproduction of printing forms that are dominated by solid areas. Balancing with priority to the solids is useful if the customer requires corporate colors consisting of solids or homogenous technical screens to be precisely maintained - especially in the package printing arena.
Five-Star-Assessment with Psychological Momentum
Employing InkZone Instrument Flight technology results in considerable cost savings. Set-up times are reduced, print results remain within closely defined standards, color consistency is brought to perfection, and the solution lends to quick and early problem detection resulting in print run security that no other system can match.
"As far as set-up times and waste reduction are concerned, we had already achieved substantial improvements four years ago by installing InkZone," said Fabio Wellenzohn. "With InkZone Instrument Flight, once again, we have been able to markedly increase the stability of color control. By taking into account all of the additional parameters covered by this new technology, we can now print with far less process fluctuations compared with the past, when we could only control the densities. Mastering this process has definitely led to significant growth in performance, as well as further cost reductions in terms of set-up time."
The increased process stability is also due to InkZone Instrument Flight’s high degree of user-friendliness. Across the entire width of the sheet, the pressman can easily judge color control independently for each ink zone by checking the Hexagon diagram. At a glance, the pressman can see where the values related to solid densities, dot gain, color balance of the primaries (mid-tones and solids), gray balance and overprint (trapping) are positioned.
"For each ink key, the system proposes a setting and indicates through arrow icons if the respective ink keys should be widened or narrowed," explains Fabio Wellenzohn. "The five-star system adds tremendous value and lends to the ease of use for pressmen. The stars represent how well the system is adhering to the printing standard. Visual assessment boosts printing quality, for it is the goal of any professional pressman to achieve the highest possible star rating."
Process Calibration by Print Expert®
In order to base the printing process on a known reference, it is critical that the plate-setter is reliably calibrated. For that task, Gutenberg Ltd. uses Plate Checker from System Brunner‘s Print Expert Suite. By means of a scanning measurement instrument, the software can capture 20 tonal values of the Plate Zebrastrip® in just one go. The measurements can then be compared with the stored reference curves and the results can be represented as an Isocontour® diagram.
Complementing their plate outputting with Plate Checker, Gutenberg Ltd. also works with PrintCurve Checker for long-term quality maintenance of the printing process (control of the characteristic curves). The identical instrument for plate calibration is used for measuring. In just one scan PrintCurve Checker detects four tonal value curves (CMYK), each representing 20 screen densities. The internal interface that connects PrintCurve Checker with Plate Checker allows for the adjustment of the calibration curves of the plate-setter’s RIP. “The Print Expert Suite’s software tools assist us in keeping the production process under control system-wide,” said Remi Nescher.
Highest Quality Meets Cost Effectiveness
The value of InkZone Instrument Flight at Gutenberg Ltd. extends beyond the technical improvement of their printing process. In fact, InkZone Instrument Flight is credited with improving internal communication between departments. According to Fabio Wellenzohn, "It is fascinating to work with InkZone Instrument Flight. The high-quality information the system provides us with invites us to look far deeper into the processes. The system lets us indicate precisely where possible deviations reside. According to the measuring results, we can analyze in great detail to what extent the print result remains within defined tolerances and correspondingly where we should interfere before a problem arises. That is where we can also save time and costs. Our prepress department and pressroom staff share the goal of achieving the highest degree of excellence in quality and cost-effectiveness. With InkZone Instrument Flight we are well-equipped to do so."
InkZone Instrument Flight® Lands Gutenberg Ltd in the Guinness Book of World Records
Gutenberg Ltd. is a world leader in the book printing industry. Demonstrating Gutenberg Ltd.'s commitment to quality, in 2010 two photographic books that were printed by Gutenberg Ltd. were awarded a prize for "Liechtenstein's Most Beautiful Books." Gutenberg's passion for aesthetics in book production also extends to their printing of postage stamps. They predominantly produce commemorative stamps in smaller editions and partly in polygonal shape by order of the Post of Liechtenstein, Swiss Post, as well as some other European postal enterprises. For perforating the stamp sheets, Gutenberg Ltd. invested in a specialized punching machine just for that purpose.
