The best of 2003

Dec 1, 2003 12:00 PM, by Katherine O'Brien | kobrien@primediabusiness.com

In 2003, we met many interesting printers. I particularly enjoyed “The green printer” (April), which profiled EcoPrint (Silver Spring, MD). The $1.6 million printer was originally housed in an old school bus: Owner Roger Telschow bolted a Multilith to the vehicle's floor and ran an extension cord from the “plant” to the “executive suite,” which also doubled as his apartment.

On the following pages we've recapped some of the most significant feature stories of 2003. Don't see your favorite? Try our article archive at americanprinter.com.

Prepress

“What's new with JDF 1.2?” (September)
Martin Bailey, the CEO of the CIP4 organization (Zurich, Switzerland), explains how JDF addresses compatibility among components from multiple vendors. A sidebar, “JDF 101,” defines JDF as well as some of the key benefits for printers.

The bottom line: Drupa 2004 will be the coming-out party for JDF-enabled products. “[People have] said JDF will spread like a virus,” says James Harvey, CIP4's executive director. “It's the biggest change to our industry's infrastructure since the application of computers to prepress and desktop applications.”
“Three cheers for XML” (November)
eXtensible Markup Language (XML) is transforming desktop publishing and is likely to impact all facets of the graphic arts. This article explores how XML's flexibility facilitates the exchange of information between dissimilar software applications. Contributing editor Hal Hinderliter also explains how to export XML from page-layout documents.

The bottom line: JDF is based on XML. Even if you have no interest in programming, you'll appreciate this concise explanation of the language. Also, if you offer any browser-based estimating or ordering, you'll want to know how an XML-based specification is extending JDF beyond the production facility.
“Real-world workflow” (June)
We've moved far beyond converting PostScript into one-bit TIFF data. Today's workflow systems offer print production format (PPF) CIP4 data, dynamic scheduling software, proofs from interpreted data as well as Internet-enabled extensions for customer input of job specifications, job-progress tracking and online soft proofing. Workflow products from Agfa, Creo, Dalim, Esko-Graphics, Fuji, Heidelberg, Screen and Shira are featured.

The bottom line: Workflow systems aren't new, but the interoperability of open standards, such as JDF, PPF and XML, are set to revolutionize the printing industry the same way PostScript transformed the prepress department.
“CTP's co-existing technologies” (May)
Here's the latest scoop from leading UV, thermal and violet plate and platesetter vendors. By all accounts, CTP devices are continuing to move downmarket. Thermal and polymer-based plates are popular for long-run applications — postbaking can extend their run lengths to more than one million impressions; polyester plates can be used for up to 25,000 impressions.

The bottom line: We expect to see more process-free plate developments at Drupa. Process-free has been a long-held, but elusive, industry goal. Presstek (Hudson, NH) has released Applause, a process-free plate that can be used for runs of 100,000 impressions. Can other vendors achieve sufficient sensitivity for longer runs without chemical processing? Will new processless solutions be nonablative?
“The new contract proof” (February)
This is not your father's Chromalin contract-proof. This feature summarizes inkjet options from Agfa, Canon, CGS, Creo, Dupont, Enovation/Fuji, Epson, Hewlett-Packard (HP) and Kodak Polychrome Graphics (KPG).

The bottom line: Analog or digital-halftone proofs can cost between $10 to $14 per page. You can produce an inkjet proof for roughly one-tenth of that. Stochastic proofing challenges and soft-proofing options also are detailed.
“Inkjet proofing update” (October)
A reader told us he enjoyed “The new contract proof” but suggested we do a chart showing printer specs and other information. This article highlights devices from Agfa, Canon, Creo, DuPont, Encad, HP, Hyphen Asia Pacific, KPG, MacDermid Colorspan, Roland and Techsage.

The bottom line: In addition to vendor products, the feature defines continuous flow, thermal and piezoelectric drop-on-demand technology, as well as the significance of droplet volume. It's easy to assess your inkjet options, including those with duplexing capabilities.
“Color management” (January)
Color-management might not be at the plug-and-play stage, but it's getting more user-friendly. Hal Hinderliter offers some practical tips for implementing an ICC workflow.

The bottom line: Color management isn't as expensive or difficult as it used to be. The benefits are proven and within your grasp.
“CIELAB: measuring color on many different media” (November)
CIELAB can be used to measure color on film, plates and press sheets, as well as inkjet proofs and LCD and CRT computer monitors. Rather than saying an image is too blue or has a magenta cast, CIELAB lets graphic-arts users communicate color in numerical terms.

The bottom line: Even diehard density fans will appreciate Abhay Sharma and Trista Goike's clear color-technology explanation.

Press

“Next-generation networking” (July)
“The only way to increase your margin is to reduce costs,” declares one vendor. Soon it will be possible to integrate all systems and equipment from prepress through postpress, even if your equipment is from several different vendors. Mayu Mishina looks at Creo's Networked Graphic Production, Heidelberg's Prinect, KBA's Logotronic, Komori's K-Station, MAN Roland's PECOM and Mitsubishi's ColorLink.

