The installation of both systems were overseen by GBC Canada, one of the country's leading providers of print finishing technologies for digital production, as well as hybrid digital-offset environments, focusing on Seal and GBC finishing, laminating and media products.
The Seal 62 Pro Series offers industrial performance, explains GBC, based on its capabilities for running a range of media at high speeds. It features fully adjustable temperature, speed and pressure settings and, according to GBC, it is ideally suited for experienced finishing departments requiring a versatile laminator.
“The dual heated rollers make most applications, including encapsulation, really easy to use. It maximizes versatility, minimizes waste and is a real value add for us,” said Joyce Wong, ARC’s Production Supervisor in Calgary.
ARC (formerly American Reprographics Company) is a global company, with approximately 170 service centres throughout North America, in addition to European centres, specializing in the distribution of information through printing and IT services. Founded in 1988 in southern California, ARC’s fiscal 2017 revenue was more than US$400 million generated by more than 2,600 employees around the world.
The company has nine service centres in Canada (BC, Alberta, Ontario and Quebec) focusing on providing document solutions to businesses of all types, with an emphasis on the commercial segments of the architecture, engineering and construction (AEC) industry. The company is also investing more into providing more health care document services.
The Jeti Ceres is a 3.2-metre roll-to-roll UV LED inkjet printer that produces print of up to 10.5 feet wide. The system, capable of unattended printing, reaches speeds of up to 2,002 square feet per hour.
Leveraging Agfa’s Asanti workflow software, the Jeti Ceres provides six colours plus an optional white and/or primer. It is also configurable with an optional dual-roll and back-up camera, allowing the Ceres to print mesh and porous substrates without a liner.
The Jeti Titan HS is a flatbed, 3-metre–wide, 6-colour UV inkjet system that reaches speeds of up to 160 square metres per hour (1,722 f2/hr) in Express Mode. The system, which can include a flat-to-roll printing option, producing a resolution of up to 720 x 1,200 dpi.
In 2008, the company changed its name to Groupe Lettra Inc. and acquired industrial printing equipment making it one of the first companies in Quebec to move in this direction for wide-format imaging.
Lettra today specializes in all types of vehicle lettering and large-format printing on both rigid and flexible medias. The company’s new Anapurna M3200i RTR is a 3.2-metre wide roll-to-roll UV inkjet printer that produces indoor and outdoor applications at speeds of up to 123 metres square per hour.
The fully automatic Duplo DPB500 features a single-clamp design for speeds of up to 525 cycles per hour, while operators can adjust, program and save up to 20 different jobs. Its automation, explains Duplo, makes it well suited for short-run and variable-data production.
To change format sizes, for example, operators select one of the stored memories, load the book in the clamp, and press the size change key to initiate the process. The side glue wheels, scoring wheels and cover positioning guide will automatically move into the desired position, according to the thickness of the loaded book. Once the size change is completed, covers can be loaded into the cover-feed section which provides controls where the operator can make and verify any adjustments aligning it with the nipping section.
Friesens Corporation of Altona, Manitoba, installed a Heidelberg Speedmaster XL-75-5+L press with coating. The company is one of North America’s leading book, yearbook and packaging manufacturers serving publishers, institutions, schools and businesses from two facilities in Altona. The 110-year-old printing company employs approximately 600 people in more than 250,000 square feet of space.
The Speedmaster XL 75 is Friesens’ first mid-size press in a plant dominated by VLF offset equipment, including a 73-inch, 8-colour Manroland R900 HiPrint XXL perfecting press installed in mid-2015 (featured as PrintAction's September 2015 cover story, World Book Giant).
Friesens’ new Heidelberg XL-75 replaced an older generation Heidelberg CD 102 press. “This press will be predominantly used for book covers and, when we analyzed the business, 80 percent of the forms would fit the 23 x 29 format,” said Byron Loeppky, GM of Friesens. “ The other 20 percent we can simply run a few more sheets to make up for the smaller layout. It is a short-run market.”