By producing a commemorative stamp in just 57 minutes and 50 seconds, Gutenberg Ltd. and Philately Lichtenstein achieved an entry in the Guinness Book of Records. Tanja Vetsch of Gutenberg Ltd. proudly presents the certificate.
In August 2012 Gutenberg Ltd. and Philately Lichtenstein joined together to set a Guinness World Record. In celebration of the 100-year jubilee of the Principality of Liechtenstein’s first postal stamp edition, a commemorative stamp was produced. The entire operation was completed in just 57 minutes and 50 seconds, beginning with the announcement of the motif which was chosen from three proposed designs and ending with the purchase of the first stamp by Craig Glenday, Editor-In-Chief of the Guinness Book of World Records, at the LIBA 2012 at Schaan, the special stamp exhibition held to celebrate the 100-year anniversary. "The prior world record for Fastest Printing of a Postage Stamp was held by Austria with a time of 1 hour and 25 minutes. With InkZone Instrument Flight in our corner, we were able to blow that record out of the water and to secure a place in this year's Guinness Book of World Records. We could not be more excited about the addition of InkZone Instrument Flight® to our technology arsenal or about sharing the honor of being a Guinness world record holder with Philately Lichtenstein", said Remi Nescher.
RR Donnelley Plant in Menasha, Wisconsin, USA
RR Donnelley Plant in Menasha, Wisconsin
Company Profile
RR Donnelley (Nasdaq:RRD) a global provider of integrated communications works collaboratively with more than 60,000 customers worldwide to develop customized communications solutions that reduce cost, increase pro- ductivity, enhance ROI and increase compliance. Drawing on a range of proprietary and commercially available digital and conventional technologies, RR Donnelley provides premedia, printing, logistics and business process outsourcing services to clients in virtually every private and public sector.
The RR Donnelley printing facility in Menasha, WI is G7 certified and employs approximately 400 people. With unmatched manufacturing capabilities and the latest tech- nology, RR Donnelley produces accurate, RR Donnelley Plant in Menasha Wisconsin high-quality, color printed materials including POP printing, corporate collateral, annual reports, books, business forms, catalogues, direct mail, packaging, labels, magazines, etc.
Technical Situation
Eight web presses and one sheetfed Komori 40" press anchor the RR Donnelley plant in Menasha, WI. RR Donnelley is an existing customer of Digital Information’s InkZone Ink- Presets and Closed Loop technology, having invested in the solution for their sheetfed press, along with the X-Rite IntelliTrax scanning instrumentation, a few years ago through CMYK Distributors. As an existing customer, RR Donnelley understands the value that InkZone brings to the pressroom in terms of automation, reducing waste, and increasing productivity. Featuring the ability to monitor trends and track job history, utilization of a rollback feature to revert ink key positioning, and the creation of ink key preset line- arization curves based on measurement data, running InkZone on their sheetfed Komori 40" press enables RR Donnelley to realize substantially shorter makeready time and a remarkable reduction in paper waste, paired with considerably-improved color quality.
Kirk Schmidt, RR Donnelley Technical Specialist
While they were extremely satisfied with the InkZone solution, the leadership team at RR Donnelley in Menasha, WI was interested in taking comprehensive quality color control to the next level and CMYK Distributors was there to deliver the solution. CMYK Distributors introduced RR Donnelley to InkZone Instrument Flight® by System Brunner for their Komori 40" press. InkZone Instrument Flight® by System Brunner is the premium upgraded product solution for InkZone for color verification, process diagnosis, and quality assessment, allowing users to harness the power of the world’s leading closed-loop instrumentation with the most sophisticated technology in standardization and printing process verification.
«At RR Donnelley, we are committed to providing our customers with the highest standard of quality and unpar- alleled service,» said Kirk Schmidt, Technical Specialist with RR Donnelley in Menasha. «By investing in InkZone and InkZone Instrument Flight® by System Brunner – technology that has breathed new life into our legacy printing equipment – RR Donnelley is realizing substantial savings in terms of time and materials on a monthly basis. InkZone Instrument Flight® by System Brunner is an invaluable tool for troubleshooting the press and helping us maintain our G7 certification.»
