IFRA

Prepress workflow automation

The comfortable times in newspaper production with high manning levels and individual workstations for text recording, image processing and retouching as well as individual page treatment are long gone. Cost pressure and rationalisation combined with progressive IT solutions allow the installation of an integrated workflow with manual intervention required only in certain areas.

The following data handling can be largely automated. Software and workflow systems offered on the market today eliminate the need for personnel for the production steps from online ad delivery up to platemaking. Ad delivery can be done with database support and based on an individual job number, with subsequent file optimisation and database-supported ad positioning on the desired day of publication.

As a system with multi-client capability, a database has the capacity to manage several, or any number respectively, of titles. The available image optimisation systems, especially with integrated EXIF evaluation, permit a high level of quality and the only sporadic use of manual correction. In view of the masses of images and a non-plannable quality of the incoming material, image optimisation software is a helpful tool. The individual pages are completed in the editorial system, the different systems permit specific automation and publishing possibilities. A pre-flight check of the finished pages, possibly ink saving, trapping, fan-out correction, etc., can be carried out via corresponding servers or directly at the time of RIPping. Softproofing, ideally of the ripped data and displayed directly on a monitor at the press, allows a low-cost final check and simplifies ink setting at the press. Theoretically, each of these software products should be able to transfer the data to the presetting routines of the press.
At IFRA Expo in Hamburg, you will be able to find many suppliers of these systems that make your prepress process safe while at the same time providing it with high-quality equipment. – By Roland Thees (roland.thees@wan-ifra.org)

Automatic colour measurement and density control

In most printing plants, printers control colour, or density respectively, by means of a visual check only. Some newspapers have integrated print control elements into their layout to achieve a better print quality control. The most effective way to do this is to use grey balance wedges, ideally arranged across the width of the entire web (except in the case of keyless inking systems). Such grey balance strips can be supplemented by additional control elements that can then be evaluated for colour and density, for example, via a spectrophotometer.

However, such control elements are not very popular among many publishers and editors, even though they can be well “hidden” in the print product. Many technicians find themselves in a dilemma because they are not allowed to use control elements but are being called upon constantly to produce better and more consistent quality.
The growing use of softproof systems at press control desks is one approach towards obtaining improvements here. A second possibility is the use of measuring and control techniques.

For a long time, measuring instruments were used operating in offline mode. But the level of acceptance among newspaper printers of such solutions was always very limited. Consequently, several manufacturers have been working for some years on a highly automated solution that is also invisible to the newspaper reader. The inline measurement of grey balance strips is now being replaced by measurements carried out directly in the motif. Instead of the control elements, prepress target values are taken and compared to measured data from inline measurement. Besides faster and automatable control, inline measurement carried out in the print image offers additional benefits: it allows verification that the plates were positioned correctly, continuous documentation of quality and makes fewer demands on operators.

Due to the faster reaction time, it can be expected that systems will have market success that do not move across the web but can evaluate and control the entire web width simultaneously, e.g. also at press start-up. To minimise metamarism effects, it would be desirable to use, instead of RGB cameras, spectrophotometers with bandwidths that are as narrow as possible. Alternatively, a precise colour measurement can be carried out also by exposing the web to spectral narrow-band light of different wavelengths. A measurement of this type can take complete charge of inking control, so that newspaper printing without printers is possible. – By Moritz Schwarz (moritz.schwarz@wan-ifra.org)

Automatic reel management

Paper reel storage and transport, especially in high-wage countries, is increasingly managed without using forklift vehicles and manpower. Automation in this area of newspaper production was tackled at the end of the 1980s. At the beginning of the 1990s, more and more systems were being designed in this way, so that it is possible to speak in terms of full automation of paper management. At that time, several ground floor-level stores were built, some of which are still operated today with crane systems. However, high-rack stores need less surface area and are therefore lower cost, with the result that this type of paper store became increasingly popular.

Paper storage capacities are frequently minimised at new printing plants, as the Just-in-Time concept with accompanying reduced capital tie-up becomes more widespread. When planning storage capacity, it is strongly advisable to make allowance also for unusual production situations because poor planning in this area can lead to considerable limitations on production or, for example, highly cost-intensive alterations to the existing building.

The situation is similar as far as planning in-plant transport capacity is concerned. As part of an expert evaluation project, we at WAN-IFRA some time ago analysed a case where an AGV-based paper management system was unable to keep pace with the capacity of the high-speed presses, so that either printing had to be done slower or paper transport carried out only by manual reel transport.