The Speedmaster XL 75 is equipped with features branded by Heidelberg as Push to Stop technology, including: Inpress Control 2, automatic colour and register measurement, Auto Plate Pro fully automated plate loading, and automated wash programs. This technology is now driven by Heidelberg’s recently introduced (May 2016) Intellistart 2 press software, activated through the Press Center XL with Wallscreen. These features can allow the press to process jobs autonomously within Heidelberg’s Push To Stop operating philosophy.
“We may have downsized the format, but we have upsized the technology,” added Friesens’ Andrew Fennell. “The plan was to drive automation into our process. This press can make job changes in 50 percent less time than our older press, and doing it with one operator. The technology is like having a second man. We are putting more sheets on the floor each day. All the targets are being met or exceeded, and we are still in a learning curve.”
The Fifth Imaging Unit of the NexPress platform, to be leveraged by Innovative Design & Print, provides Dimensional Clear Dry Ink for a tactile feel with raised or textured printing for a 3D effect; Clear Dry Ink for watermarking, spot or flood-coating techniques; and Light Black Dry Ink for what the company describes as ultra high-quality printing, particularly with neutral tones, gray layers and flat fields.
“Innovative was looking for a new digital press with long sheet capabilities and high-resolution imaging for photo products,” said Calvin Frey, President, Innovative Design & Print. “We spent time doing our research and performing press tests and chose to proceed with the NexPress. We have been very impressed by the image quality, the flexibility of the press and the reliability.”
Established in 1931, Glatz started out in the stamping and engraving field. Sign making and plate making were added later. The third-generation family business has five locations. Since 1999, Glatz Klischee has been an independent company in the Glatz Group. At the Bregenz site, there are 40 employees, specializing in flexible packaging and corrugated cardboard work for clients in Austria, South Germany and Switzerland.
Before its recent investment in the new XPS Crystal 5080 system, Glatz Klischee explains that UV plate exposure was a weak link in its process and that traditional light tube exposure units had reached their quality limits.
Glatz Klischee investigated Esko’s LED exposure as early as 2010. Since then the trade shop has gained experience with several generations of inline UV exposure and worked with prototypes of the XPS Crystal 5080. “In our opinion, UV main and back exposure in one unit represents a milestone in flexographic plate making. It improves plate exposure quality and ensures extremely consistent flexographic plates,” said Manfred Schrattenthaler, Managing Director of Glatz Klischee.
Glatz Klischee has been working with the new XPS Crystal 5080 from Esko since the start of 2017. “Thanks to this technology, we now are able to supply our clients with standard screens [54 and 60-line], up to the absolute premium range with 250 lpi. We can deliver the best possible plate quality with the highest level of consistency and repeatability that we have not experienced to date,” said Schrattenthaler.
Holger Stier, Technical Manager at Glatz Klischee, described the importance of back exposure in producing flexo plates: “We are realizing that, in terms of quality, especially with very fine 250-lpi screens, back exposure is more important [than] previously assumed. Even small print points and delicate screen structures are better placed than before, and the reliefs are extremely consistent.”
In conjunction with the new facility, Dome began a new partnership with Koenig & Bauer to install two sheetfed presses, including a 41-inch, 10-colour Rapida 106 UV perfector and an 81-inch Rapida 205 large-format offset press.
The company explains its new Koenig & Bauer presses will add creative options for the display designers who are employed by Dome’s retail clients. This includes offering an enlarged litho format of 81 inches and the greater reproduction versatility afforded by a 10-colour press. Dome provides retail in-store media, direct mail and general commercial print, and operates ArrowClick E-Commerce and Custom Fulfillment services.
“With these purchases, Dome is taking a bold step into the world of super-large format and super-speed sheetfed offset printing,” said Misha Pavlov, Dome’s President. “The [Koenig & Bauer] Rapida 205’s XXL sheet size with 5-colour UV printing, on substrates up to 48 points at 9,000 sheets per hour, is the perfect addition to our business.