Solution
InkZone Instrument Flight® by System Brunner brings RR Donnelley color control with the priority on color/gray balance, leading to optimal color consistency with a high level of automation. The solution safeguards print results in accordance with international standardization concepts (Globalstandard®, ISO/PSO, worldwide standards) and rates print quality based on System Brunner’s 5-Star quality rating system. Moreover, the system permits extensive print process diag- nosis in real time that enables problems with the process or materials to be recognized and resolved by RR Donnelley’s press crew at an early stage.
(L to R) Randy Docta, 2nd press operator; Toralph Franz,System Brunner; Shawn Buelow, 1st press operator
Prior to installing InkZone Instrument Flight® by System Brunner, RR Donnelley noticed that even when measuring consistent solid densities and LAB values, it was still possible for disturbing color variations to appear in the image during a print run. A number of factors were responsible for these variations including ink; substrate; blanket; fountain solution composition, balance, and conductivity; press settings, etc. These color variations in the image were influenced by tonal value increases, gray balance, the three-color overprint behavior of the inks, trapping, the relationship of the solids to the tonal value, LAB deviations of the inks, etc. InkZone Instrument Flight® by System Brunner controls and regulates these technical parameters.
«With InkZone Instrument Flight® by System Brunner, RR Donnelley makes great strides in taking color control to a whole new level,» said Kirk Schmidt, Technical Specialist at RR Donnelley in Menasha. «First with InkZone and now with InkZone Instrument Flight® by System Brunner, RR Donnelley is poised to keep pace with the international printing industry by employing this cutting edge new technology.»
Offset Büttner GmbH, Westerngrund, Germany
InkZone Instrument Flight®: Efficiency in Color
In the Heart of Europe: Quality, Environmental Sustainability and Economy with InkZone Instrument Flight®. The recent admittance of Croatia into the European Union has shifted its geographical center to the German country town of Westerngrund, in the district of Aschaffenburg, at the northwestern corner of Bavaria. Defined by the «Institut de Geographie» of Paris, the location has been officially confirmed by the Bavarian Agency for Surveying and Geoinformation.
52 Years of Progress
In the more than half-century since Herbert Büttner founded Offset Büttner GmbH, the company has grown exponentially from a small copy shop to a commercial printing plant committed to delivering the highest quality printed materials and featuring the latest technology. Located in the small Franconian country town of Westerngrund, Offset Büttner GmbH is an important mainstay in the local business community.
Their choice to go with InkZone Instrument Flight® is reaffirmed daily: Harry and Michael Büttner (from left).
After growing and refining Offset Büttner GmbH for more than 30 years, Herbert Büttner passed the torch to his sons, Harry and Michael Büttner, who have been capably running the family business since 1993. Honoring the standard of excellence set by their father, Harry and Michael Büttner have taken the company to new heights, positioning Offset Büttner GmbH as the industry’s premier innovation partner for print and media services. In addition to local advertising agencies and direct print customers, Offset Büttner GmbH’s reach extends beyond regional bound- aries, encompassing the entire federal state of Bavaria, and serving well-known companies in industries including medical goods, organic food delivery services, tourism, etc.
Commitment to Environmental Sustainability
Offset Büttner GmbH is committed to investing in technology that enhances the efficiency and cost-effectiveness of their business, as well as minimizes their environmental footprint. Under Harry and Michael Büttner’s leadership, Offset Büttner GmbH has become a best practice model for environmental protection and stewardship in the printing industry. For plate imaging, Offset Büttner GmbH uses chemistry-free materials in which the moistening solution has an alcohol content of zero percent. In addition, they print with mineral oil-free inks and their paper supply originates from sustainably managed forests. They also use «green» energy to power their facility.
Why InkZone Instrument Flight®?
Advancing the company’s overall strategy and commitment to technology and solutions that promote sustainability, Offset Büttner GmbH recently investigated and selected a new ink preset and color control system for their sheetfed offset printing press. The company sought a solution that would enable them to reach target color values quickly, thereby reducing paper waste and makeready time.
Upon learning that Offset Büttner GmbH was evaluating this type of technology, their graphic products supplier, Heinrich Baumann Grafisches Centrum, introduced Harry and Michael Büttner to InkZone Instrument Flight®, the world’s leading universal solution for color control developed in partnership by Digital Information and System Brunner.
