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90 Years Ago<br />
This is where it all started. Ninety years ago in the Azumabashi area of Tokyo<br />
— home to the shokunin artisan community that gave birth to the monozukuri<br />
culture of ‘making things.’ A culture that flourished in the second half of the<br />
20th century and thrives today in producing innovations and breakthroughs<br />
that enrich everyone. Here <strong>Komori</strong>’s first ‘head office’ was the launching pad<br />
for a company that is still writing the history of the printing industry. Everything<br />
has changed since then — technologies, materials, people, even visions.<br />
Everything except the way <strong>Komori</strong> thinks about its customers.<br />
th Anniversary
Feature<br />
The Designer’s View<br />
Art Director Masahiro Aoyagi and Printing Director Akihiro Takamoto of Toppan<br />
Printing describe the making of the <strong>Komori</strong> 2013 calendar, Perfection on Earth,<br />
made jointly by <strong>Komori</strong> and Toppan. The image selection and editing, the colors<br />
and varnishes, the pages that went smoothly and those that caused headaches —<br />
everything that went into creating the <strong>Komori</strong> identity and environmental theme in ink<br />
on paper.<br />
Art Director Kiyotaka Takeuchi outlines the challenges facing packaging designers<br />
working in Japan’s frenetic consumer sector. Driving the development of new creative<br />
expressions are shifting demographics, regulations and technologies. All for the fivesecond<br />
window of opportunity.<br />
User Pro<strong>file</strong>s<br />
Feature<br />
PESP to Offer Advantages to Customers<br />
New products, new business lines and new ways of interacting with<br />
customers are part of <strong>Komori</strong>’s plan to evolve into a print engineering<br />
service provider. A graphic look at some of the specifics as they might<br />
play out in a typical print shop.<br />
Looking Ahead:<br />
Users See the Future in a <strong>Komori</strong> Press<br />
Sheetfed and web offset presses, H-UV-driven machines as well as presses that print<br />
with conventional inks, both publishing and commercial printers. Every <strong>Komori</strong> user<br />
has a view of his future. Their markets and outlook and how they are partnering with<br />
<strong>Komori</strong> to create new business.<br />
Topics<br />
Techno Service Center and KGC<br />
Outline of case studies of two web offset printers — one in the<br />
U.S. and another in Tokyo — where <strong>Komori</strong> Techno Service Center<br />
attention paid off in quantifiable ways. Plus, a look at the <strong>Komori</strong><br />
Graphic Technology Center as it turns three.<br />
Show Reports<br />
New Initiatives Spell Change Ahead<br />
Open house events, printing exhibitions and critical moves at key distributors in major<br />
markets. All the news and quotes plus pics from Frankfurt, New Delhi and Tsukuba.<br />
4<br />
14<br />
16<br />
32<br />
34<br />
no.78<br />
Printing specification of this issue:<br />
All pages printed by 4-color process H-UV.<br />
Cover laminated with gloss polypropylene film.<br />
<strong>Komori</strong> On Press<br />
3
The<br />
Because graphic design is the creative process that comes before any<br />
step in the printing workflow and determines not only what printed<br />
work will look like but also how it will be printed, On Press decided<br />
to sit down with some of today’s notable designers to talk about<br />
their work and how it relates to printing. While as old as civilization,<br />
visual communication exploded in the 20th and 21st centuries as<br />
technologies and mass markets combined to create soaring demand<br />
for the visual representation of ideas and messages. Two creatives<br />
from Toppan Printing, the diversified global Japanese printing<br />
company, Art Directors Masahiro Aoyagi and Kiyotaka Takeuchi,<br />
along with Printing Director Akihiro Takamoto, describe the process of<br />
creating a work featuring high added value printing — <strong>Komori</strong>’s 2013<br />
calendar — and packaging for consumer products. How they move<br />
from the stage of creative brief to deal with issues of branding and<br />
visual identity and finally to produce a <strong>file</strong> for the printer is a fascinating<br />
account of the prologue to printing.<br />
4 <strong>Komori</strong> On Press
Designer’s View<br />
<strong>Komori</strong> On Press<br />
5
An interview with Toppan Art Director Masahiro Aoyagi & Printing Director Akihiro Takamoto<br />
Perfection in Print<br />
The <strong>Komori</strong> 2013 Calendar<br />
As a press manufacturer, <strong>Komori</strong> creates a<br />
calendar every year that features stunning<br />
design and exceptional value added printing.<br />
<strong>Komori</strong> staff and Toppan Printing together<br />
undertake the mission of producing the<br />
calendar, which over the years has won a<br />
raft of awards, including the prestigious<br />
Minister of Economy, Trade and Industry<br />
Award. This year for the first time On Press<br />
interviewed Masahiro Aoyagi, art director<br />
at Toppan Printing, and Akihiro Takamoto,<br />
printing director at Toppan, the talent behind<br />
the 2013 calendar. Aoyagi and Takamoto, who<br />
have worked together with <strong>Komori</strong> staff in<br />
creating the calendar for the past three years,<br />
reveal the vision and the artistic and technical<br />
considerations and decisions behind this year’s<br />
calendar, the third in the Perfection on Earth<br />
series. They also describe the development of<br />
their careers at this unique megaprinter as<br />
well as their views on the H-UV system and the<br />
full-spec LS-840 used in the production stage.<br />
On Press: Tell us about your careers at Toppan Printing and<br />
the work that you do.<br />
Masahiro Aoyagi: Corporate calendars account for 99<br />