“This is a game-changer for Northern California, Oregon, Northern Nevada and Washington,” continued Pavlov, “enabling Dome to serve customers and prospects in these markets better than anyone, as this is the only 81-inch press in the area.”
The large-format Rapida 106 is a 10-colour, double coater, full-interdeck UV press. Dome explains the press will bring increased quality, efficiency and greater productivity while offering high-end applications previously not offered in-house. The presses are scheduled to to be up and running by the end of 2017.
The Achieve T800, leveraging Kodak’s thermal imaging technology, features a compact footprint and consumes up to 70 percent less power than previous CTP generations. By combining this CTP installation with a switch to Kodak Sonora XP process-free thermal plates, Imprimerie BBM also eliminated plate processing and, therefore, chemicals in the plate-making process. The new technology is also designed to reduce water consumption and energy costs.
At 2,400 dpi, the Achieve T800 has a rated throughput, for plate sizes of 1,030 x 800 mm, of 16 plates per hour (S speed) and 22 plates per hour (F Speed). Plates go directly from the CTP to the press, which Kodak explains to eliminate processing variability, resulting in fewer remakes and higher quality on press.
Designed to be run by a single operator, the Océ ProCut flatbed cutter leverages a modular tool system, which can simultaneously cut and crease a piece of cardboard, or transition from routing a piece of Dibond to kiss-cutting a roll of vinyl. The machine’s vacuum system automatically adjusts to materials put on the table.
The Océ Arizona is a UV-curable inkjet printing system aimed at mid-volume print producers. It is available with a Roll Media Option and features Océ VariaDot grayscale printing technology.
The drives and controls upgrade involved replacing existing consoles with new Omnicon and Omnicolor consoles, new Siemens PLC CPU hardware, controllers and drives. Goss technicians rebuilt the ink fountains on eight existing units and added new four- and 16-channel driver boards, embedded controller boards, ink fountain balls, and single piece ink keys. The Omni Make-Ready package, a combination of hardware and software functions, is designed to reduce waste.
“We have invested a significant amount of money into this press to ensure longevity and reliability, says Ted Schneider, Maintenance and Engineering Manager of RBW Graphics. “The new upgrades will also help to gain efficiencies and help to provide consistency in quality. By adding the Omnicon control system to this press, it aligns with the operating platforms on our other Goss Sunday presses which all run the Omnicon system.”
Their new finishing systems purchased from KBR Graphics, the exclusive Canadian distributor for Standard Horizon, includes a CRF-362 creaser/folder that will be primarily be used for handling digital colour output across a range of coated or uncoated light and heavy weight stocks.
In 2009, Imprimerie Bourg Royal, led by President Yves Paquet, shifted its production toward digital printing. The CRF-362 can be used for one-pass processing of applications like restaurant menus, greeting cards, book covers and many types of marketing collateral.
“Attaining an accurately finished product is categorically the most-important step the production of digitally printed material,” said Karl Belafi Jr., Vice President KBR Graphics Ltd. “The CRF-362 is a really good fit for them and we are so pleased on how the operators have easily taken to the equipment and have hit the ground running.”
In addition to the creaser/folder, Imprimerie Bourg Royal purchased a Horizon SPF/FC-200A booklet-maker with a VAC-1000 collator. This upgrade replaced a 20-year-old Horizon system. The SPF/FC-200A is described as a high-performance inline bookletmaking system with collating, stitching, folding and fore-edge trimming.
The SPF/FC-200A can process up to 4,500 books per hour and features a 200-job memory storage and an icon-based touch-screen for job set-up. The 10-station VAC-1000 collator features a patented rotary-pulse vacuum feed system, which can operate at speeds up to 9,900 sets per hour. The system is expandable from one to six towers, with the ability to run in both directions at full rated speed.