The bottom line: Computer-integrated manufacturing (CIM) can minimize potential human error while maximizing a plant's efficiency. It will be a key Drupa theme and vital knowledge for progressive printers.
“So long moiré, hello stochastic,” (April)
Thanks to CTP and more powerful RIPs, there's a new day dawning for stochastic and hybrid screening. In addition to an overview of basic screening technology, this article provides insights from Sells Printing (New Berlin, WI); Quality Color Graphics (Pewaukee, WI); Haig's Quality Printing (Las Vegas); Glenbard Graphics (Carol Stream, IL); Lake County Press (Waukegan, IL); and Rink Printing (South Bend, IN). European printers Billes Trykeri, GraphX and Zwaan Offset also add their $.02.

The bottom line: Screening will be a hot topic in 2004 as well, as printers seek to differentiate themselves. Look for more news from Agfa, Creo, Fuji, Heidelberg and Screen.
“UV cures all” (June)
Suttle Straus (Waunakee, WI); Anderson Lithograph (Los Angeles); Buhl Press (Berkeley, IL); and Tim-Bar POP (New Oxford, PA) discuss their UV setups as well as some challenging pieces printed on foil, plastic and other unusual substrates. A sidebar describes curing systems from Eltosch North America, Fuchs-Devries, Grafix, IST Metz, Nordson, Oxy-Dry and Prime UV.

The bottom line: UV printing has been a bright spot in a slow industry. Hybrid and UV coating offer the vibrancy and shine of full UV without the cost of a complete set of interstation lamps.
“Buying a new sheetfed press” (January)
Don't buy a press based on price or emotion — make sure you're getting the best business solution. What do you need to know before you sign off on new equipment? Get the scoop from industry consultants, a financial advisor and sheetfed press vendors.

The bottom line: This article offers ROI suggestions as well as some practical approaches to financing.
“Digital wide-format: a growth opportunity” (February)
According to a Graphic Arts Marketing Information Service (GAMIS) (Alexandria, VA) study, proofing is the commercial printing industry's dominant application of digital color wide-format technology. Wide-format proofing got its start in 1992 with the introduction of eight-page filmsetters. Today, however, many wide-format printers are often idle. This article discusses potential markets for signs, banners, posters, vehicle graphics, wallcoverings, floor graphics and niche applications.

The bottom line: Digital-color wide-format printing represents a missed opportunity for many. It's a chance for commercial printers to diversify and differentiate themselves. And, at least through 2006, it is likely to be the highest-growth segment of the graphic arts.
“Real-world variable-data printing” (March)
Mayu Mishina profiles five printers' variable-data efforts. Find out what Microdynamics Group (Naperville, IL); Mail-Well (Englewood, CO); The Document Centre (Carol Stream, IL); Digital Marketing (Minneapolis); and Creative Digital Color (Elk Grove Village, IL) are doing for American Express Financial Advisers, Fortune 500 corporations, pharmaceutical companies and others.

The bottom line: We've all read optimistic forecasts for variable-data printing. What do these users think?
“Innovative perfectors” (May)
Representatives from Japs-Olson (St. Louis Park, MN); Hagg Press (Elgin, IL); Quad/ Graphics (West Allis, WI); Eva-Tone (Clearwater, FL); and Dynagraf (Canton, MA) describe unique perfecting features of their presses.

the bottom line: Some pundits say perfecting presses are twice as productive as conventional straight-printing presses.
“Why di?” (August)
Direct-imaging (DI) presses reportedly offer 15-minute makereadies and are ideal for runs ranging from 500 to a few thousand impressions per jobs. Representatives from Heidelberg, KBA and Ryobi compare DI vs. CTP, describe typical customers and applications, and offer some predictions. Sidebars cover KPG's entry into the DI arena — it's selling a two-page, four-color Ryobi press — as well as the second MAN Roland DICOweb installation at a Swiss printer that specializes in magazines, directories, catalogs, calendars and other commercial products.

The bottom line: According to one report, by 2010, 43 percent of all pages printed will have run lengths of 2,000 or less. Maybe there's a DI press in your future.
“Small-format presses” (July)
Today's two-up presses offer more color units, improved inking, tighter registration and better control of a wider range of paper stocks.

The bottom line: These 20-inch presses can deliver short-run, fast-turnaround jobs without compromising print quality, even on plastics. Many also offer inline finishing, such as scoring, perfing, cutting and numbering. Heidelberg has since unveiled the Printmaster PM 52 and Speedmaster SM 52-D. In the GTO arena, look for KBA's Genius press.
“Halfsize presses” (September)
Potential halfsize-press benefits include automation that compares favorably to that of a fullsize press, lower labor costs, reduced overhead and smaller capital outlays. This article examines why Allstate Printing & Graphics (Clifton, NJ); CrossTech Communications (Chicago); First Impression Group (Eagan, MN); Green Street Press (Pasadena, CA); and Oakland Printing Services (Troy, MI) chose halfsize presses. A sidebar highlights presses from Heidelberg, Komori, MAN Roland, Mitsubishi, Grafitec, KBA, Ryobi and Sakurai.