percent of my work. This consists of searching for materials<br />
— photographs or other visual art — executing the design<br />
and sometimes working with a Printing Director, or PD, to<br />
set the specifications for actual printing. Usually my role<br />
is implementing design, checking the proofs, and getting<br />
approvals from the creators when necessary. Calendars are<br />
seasonal products, of course, and I am usually busy with<br />
proposals in the March to May time frame and then occupied<br />
with production from June to mid-August. If work were delayed<br />
beyond that time, everyone would be in a tight spot.<br />
Akihiro Takamoto: I have worked as a Printing Director for<br />
about 15 years, ever since joining Toppan. This specialty was<br />
developed here about 30 years ago. There are two types of<br />
PDs at Toppan: the first works in prepress or the pressroom<br />
for 20 or 30 years and then starts working as a PD, while the<br />
second type is trained as a PD upon joining the company. I’m<br />
the second type. In college I majored in graphic design and had<br />
never dreamed of becoming a printing director – I didn’t even<br />
know what the words meant. I worked for a year in prepress<br />
and then studied for about five years with a senior PD. I learned<br />
6 <strong>Komori</strong> On Press
Silver<br />
Matt varnish<br />
through trial and error and from the people I worked with.<br />
Fundamental to becoming a printing director is learning the<br />
limits of expression with four-color process using sheetfed,<br />
web offset and gravure presses. This is the basis, and of course<br />
this varies with different papers, so a PD must also have a sense<br />
of the limits of each printing paper. When four colors are not<br />
sufficient for the graphic expression, we consider using a special<br />
color. But adding a special over four colors, for example, can<br />
result in dullness. In such cases, it is necessary to reduce the<br />
density of the 4C inks and use the additional special color to<br />
balance them out. Naturally, when the special color ink makes<br />
the colors more intense and vivid, there is no need to bring<br />
down the 4C densities. The only way to acquire this sense is<br />
through experience.<br />
Could you explain for us the process of producing <strong>Komori</strong>’s<br />
calendars?<br />
Aoyagi: In the past, <strong>Komori</strong>’s calendars were a series of original<br />
creative works by graphic designers. Three years ago, though, the<br />
direction was changed and the natural environment was chosen<br />
as the overall theme. We held brainstorming sessions to decide<br />
what the best means of expression would be — photographs or<br />
illustrations or something else. For <strong>Komori</strong>, the ideal calendar<br />
is beautiful and artistic rather than functional. For the first<br />
calendar in the new series, we worked with the animal photos<br />
of Mark Laita. For 2013 we used Joel Sartore’s photographs.<br />
We had to decide which photos from about a dozen or so<br />
would be best for showing added value printing techniques<br />
and the possibilities of the new H-UV curing system. With an<br />
ordinary calendar, the designer selects the photos to be used<br />
and special printing treatments follow from that selection. In<br />
<strong>Komori</strong>’s case, we had to select photos to illustrate specific<br />
printing techniques and achieve a balance between visual<br />
appeal as we saw it and the possibilities of added value printing.<br />
This was a very difficult point — the balance of images and<br />
printing techniques.<br />
Another challenge was the difference between the effect we<br />
anticipated a given printing technique would produce and the<br />
actual result when we did test printing. Some effects can only be<br />
confirmed by test printing. The drip-off technique with H-UV,<br />
for example, was very effective but it took some reorientation<br />
on our part to get it right.<br />
We also had to take into account the <strong>Komori</strong> corporate<br />
identity. Since <strong>Komori</strong> is a printing press manufacturer, we<br />
had to create a calendar that would project strength. The<br />
design had to show not only beauty but also the capabilities<br />
of print technology. It had to communicate to users around<br />
the world that these print effects are achievable with a <strong>Komori</strong><br />
press. And <strong>Komori</strong>’s calendar had to be executed at a level<br />
befitting <strong>Komori</strong> — a press maker — as well as us — the printing<br />
company. Everyone has likes and dislikes when it comes to<br />
images and that is unavoidable, but we felt that if people looked<br />
at the calendar and said, “I don’t like turtles, but that printing<br />
technique is terrific,” or “I wonder how that was printed,” we<br />
would be satisfied.<br />
Cover<br />
January–February<br />
March–April<br />
May–June<br />
OP varnish Coater<br />
Red<br />
Matt varnish<br />
OP varnish (pearl x 2)<br />
Matt varnish OP varnish (patterned)<br />
Coater<br />
Green Matt varnish<br />
OP varnish Coater<br />
<strong>Komori</strong> On Press<br />
7
Conversely, it would not be ideal if the<br />
technique were obvious to everyone at a glance.<br />
We consulted with the director of the <strong>Komori</strong><br />
Graphic Technology Center, and there was lively<br />
consideration of every aspect of the techniques<br />
and extensive deliberation between finalizing the<br />
visuals and the actual printing.<br />
The paper of the calendar was chosen for its high<br />
color-reproduction capabilities and its excellence<br />
with matt and gloss coating. Inks also differ<br />
somewhat by manufacturer in flow and tack and<br />
these variables must be considered. And even with<br />
temperature and humidity control in the plant, the<br />