At a large-size monitor, Michael Büttner monitors all of the parameters of safe color control.
We wanted a system that measures not just the densities in the solids, but also considers how screened halftones and color balance influence the settings,» said Michael Büttner. «InkZone Instrument Flight® is exactly what we were looking for. It is a multi-channel solution that takes into account the L*a*b* values, dot gain, and the gray balances in the midtones and shadows – according to control priority chosen. InkZone Instrument Flight® gives us the tools we need to achieve optimal comprehensive industry standards.»
High color consistency during the print run
Offset Büttner GmbH uses different control priorities depending on the requirements of each print job (density balance in the solids, ISO/PSO, or gray balance). InkZone Instrument Flight® safeguards the print results in accordance with international stan- dardization concepts (Globalstandard®, ISO/PSO, wolrdwide standards) and rates print quality based on System Brunner’s 5-Star quality rating system. Moreover, the system permits extensive print process diagnosis in real time that enables prob- lems with the process or materials to be recognized and resolved at an early stage. Or, as Michael Büttner put it, «One sheet is like the others.»
Harry Büttner expressed his satisfaction with InkZone Instrument Flight® and noted the fact that the presetting system does not necessarily require CIP3 data transmission from prepress. It is capable of optimizing the preset calibration from saved press data. «InkZone Instrument Flight’s® simple and straightforward user interface – especially the concept of working with “image zones,” – has enabled our team to get up to speed quickly and to harness the color verification, process diagnosis, and quality assessment capabilities of InkZone Instrument Flight,» explained Harry Büttner. «We are very pleased with the comfortable way that color casts can deliberately be set. The fact that color balance is regulated not only by solid density but also by several other variables took some getting used to. But it was extremely helpful in getting a better understanding of how the solids and dot gain depend on each other.»
nkZone Instrument Flight® contributes to a higher awareness of quality, indicated by the fact that more and more proofs are produced in order to define the target point visually. «During the production run, we are able to reach the required standards without any problem and we can also adhere to them,» confirms Michael Büttner. «In this context, I would like to highlight that InkZone Instrument Flight® is capable of maintaining the visual appearance alongside the sheet mar- gins in case the densities change (e.g. unstable ink/water balance).»
Thanks to InkZone Instrument Flight®, Offset Büttner GmbH has gained considerably better control over the offset process. «This is of particular importance when working without alcohol in the moistening solution because the ink/water equi- librium tends to lose stability/balance more quickly» says Michael Büttner.
Important component: the PrintCurve Checker
Further enhancing the functionality and success of their installation of InkZone Instrument Flight®, Offset Büttner GmbH took the recommendation of Digital Information’s German distributor, go4color, and added PrintCurve Checker by System Brunner to their overall solution. The PrintCurve Checker measuring system integrates Techkon’s SpectroDrive scanning device to collect the measuring data within seconds. The Software calculates the mean Tone Value curve from serveral readings, from which the RIP correction curve for each color is then extracted. Printing characteristics are produced within seconds and measurements are curves across the entire print run. With these checks, process variations can be detected which may occasionally occur due to the materials used.
The PrintCurve Checker by System Brunner enables the creation of reliable tone value curves in just a few seconds. From several readings, the mean curve is calculated and a RIP correction curve is deduced.
For example, thanks to the PrintCurve Checker, Offset Büttner GmbH recently discovered that their printing plates were prematurely wearing during long print runs and were able to resolve this problem, saving time, money, and resources. «Without the tools we now have with our com- prehensive InkZone Instrument Flight® solution, we would never have been able to monitor such fluctuations or to resolve issues so expeditiously,» said Michael Büttner.
Objective achieved
The Büttner brothers and their team at Offset Büttner GmbH are very pleased with the InkZone Instrument Flight® solution. Thanks to an initial introduction from Heinrich Baumann Grafisches Centrum and further recommendations, support, and professional assistance from the team at go4color and System Brunner, Offset Büttner GmbH is now a best practice InkZone Instrument Flight® operation, equipped to handle color control far more consciously. «We are delighted with our decision to install the InkZone Instrument Flight® solution on our offset press. The quality of the sup- port that we get is incomparable and the value and wis- dom of the decision to go with InkZone Instrument Flight® is reinforced daily by the quality of our work and the meas- urable savings we are seeing in terms of our resources and time,» said the Büttner brothers.