The bottom line: If your typical run length is under 10,000, this flexible format might be a good fit.

Postpress

“Capitalizing on mailing and fulfillment” (September)
A Q&A with consultant Clint Bolte also features new product introductions showcased at Graph Expo's Mailing & Fulfillment Center.

The bottom line: “The great underappreciated payoff of mailing is that all of these added services actually drive press cylinders,” says Bolte. “Often a 50,000 press run will become three or more 30,000 runs, or a twice-a-year job turns into a monthly project.”
“Laminators” (January)
This laminator primer explains the difference between thermal and cold adhesive films. It highlights wide-format machines and materials from Autobond, Advanced Grieg Laminators, Billhofer, D&K International, GBC Films Group, Seal Graphics and Transilwrap.

The bottom line: We are still receiving a steady stream of requests for the CD mentioned in this article: “I Could Just Scream: Troubleshooting the Top 5 Laminating Mistakes.” It's now available online at davidgoetter.com.
“Smarter folding” (February)
Along with the latest developments from GBR Systems Corp., Heidelberg, MBO and Standard Finishing, this article features a sidebar on solving common folding problems.

The bottom line: We can't prove it, but a folder is probably the most difficult piece of bindery equipment to operate. Bending paper requires a lot of brain power!
“Avoiding on-demand paper pitfalls” (March)
Unlike a conventional press, once a job is running on a digital press, operators have limited compensation adjustment options. In addition to discussing the use of climate control and acclimation to combat warping, drying and blistering temperatures, author Steve Johnson offers strategies for dealing with other digital printing issues, such as wrinkling, excessive waving, cracking, flaking and rubbing.

The bottom line: Steve Johnson is the president of Copresco (Carol Stream, IL ), an on-demand printer. His advice is practical and field-tested. (Steve also wrote September's “The Copies Overnight/Copresco story.”)
“Do you want that booklet stapled, stitched or squashed?” (July)
A look at offline, inline and nearline options from Xerox, CP Bourg, Duplo, Global Print Finishing, MBM, Standard Horizon, Spiel and others.

the bottom line: This feature also describes new hybrid bookletmaker/saddlestitchers from Standard and IBIS Americas.
“Pur and perfect binding” (May)
Polyurethane reactive (PUR) is unique in that it will bond to lacquer and UV-coated curings, and films such as Mylar, as well as paper. First developed in 1994, PUR is now a fourth-generation product that enables printers to ship books the same day they've bound the spines.

The bottom line: PUR can help you avoid some UV and ink-migration headaches.
“Building better binderies through benchmarking” (August)
Robert Diehl and Peter Doyle explain how to use data collection to achieve predictable throughput.

The bottom line: A predictable process is more productive process!

Dazzling dots at Graph Expo

New screening technology was recognized in the “Must See 'em” technology category at Graph Expo this past fall. “Frequency modulation (FM), or stochastic screening, has been available for many years as an alternative to conventional amplitude-modulation (AM) halftone screening,” says consultant and “Must See 'em” chair Bill Lamparter. “Implemenation of FM screening [had been] hampered by film limitations until CTP made the process more practical. Now FM screening is finding wide acceptance and is spawning a variety of new screening techniques from several prepress suppliers.”

Creo's (Billerica, MA) booth featured more than 1,000 printed samples from sheetfed and web printers showcasing Staccato, its second-generation stochastic printing technology. Visitors were challenged to distinguish offset prints from original photographs.

Agfa (Ridgefield Park, NJ) debuted :Sublima, a cross-modulation (XM) screening technology that uses AM for midtones and FM for highlights and shadows, transitioning smoothly between the two. Users reportedly can generate line screens of 210, 240, 280 and 340 lpi.

Other hybrid products include Fujifilm's Co-Rés and Screen's Spekta. At Graph Expo, Heidelberg indicated it is completing beta testing for its new Satin screening technology.

If you want to hear how fellow printers are using new screening technologies, consider attending GATF's Tech Alert, Feb. 8-9 in Pittsburgh (see gain.net); or VUE/Point, March 29-31 in Washington, DC (see gasc.org).

Better days ahead?

According to The NAPL 2003-2004 State of the Industry Report, the graphic arts is “finally showing signs of what may be a sustainable upturn.”

Andrew Paparozzi, NAPL's (Paramus, NJ) vice president and chief economist, warns, however, that printing companies shouldn't rely on an economic rebound to grow their businesses. “There's a redistribution of business going on in our industry,” says the economist. “To be on the right side of that redistribution, printing companies have to take share in markets that aren't growing fast enough for everyone and defend market share from an expanding array of competitors.”

The NAPL 2003-2004 State of the Industry Report is free for NAPL corporate and associate members; non-member printers may purchase the report for $299. To order, contact NAPL at (800) 642-6275, option 3.