weather can still have an effect. Also, test printing<br />
can be just right, but something will sometimes<br />
be just a bit different in production printing due<br />
to some slight variation in conditions. Drip-off<br />
coating, for example, will vary according to its age.<br />
Any impurities left over from the previous job can<br />
completely change the outcome of the current job.<br />
Once the ink conditions have stabilized, however,<br />
there is no change during the production run.<br />
Can you tell us the story of the 2013 <strong>Komori</strong><br />
calendar?<br />
Takamoto: On the calendar cover, the lines on<br />
the shell of the turtle were tricky. We sought a dry,<br />
crispy look. But it couldn’t be too strong or too<br />
weak. There is a slight filling out on the fringe of<br />
the coating that I thought would be smoothed by<br />
the use of drip-off coating. Unfortunately, there<br />
is a faint line made by the drip-off effect. It would<br />
be perfect if it was random rather than linear, but<br />
it is not. We have tried to attain perfection with<br />
this effect for the past three years but we still have<br />
room to improve. We were aiming for a smooth<br />
gradation from the glossy area to the drip-off<br />
area and on to the area where there is no coating.<br />
To make this boundary unnoticeable, we varied<br />
the coverage of the coating and the overprint<br />
varnish for drip-off. Reconciling these in a natural<br />
way might be impossible due to the chemistry of<br />
the materials.<br />
Regarding special colors, the bright gold color<br />
of the turtle’s shell was achieved by using silver<br />
with yellow since gold has a brownish element<br />
that tends to darken the image.<br />
January–February Parrot<br />
Aoyagi: The main point with the parrot was<br />
vivid color. After the inks we applied two layers<br />
of pearlescent varnish to get the fine, delicate<br />
feeling of the feathers. This varnish is used twice<br />
on the white feathers but not on the red feathers<br />
so as to preserve their vivid color.<br />
March–April Cheetah<br />
Aoyagi: The key point in the rendering of the cheetah is the<br />
pattern in the varnish. We wanted to use a pattern with overprint<br />
varnish somewhere in the calendar, and in consultation with<br />
KGC it was decided at a fairly early stage to use it with this<br />
motif. Selecting the borderline for the application of the varnish<br />
required an enormous amount of work in prepress.<br />
May–June Chameleon<br />
Takamoto: The chameleon went comparatively smoothly. We<br />
wanted to be rather showy here with the rough, horny surface<br />
and the special green. It went rather well right from the start but<br />
the varnish inside the mouth stood out too prominently, so we<br />
had to make adjustments using the overprint varnish. We used<br />
drip-off and gloss coatings in different ways according to the<br />
form of the scales so that it would not become monotonous.<br />
July–August Arowana<br />
Aoyagi: This image of the fish, an arowana, was a headache<br />
because the difference between the matt varnish and gloss<br />
coating as well as between the actual fish in the lower part of<br />
the image and the reflected fish above did not materialize as<br />
we expected. Opinions on what would be best here flew back<br />
and forth, and it was difficult for us to turn abstract ideas into<br />
graphic reality.<br />
The pink tone of the upper image is the effect of two<br />
overprintings of pearlescent varnish. Originally there was<br />
probably something to indicate the surface of the water but<br />
the image had already been edited when we used it, so it<br />
was difficult to bring out that the image is of one fish and<br />
its reflection.<br />
September–October Monarch Butterflies<br />
Aoyagi: The image of the monarch butterflies shows the effect<br />
of the coating most clearly. The glossiness stands out because<br />
of the matt varnish that encircles it.<br />
This page also uses a bluish-black background, unlike the<br />
orangish-black background on all the other pages. Since<br />
the butterflies are orange, the blue makes that color stand<br />
8 <strong>Komori</strong> On Press
out. The most difficult aspect of this page was ensuring that<br />
the line of the gloss coating matched the line of the image<br />
perfectly. The butterflies are not only gorgeous but also<br />
symbolic of the concept of endangered species that is vital to<br />
our environmental theme.<br />
November–December Mandrill<br />
Takamoto: We used a gold for the hair of the mandrill, taking<br />
care that it did not <strong>see</strong>m unnatural. Using gold on brownish<br />
areas stabilizes the color tones but makes for difficulties in<br />
prepress, so this technique is not used very often. It is essential<br />
that the gloss coating not make the borderline of the hair stand<br />
out. Control in creating a gradation from the glossy to the<br />
drip-off areas is usually very difficult, but it was very smooth<br />
in this case. We failed in attempting this two years ago. In the<br />
past, I used gradations — from a certain percentage to another<br />
percentage — and this approach failed. This time I used a tone<br />
that was matched to the image and made it harder or softer as<br />
necessary. This yielded a boke effect that was well adapted to<br />
the image. There’s no abrupt change.<br />
July–August<br />
September–October<br />
Matt varnish OP varnish (pearl x 2)<br />
OP varnish Coater<br />
Orange Matt varnish<br />
Coater<br />
Tell us your opinion of H-UV and the LS-840+C H-UV press.<br />
Aoyagi: Although I haven’t directly compared them, I don’t<br />
think there’s such a great difference from conventional UV in<br />
terms of graphic expression. However, I think that it’s easier<br />
to manage and adjust H-UV drip-off coating. With UV, we<br />