Key benefits of InkZone Instrument Flight by System Brunner include:
Optimal color consistency
Better harmony between human color perception and control software
The most comprehensive industry standards
Quality rating with the System Brunner 5-Star Score
The most comprehensive printing process diagnosis
Permanent training tool, optimized communication between the prepress and printing operations
Gets in the Zone with InkZone
For over 40 years, Coburn, Inc. has been a leading manufacturer of folding cartons, blister packs and point-of-purchase displays.
Coburn, Inc. is a large format facility with the flexibility and technology to provide superb service and quality at a competitive price. In fact, their award-winning products and services have been utilized by thousands of clients, including many Fortune 500 companies.
High-quality packaging made by Coburn, Inc.
Technical Situation
Two Nebiola presses and one Miller press anchor Coburn's printing department. Their ability to print five colors plus coating (front side) as well as one-color backside affords the versatility to meet a wide range of printing needs. However, upon a recent audit of their printing equipment, the Coburn management team recognized the challenge of keeping pace with their competitors who are operating newer equipment. Coburn's presses are late 1980's/early 1990's models, which are run around the clock, 4-5 days per week.
While, Coburn, Inc. had the technology and equipment to provide excellent quality, timely order fulfillment and unparalleled service to its customers, their legacy printing equipment was still lacking the latest press features like ink-key presetting and closed-loop technology. The management team at Coburn, Inc. knew that these advanced features could save the company thousands of dollars in time and materials on a monthly basis by speeding up makeready time. They also knew that the finished product would be a better quality printed carton. They needed to find a solution that would offer the latest technology advantages without the cost associated with purchasing newer presses.
InkZone drives 95% of all offset sheetfed presses installed.
Solution
Upon recommendation from a dealer, Coburn, Inc. con- tacted CMYK Distributors, Inc. and they were introduced to Swiss manufacturer Digital Information's InkZone product line. CMYK Distributors, Inc. is the exclusive distributor of Digital Information products in the United States and the leading distributor and installer of graphics and printing products that bring automation and waste reduction technology to the industry.
Based on Coburn's workflow needs and pressroom configuration, DI-Plot, InkZone Perfect and InkZone Loop were added to their two Nebiola presses, which are attached to X-Rite IntelliTrax scanners.
Benefits
Coburn, Inc. immediately began realizing the benefits of InkZone. In only three months, they have seen a 30% decrease in virgin paper waste from 500 sheets to 350 sheets and they have consistently reduced makeready time up to 20%. The combination of the ink presets and closed- loop technology are proving to be an enormous asset to the company in helping to refine and train in their pressroom. This winning solution is helping the Coburn, Inc. pressroom team to "kick it up a notch" in their understanding and application of densitometry and spectral data.
Fast and reliable color scanning with X-Rite's IntelliTrax.
With InkZone Loop, Coburn Inc. has eliminated the problems of multiple pressmen seeing color differently and discrepancies in the color vision of single pressmen over the course of a shift, as they become increasingly tired.
"InkZone has given us the tools to better troubleshoot printing related problems on press such as pressures and chemistry, as well as increased capacity to measure and monitor the quality of our work and identify areas where additional training is needed." Todd Zimmerman, President, Coburn, Inc.
Given the fact that much of Coburnss work is repeat orders, the archiving of presets is extremely useful in keeping their products consistent from one run to the next. For example, there have been jobs since the solution was installed where the color has been adjusted on press by the client. With InkZone, once these changes were made and the job was archived, the Coburn team was able to repeat the saved settings on other products in the same line for better consistency on store shelves.
"The InkZone product line has been an excellent investment for Coburn, Inc. With InkZone, we have significantly and measurably reduced start-up time and make-ready waste. It is definitely a key solution for any pressroom interested in saving time, money, and contributing to the sustainability of our environment." Todd Zimmerman, President, Coburn, Inc.