The trend towards larger reels (wider for six plates, larger diameter) reduces the required reel transport capacity. This is appropriate also due to the increasingly high-speed presses. But it must be borne in mind also that a triple-width press requires the storage of two additional reel categories (reel widths: 5/6 and 6/6) compared to double-width presses, so that the store must be designed accordingly. The weight of the wider, or thicker reels respectively (up to three tonnes) means that their manual transport must be discontinued in most cases. All these aspects must be taken into account in the overall planning for a printing plant.

Besides for the transport in the store or day store respectively, automation can be introduced also for reel unwrapping and preparation. The development of the straight splice and multi-functional adhesive tapes, such as have been used successfully worldwide for several years, greatly simplified these processes.
When considering automation in this area, in addition to the possible personnel savings, the potential for waste reduction offered by automatic paper management should also be considered. – By Moritz Schwarz (moritz.schwarz@wan-ifra.org)

Ink saving

Ink saving software in the printing industry has long outgrown the experimental stage for data handling and prepress specialists. Many systems suppliers of software products for editorial, image processing, prepress, RIPs and imaging systems, respectively, have an application in their portfolio that permits the use of their ink saver or a different manufacturer’s software. The saving potential for ink consumption is uncontested; taking the average of all suppliers and based on practical experience, some 15 percent ink savings are realistic.

But saving costs is just one aspect among several. The technical benefits are also considerable. The risk of set-off and smearing is less, the reduced ink application means a shorter drying time (or more accurately, absorption time) as well as less show-through, even the irritating ink mist in the press is reduced. All in all, print production becomes simpler and of a higher quality.

IFRA Expo offers a good opportunity to find out in detail from the relevant suppliers about the possibilities offered by their software.

Ink saving can be used already at the time of image conversion via a corresponding ICC profile as a purely image optimisation solution. After production of the complete pages in the editorial system, an ink saver can optimise the entire editorial page with all elements. Ink saving can be applied exclusively to ad pages and thus be part of the pre-flight check. To the extent that a data correction with technical optimisation of all newspaper pages before the RIP process is included in the workflow, it is possible to expand this procedure with ink saving; in most cases this process requires an independent server. Finally, ink saving can be an integral part of the RIP process, in which case care must be taken to ensure that all RIPs are equipped with identical features.

At exactly what point in the workflow the ink saver should be integrated must be decided in the individual case of and existing conditions at the operation concerned. Based on these preliminary considerations and identification of the potential system partners, it is possible to limit the number of suppliers. As a next step, the outcome of this preliminary selection should be matched up with live data from production and the optimisation results verified by a test print to obtain meaningful results before taking the investment decision. Professional, standard software can be bought for a price ranging from below 10,000 euros to more than 20,000 euros. The costs for hardware and training come on top of this. Depending on the existing standard of image quality, length of print run and ink costs, an ROI of less than 12 months is possible. – By Roland Thees (roland.thees@wan-ifra.org)

Everything green?

As far back as 1995, a WAN-IFRA research report (Special Report 6.17) began with the statement: “In the corporate policy of today’s manufacturing operations, protection of the environment has the same status as, for example, product quality, efficiency and safety of man and machine.” Now, 15 years on, slogans such as environment-friendly, ecological, and green printing are more than ever to the fore. But what does that really mean and just what do ecologically-oriented measures (in relation to emission, waste water, waste, use of resources, environmental protection) consist of for the industry?

The main objective is to manage natural resources and minimise negative effects on the environment. Efforts to reduce waste and save consumables have been undertaken before today’s increased awareness of climate change – although in the past such efforts were motivated more by economic than ecological considerations.

Environment-friendly production starts with an environmentally aware management. Examples for sustainable measures at printing plants are optimised use of ink, plate recycling, paper recycling, use of environment-friendly materials, energy control systems for the optimised consumption of power and heating energy, use of renewable energy, lowering emissions, environment-friendly means of transport and optimised logistics to eliminate unnecessary journeys.

It cannot be stated often enough that the efficient use of energy and materials also produces financial savings!

The plate sector can make a considerable contribution to improving environmental friendliness. Many newspaper printing plants have changed to materials and processes that reduce the consumption of chemicals significantly, without compromising on quality.

Companies that practise a genuine involvement in this respect and actively communicate the fact enhance their image and convince consumers. The Expo offers the opportunity to convince customers. This is the chance for them to find out about actual green offerings. – Beatrix Beckmann (beatrix.beckmann@wan-ifra.org)

The Focus Report published in the April 2008 edition of WAN-IFRA Magazine was dedicated to the topic of environmernt-friendly printing.