would use gradations and sometimes the effect would not be<br />
noticeable, but with H-UV drip-off coating the effect is very<br />
apparent even with gradations.<br />
Takamoto: Dot gain is less with H-UV inks and the gloss levels<br />
are significantly higher, which are definite pluses for graphic<br />
expression. In fact, the range of expression is remarkably<br />
broader with H-UV. With ordinary UV ink, we would add a<br />
layer of gloss coating for the glossy effect but sometimes even<br />
this did not produce sufficient glossiness. Now the high gloss<br />
level attained by the H-UV inks actually allows us to consider<br />
using a matt varnish. I was amazed that it doesn’t have any of the<br />
peculiar smell of UV ink. Print directors are sometimes at the<br />
side of the press for long periods and the UV smell can cause<br />
headaches. H-UV is definitely an improvement. Someday we<br />
would like to use an H-UV version of Toyo Ink’s Kaleido inks.<br />
What would you like to <strong>see</strong> from the printing industry?<br />
Aoyagi: Overall I would like to have more information on<br />
new methods of expression that can be achieved with various<br />
combinations of the materials that are now available. Sometimes<br />
discoveries are accidental, as in the case of drip-off coating.<br />
What can be done with various inks, varnishes and coatings<br />
on different papers — the creation of new amalgams — is what<br />
would be of most value.<br />
Takamoto: Although the precision of today’s machines is<br />
extremely high, customers’ demands are also becoming<br />
more exacting. These days the requirement for screen<br />
frequency of 230 or 280 lpi rather than 175 is not uncommon.<br />
The entire production process must be capable of meeting<br />
these requirements.<br />
November–December<br />
Gold<br />
Akihiro Takamoto<br />
Printing director at Toppan Printing<br />
since joining the company in 1997.<br />
Involved in the production design of<br />
posters and calendars by well-known<br />
creators that require high quality color<br />
reproduction. Widely experienced<br />
in the production of comic book<br />
covers, collections of illustrations and<br />
photographs, and printing that uses<br />
special colors. Ensures high quality<br />
by managing manufacturing lines for<br />
his work.<br />
Masahiro Aoyagi<br />
In charge of art direction for corporate<br />
calendars ever since joining Toppan<br />
Printing in 1998. In the past few<br />
years, Aoyagi has collaborated with<br />
distinguished Japanese and foreign<br />
creators and also taken charge of<br />
works that make use of special<br />
printing techniques. A member of the<br />
Japan Graphic Designers Association,<br />
h e h a s w o n a h o s t o f a w a r d s ,<br />
including the Minister of Economy,<br />
Trade and Industry Award presented<br />
by the Japan Federation of Printing<br />
Industries and both Silver and Bronze<br />
awards in the Gregor International<br />
Calendar Award.<br />
Coater<br />
OP varnish<br />
<strong>Komori</strong> On Press<br />
9
Chef de<br />
Cuisine for<br />
Tasty<br />
Printing<br />
An interview with Toppan Art Director Kiyotaka Takeuchi<br />
On Press interviewed Kiyotaka Takeuchi,<br />
Art Director in charge of the Package Creative<br />
Team in the Toppan Idea Center of Toppan<br />
Printing, on the latest trends in packaging<br />
design in Japan and his own experience in<br />
designing packaging for national brands.<br />
As an award-winning designer with his<br />
finger on the pulse of the consumer sector in<br />
Japan, Takeuchi shared his insights into the<br />
dynamic retail scene and the ways packaging<br />
is changing to meet emerging needs.<br />
Last June, Takeuchi participated in a Graphic<br />
Trial, held by Toppan’s Graphic Arts Center,<br />
that focused on the theme of ‘ delicious<br />
printing.’ Graphic Trials are endeavors to<br />
acquire new expressions by exploring the<br />
relationship between graphic design and<br />
printing expression. The challenge is to create<br />
a variety of expressions by having a front-line<br />
creator produce a poster. In collaboration<br />
with a printing director, Takeuchi sought<br />
‘the next’ in printing expressions for food<br />
packaging. “In fine cuisine, the chef has<br />
ways of adding subtle flavors and finishing<br />
touches that cannot be <strong>see</strong>n. I was aiming<br />
for a tastiness that can be perceived visually<br />
by adding imperceptible subtle tinges and<br />
finishing characteristics achieved with the<br />
printing process,” says Takeuchi.<br />
On Press: The role of art director is often quite broad. In your<br />
case, how does your role as art director play out in the creation<br />
of the designs that come off the presses?<br />
Kiyotaka Takeuchi: Packaging is an important business asset<br />
of the client and must be in accord with the product strategy.<br />
The art director is responsible for the creative work and is in<br />
charge of the aesthetics of the package. In my case, since I am<br />
employed by a printing company, my role is even broader. It<br />
is not unusual that an outstanding design is not rendered very<br />
well once the process shifts to production. So the distinctive<br />
characteristic of an art director’s role in a printing company<br />
extends to developing a creative expression that ensures the<br />
final product realizes the promise of the design.<br />
In fact, sometimes I have to develop ideas that encompass<br />
the contents of the product. In recent years the marketing<br />
environment and purchasing patterns have significantly affected<br />
creative expression. I believe that the vital point is whether<br />
10 <strong>Komori</strong> On Press
an instantly understandable communication can have strong<br />
originality. Thus, an AD must have a broad outlook.<br />