Driven by Agfa’s Asanti workflow, the Jeti Tauro LED is a 100-inch (2.5 metre) wide hybrid UV printer with an integrated roll-to-roll system. It is designed to reach speeds of up to 2960 square feet per hour and can feed a range of media including corrugated board.
The Tauro uses an adaptive vacuum system to hold corrugated and thin media flat for accurate ink placement. Its automated board feeder (ABF) can process up to four boards automatically, which Agfa claims to increase production efficiency by up to 30 percent. The white ink capability of the Tauro expands applications to backlit POP/POS or for using white as a spot colour on both rigid and roll media.
The new Jeti Ceres RTR3200 LED, aimed at higher-quality work, reaches speeds of up to 2,002 square feet per hour (186 square metres) on flexible media for both indoor and outdoor applications. The 126-inch (3.2-metre) wide roll-to-roll system provides six colours plus white to enhance the opacity, boost colour contrast, and improve text readability.
Earlier this month, CJ Graphics announced the addition of a six-colour Heidelberg XL106 press to its existing sheetfed-offset line-up of two 6-colour XL presses. The company’s most recent XL106 press is equipped with an Anilox AQ coater and Inpress Control, which CJ Graphics explains will be directed toward Heidelberg’s recently introduced Push To Stop operating philosophy. In late September, CJ Graphics began to install two fully loaded Xerox iGen 5 presses.
The company’s most recent XL106 press is equipped with an Anilox AQ coater and Inpress Control, which CJ Graphics explains will be directed toward Heidelberg’s recently introduced Push To Stop operating philosophy – unveiled at drupa 2016 in conjunction with its Press Center XL 2 with Intellistart 2 technology.
The Push to Stop concept is to have the press initiate a series of print jobs that are properly queued up by Heidelberg’s Prinect software, which also relies on the new-generation Press Center XL 2 console, Intellistart 2 and assistance systems such as Intelliguide.
Depending on ink layout down and imposition, print jobs can then run consistently without operator intervention. Ultimately, the technology platform can also leverage colour management tools to reach pre-specified Delta levels and tagging systems in the press delivery.
Push to Stop is available for the new generation Speedmaster, covering the series XL 75, CX/SX 102, XL 106 and XL 145/162, which are equipped with the Prinect Press Center XL 2, the Wallscreen XL, and AutoPlate Pro or AutoPlate XL 2 and Inpress Control 2 automation components.
The press is driven by Heidelberg’s recently introduced Press Center XL featuring Intellistart 2 operating software, which the press maker describes as providing for autonomous processing of jobs at speeds of up to 18,000 sheets per hour.
Premier Printing explains, as a manufacturer of school, college and university agendas, as well as general commercial printing, when agenda season hits, the plant must double production and meet stringent deadlines. This created a backlog on its current sheetfed offset presses, including a Speedmaster XL-106-10P and a Speedmaster SM 74-8P+L. The new Speedmaster has filled the gap for the 2/2 signatures that are typical in this printing business.
“AutoPlate Pro is a gift,” said Tom Bennet, Special Projects Manager, Premier Printing. “Agenda run lengths are 300 to 1,500 per form, so we are performing up to 150 plate changes per day. Job changes on the 4P were as low as 1½ minutes. Keeping plates coming is the new challenge.”
Another of Premier’s recent investments for productivity improvement came in the installation of a TH-82-P Stahl folder with PFX feeder. Capable of running signatures at 18,000 pieces per hour, the company explains this folder has doubled the amount of throughput in its finishing department.
“This new folder is a game changer. Of all the areas in our plant, folding was the real bottleneck,” said Ted Gortemaker, Operations Manager at Premier. “The ease of operation, set up and throughput is amazing. Watching skids of print disappear is stunning. Using the pallet feeding and Palamides stacking table has greatly reduced the operator work level required.”
Founded in 1962, Premier Printing today employs 80 full-time staff, and up to 120 part-time staff during agenda season, in a 75,000-square-foot facility in Winnipeg’s St. Boniface Industrial Park.
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