What are the most recent trends in packaging that you <strong>see</strong><br />
as a creator?<br />
Lifestyles are becoming more diverse. There have been major<br />
changes in communication, for example. Social networking<br />
and the Web are part of the media mix now, and the identity<br />
of the package and product is defined in part before and in<br />
part after the consumer comes into contact with the package.<br />
The environment around packaging is driven by factors such as<br />
consumption, distribution, and society. On the distribution side,<br />
private brands are rapidly increasing their market share. On the<br />
other hand, consumers’ desires are becoming more high-end,<br />
and there is a limit to the tactic of copying national brands. New<br />
approaches are necessary. The division of consumption into<br />
two very different groups — national brands on the one hand<br />
and private brands focused on low price on the other — will<br />
also strongly influence creative expression.<br />
Then of course, while not trends, there is the necessity of<br />
ecological awareness and adherence to the concepts of<br />
Universal Design.<br />
Who is in charge of the structural design of the container?<br />
As a brand asset, the structure incorporates shape and<br />
function, and the responsibility for the structural design differs<br />
according to how the priorities are set. Those who decide on<br />
the materials that will be used and who have knowledge for<br />
getting the containers running in the production line actually<br />
work in this building. When the container has new or superior<br />
functionality, the design must lead consumers to take an interest<br />
in it and want to experience it. This is where package design and<br />
structural design must link up, so it is difficult to draw clear lines.<br />
The makeup of the target household is shifting today, isn’t it?<br />
A greater number of smaller households, couples and singles,<br />
especially in developed countries. Is this a factor?<br />
Yes, in fact, last year, ‘appropriate materials and appropriate<br />
amount’ was sort of a watchword in the Japanese packaging<br />
industry. Packages containing individual portions of products<br />
such as fabric softener and food — miso soup, for example —<br />
came onto the market to meet the needs of consumers living<br />
alone. I think changes in the functions and styles of packaging<br />
to meet these needs will continue to broaden.<br />
What is the most difficult element in the printing stage?<br />
Cost. When the unit price of the product is low, there is great<br />
pressure to keep the cost of packaging as low as possible. As<br />
a designer, I want to add to the product, but the cost must be<br />
held down. This varies a great deal with the category of the<br />
product. Cost must be kept down with ramen noodles and<br />
cookies, for example. With cigarettes, on the other hand,<br />
advertising is prohibited but giving a higher priority to the<br />
creative expression of the package, even if it is more costly,<br />
is one option for communicating with the consumer. At any<br />
In the Graphic Trial, Takeuchi sought to create five expressions of<br />
chocolate using different treats such as truffles and macaroons.<br />
The poster (above) makes use of the truffle motif. He found that<br />
there is considerable variation in the color perceived as ‘delicious’<br />
even with the same chocolate. The poster illustrates various grades<br />
of tastiness.<br />
This chart at right was<br />
created to determine<br />
color balance using different<br />
degrees of lightness<br />
and color saturation.<br />
Higher levels of lightness<br />
and saturation increase<br />
the perceived sweetness.<br />
Lower levels raise<br />
perceived bitterness.<br />
C o m p l e t e l y d i f f e r e n t<br />
tastes — sweet and bitter<br />
chocolate, as shown in<br />
the photos below — can<br />
be created from these<br />
two variables.<br />
<strong>Komori</strong> On Press<br />
11
ate, cost is the limiting factor in a great deal of<br />
ordinary work.<br />
The critical question in packaging is indisputable.<br />
Amid a huge variety of products in the store, how<br />
does the package communicate to the consumer?<br />
How does it motivate the consumer to find it,<br />
hold it and remember it? In supermarkets and<br />
convenience stores, the consumer decides<br />
whether or not he wants the product within<br />
five seconds. That is a very narrow window to<br />
communicate a message.<br />
Could you outline the process up to the<br />
completion of the package?<br />
Although each assignment is different, the<br />
process begins with analysis to determine the<br />
brand strategy, which is sometimes done by the<br />
client and sometimes done by us. Work on the<br />
design strategy is then initiated, and the structural<br />
design proceeds parallel to and entwined with<br />
the graphic design. Then, for example, when we<br />
propose a structural design, it must be compatible<br />
with the client’s production line, so the work<br />
proceeds with the involvement of the relevant<br />
departments in the company. In some cases, the<br />
production line must be changed to produce the<br />
new container. Not every proposal is accepted, but<br />
for every project we indicate what we think is the<br />
best solution for making the product successful.<br />
As far as the process is concerned, I think that we<br />
are able to cope with the many different ways<br />
clients use to advance their projects. Finally, the<br />
graphic design goes through validation studies<br />
before final approval is given.<br />
You worked with a printing director last year in<br />
Toppan’s Graphic Trial. What role does the printing<br />
director have and how did you collaborate?<br />
An art director for a printing company has<br />
printing director (PD) type skills, but this was my<br />
first experience of collaborating with a printing<br />
director who is working in a different stage. In<br />
last year’s Graphic Trial I learned a great deal<br />
about printing and also had some misconceptions<br />
dispelled. Typically my contact with the pressroom<br />
team is to give directions regarding what I aim to<br />
achieve. And sometimes the pressroom tells me<br />
that my proposal is not feasible for mechanical<br />
reasons. But the printing director understands the<br />
language and intentions of both the designers and<br />
the pressroom team, so it was a great opportunity.<br />
He offered many ideas, and his advice was based<br />
on a clear understanding of the design, so the<br />
collaboration was very instructive.<br />
The PD’s knowledge and experience are a<br />
wellspring of ideas for creating expressions and this made a great<br />
difference. I believe that Toppan was the pioneer in developing<br />
this profession. I hope that there are more opportunities to work<br />
with a printing director. Generally the PD looks at things from<br />
the pressroom side rather than the creative side, but his ideas<br />
are extremely stimulating and he is also capable of channeling<br />
the best efforts of photographers and graphic designers in ways<br />
that can be appreciated.<br />
What sort of added value printing are you interested in?<br />
I am interested in many different added value applications and<br />
approaches. There are many things that I would like to try which<br />
are not usually a part of my job. I am particularly interested in<br />
expressions that are not restricted by costs and regulations.<br />
I would like to work with fluorescent inks, which cannot be<br />
used with foods. Many inks and papers cannot be used in food<br />
packaging, so I hope that these materials are improved. There<br />
are not only migration issues but also functional problems,<br />
such as the performance of the materials during transport<br />
and when displayed in stores. Added value printing is often<br />
very well received by the client but the project then stumbles<br />
because it cannot be performed at the speed required by the<br />
production line. Nonetheless, many customers are trying to<br />
decommodify their products and are looking to better materials<br />
or stronger creative expression to achieve this.<br />
What are some of the ways that package design differs from<br />
other fields of design?<br />
The main differences are that packaging stands close to<br />
everyday life and reflects the times, such as social trends<br />
and changes in the law, and also it must accommodate mass<br />
production. As an aspect related to mass production, for<br />
example, when using gravure printing, if the design incorporates<br />
12 <strong>Komori</strong> On Press
ink concentrated in one area, the thickness of the ink will cause<br />
the web of film to swell, making it very difficult to control. The<br />
rules and regulations are endless, not only in production but<br />
also in transportation and in-store display. And whenever the<br />
laws change, the packaging must change. Today there are items<br />
that can be bought over-the-counter that previously were sold<br />
only by pharmacists, and the designs for these items changed<br />
when the law changed.<br />
What about printing has changed in the last 10 years as far as<br />
designers are concerned?<br />
The possibilities for creative expression have certainly<br />
expanded. The progress made with inks and chemical<br />
embossing, for example, has opened new opportunities.<br />
Color separations have become much more accurate. The<br />
progress made in printing technology has been phenomenal.<br />
The printing directors study these advances, and I am looking<br />
forward to working with them to explore the promise of<br />
improved technologies.<br />
What are your wishes regarding printers?<br />
I would like to work more closely with the printer when I am<br />
creating a product. When a printed item deviates from the<br />
ideal aimed for by the designer, the printed product is typically<br />
abandoned. But simply by changing one’s point of view, it<br />
could easily be <strong>see</strong>n as a compelling design or an innovative<br />
technique. I think that such work can be given life by changing<br />
the workflow. Although it entails risk for printing companies, I<br />
hope that they continue to stay on the offense. I would like the<br />
people from the pressroom floor to join with the creative side<br />
in driving innovation. Perhaps something like joint workshops<br />
would be helpful. I hope the printing side will participate in the<br />
creation of the design rather than just receive the design from<br />
the creative side. I would also like to <strong>see</strong> improvement of test<br />
prints. Sometimes I get a digital proof and sometimes a <strong>PDF</strong>.<br />
The poster (above) was<br />
meant to express the<br />
smoothness and luster of<br />
thick, dripping chocolate.<br />
In the photos at left, the<br />
impression of an almost<br />
imperceptible difference<br />
in taste is created by the<br />
use of fluorescent orange<br />
on the chocolate, 70 percent<br />
in the left photo and<br />
10 percent in the right<br />
photo, along with gloss<br />
varnish.<br />
There is a great deal of attention given to packaging these<br />
days, isn’t there?<br />
Very much so. In the past, packaging was just something that<br />
would be thrown away once it was opened. Today, however,<br />
because the influence of mass media advertising has become<br />
fragmented, packaging is valued as a medium of touchpoint<br />
communication. Packaging is positioned as a marketing tool<br />
— right along with television.<br />
Package design is also an increasingly attractive field for<br />
graphic designers working in other areas. And this development<br />
is clearly attracting attention. In last year’s Japan Package<br />
Design Awards, held biennially by the Japan Packaging Institute,<br />
designers from other fields were in the forefront. Of all things,<br />
package design has become a hot field.<br />
Kiyotaka Takeuchi<br />
Kiyotaka Takeuchi is an art<br />
director and a leader of the<br />
Package Creative Team of the<br />
Product Planning Department,<br />
Marketing Division of Toppan<br />
Printing in Tokyo. Takeuchi<br />
also works in the Toppan Idea<br />
Center. Takeuchi has also won<br />
many awards in the Japan<br />
Packaging Contest and is a<br />
director of the Japan Package<br />
Design Association.<br />
<strong>Komori</strong> On Press<br />
13
With the managing director ...<br />
I want to find a business model for increasing sales.<br />
<strong>Komori</strong> will build a business model with the customer.<br />
PESP to Offer Advantages<br />
to Customers<br />
Dedicated to offering kando-inspiring products for customers, <strong>Komori</strong><br />
is now dynamically evolving into a print engineering service provider<br />
(PESP: provider of press-related systems, printing materials and printing<br />
know-how) with new business targets. Through the optimum combination<br />
of printing technologies acquired over many years and with numerous<br />
partner companies, <strong>Komori</strong> is working toward creating products with<br />
new value suited for the times and providing integrated total solutions.<br />
In addition to <strong>see</strong>king greater advantages for customers, <strong>Komori</strong> will<br />
deepen existing businesses and evolve into a consultant/coordinator<br />
capable of recommending the optimum equipment and setup that meets<br />
customers’ wishes and needs.<br />
PESP Products for Optimum Solutions<br />
<strong>Komori</strong> is developing and selling a wide range of products in order to<br />
provide not only offset presses but also a full lineup of outstanding products<br />
and services that meet customers’ requirements. As a specific example,<br />
the H-UV drying system that enables the renowned OffsetOnDemand<br />
presses became a reality through the linking of PESP activities.<br />
A broad range of products — such as the Impremia Series of print-ondemand<br />
full-color printing systems, prototype inkjet digital presses as well<br />
as prepress and postpress equipment — will be included in the lineup.<br />
14<br />
<strong>Komori</strong> On Press
With the manufacturing manager ...<br />
I am looking for greater efficiency and coordination in the<br />
manufacturing department.<br />
<strong>Komori</strong> will recommend preventive maintenance and<br />
the optimum facilities for the entire printing process to<br />
increase production capacity and coordination.<br />
With the plant manager ...<br />
Despite the rise of prices of<br />
materials, I want to maintain profits.<br />
<strong>Komori</strong> will propose the optimum<br />
<strong>Komori</strong>-preferred materials and<br />
equipment to enhance both quality<br />
and cost competitiveness.<br />
<strong>Komori</strong> On Press<br />
15
User Pro<strong>file</strong><br />
H-UV wins converts in France<br />
Imprimerie des Hauts de Vilaine, Châteaubourg, France<br />
Company, after he took delivery of his new<br />
H-UV press in August 2012.<br />
Established in 1985 by Jean Jenin and his father,<br />
who had previously worked for Oberthur, the<br />
company was very quick to abandon traditional<br />
printing with lead typesetting in favor of<br />
desktop publishing. Based from the outset<br />
in Châteaubourg, located between Rennes<br />
and Vitré, it has continued to grow thanks<br />
to a diverse range of clients, the majority of<br />
whom are based in the “great West” part of<br />
France. Having doubled the surface area of its<br />
site in 2010, the company now has a printing<br />
works covering 2,300 square meters, where 33<br />
employees work in three rotating shifts.<br />
Two companies united by common values<br />
“We bought our first <strong>Komori</strong> in 1999. That<br />
was a four-color press,” recalls Mr. Jenin.<br />
“Since then, we’ve always remained faithful<br />
to the brand. First of all because <strong>Komori</strong> is a<br />
company built on a human scale, and that’s a<br />
good match for us. The other reason is because<br />
we appreciate the quality of <strong>Komori</strong> presses. In<br />
2005 we bought a five-color Lithrone 28 with<br />
CIP3, but the real strategic shift we made was<br />
the acquisition of our first large-format press<br />
in 2006 — a five-color Lithrone S40. Then in<br />
March 2011, we replaced the L-528 with an<br />
LS-529 fitted with the PDC-Lite II.”<br />
Jean Jenin, Manager<br />
The H-UV system launched at the Graphitec trade show in<br />
June 2011 immediately won the hearts of printers, and <strong>Komori</strong><br />
France has already sold more than a hundred units fitted<br />
with this innovative technology. Using high-sensitivity inks<br />
that dry instantly under an H-UV lamp, the system allows for<br />
improvements in response times and quality while also opening<br />
unexpected design possibilities. This has been the inspiring<br />
experience of Jean Jenin, manager of Hauts de Vilaine Printing<br />
Considerable time gains<br />
Always keen to move forward, Jenin switched<br />
to H-UV technology in mid-2012. He explains:<br />
“We had to renew one of our presses and I<br />
wanted to optimize our production speed in<br />
order to cut delivery times. I went to drupa in<br />
Düsseldorf, along with all my press operators,<br />
and we chose an H-UV-equipped five-color<br />
Lithrone G40 with PDC-SII and CIP3. I signed<br />
the purchase order right there on the stand<br />
on the 7th of May. The aspect that most<br />
appealed to us was the instant drying, which<br />
means work can be sent directly to finishing<br />
from the delivery. Also, the acquisition of<br />
this latest-generation machine allows us to<br />
set ourselves apart from the competition by<br />
proposing different things to our customers.<br />
Another considerable advantage is that color<br />
rendering is better than with aqueous coating<br />
— the whiteness and texture of the paper are<br />
maintained. The substrate is very white, with<br />
a superb degree of contrast. Thanks to instant<br />
16 <strong>Komori</strong> On Press
User Pro<strong>file</strong><br />
drying, we can run work with screen rulings of<br />
300 lpi, which produces a great deal of finesse<br />
and detail in photos.”<br />
Long-term support<br />
Jenin appreciates the involvement of those<br />
he deals with at <strong>Komori</strong> — whether it’s for<br />
training in the different functions of the new<br />
press or for maintenance: “For us, <strong>Komori</strong> is<br />
more than just a supplier — the company is a<br />
partner who is always there when we need<br />
them. We know all the members of their<br />
team: the director, the technical advisor, the<br />
salesperson, the engineers, the trainers. The<br />
trainers stayed on-site for four weeks, and<br />
even organized themselves to fit in with our<br />
three-shift working pattern.”<br />
A press that stimulates creativity<br />
Since the installation of the GL-540 H-UV in August 2012, each<br />
week brings a new series of discoveries. “We haven’t finished<br />
exploring all the things that it allows us to do. Before, we were<br />
stuck in a little bit of a rut, but since we got this new press,<br />
we’ve been in a permanent Research & Development phase!”<br />
Jenin enthuses. “It’s interesting for me and for everyone else<br />
on the team — we do trials, we create models and prototypes<br />
that we show to our customers. And that convinces them to<br />
take the plunge.” The H-UV revolution is under way at the<br />
Hauts de Vilaine Printing Company and is winning over new<br />
converts every day.<br />
Able to cope with all special substrates<br />
Thanks to H-UV technology, the Hauts de<br />
Vilaine Printing Company has expanded the<br />
services it offers: “We can now print on sealed<br />
surface substrates, such as Chromolux metallic<br />
paper, cardboard and even tracing paper. We<br />
also do a lot of printing on offset and creative<br />
papers. So, for example, we produced a job<br />
for a publisher in Paris that was printed on<br />
Munken with large areas of solids. Being able<br />
to choose the level of ink coverage made the<br />
task much easier for us,” Jenin says.<br />
<strong>Komori</strong> On Press<br />
17
User Pro<strong>file</strong><br />
Berforts takes UK’s first E-529P<br />
Berforts, Hastings, UK<br />
Den Edwards, Operations Director<br />
Berforts Ltd. has become the first company in the UK to<br />
buy a five-color Enthrone 29P perfector. The new B2 press<br />
was installed at the company’s commercial printing arm in<br />
Hastings. Berforts also has facilities in Oxford and Stevenage.<br />
Across its three sites, its plant list includes B1 and B2 Heidelberg<br />
Speedmasters, Konica, Kodak and Nipson digital presses, and<br />
an extensive array of finishing equipment to handle general<br />
print and specialist book printing.<br />
Need for additional capacity<br />
Says Hastings Operations Director Den Edwards: “We’d<br />
been running for almost a year with just one B2 litho press at<br />
this site and, with additional business on offer, we needed<br />
to increase makeready speeds and up our quality levels<br />
further. We had been looking at pre-owned machines but,<br />
having <strong>see</strong>n the Enthrone at its drupa 2012 launch and in<br />
demonstration at <strong>Komori</strong>’s Utrecht showroom, we recognized<br />
that investing in the latest <strong>Komori</strong> technologies would provide<br />
us with greater productivity and enable us to offer customers<br />
a faster turnaround with the assurance of higher, more<br />
consistent quality.”<br />
“We also recently consolidated our production<br />
space at Hastings from 13,000 to 9,000 square<br />
feet, although we still had a need to increase our<br />
production output, which meant we needed to<br />
replace our existing five-color press with newer,<br />
faster technology. So the high productivity rate<br />
and the small footprint of the Enthrone also<br />
suited our factory planning.”<br />
“We have 18 staff here at Hastings out of our<br />
organization’s total of 120, and we think of<br />
ourselves as a medium-size company with a big<br />
business approach — offering a personal printon-demand<br />
service for whatever our customers<br />
require. That can regularly mean a call for a<br />
print concept and design for which we have<br />
our own in-house designers. Then we take our<br />
services all the way through to total fulfillment,<br />
which includes printing jobs on the Enthrone,<br />
then digitally personalizing them along with<br />
envelopes, and enclosing the finished print<br />
for distribution by mail,” Mr. Edwards explains.<br />
18 <strong>Komori</strong> On Press
User Pro<strong>file</strong><br />
Versatility required<br />
Continues Edwards: “We operate nationally<br />
and regionally, and our customers include<br />
business-to-business clients, educational<br />
organizations, charities and several retail<br />
companies as well as print management<br />
services. Every one of them is looking for<br />
quicker turnaround, optimum quality and<br />
keener pricing. Our work itself is varied —<br />
magazines, brochures, mailings, newsletters,<br />
and business cards — we handle them all.<br />
This range of work can obviously mean using<br />
widely varying material thicknesses, and so<br />
the ability of the Enthrone to change over from<br />
lightweight to heavyweight materials with<br />
almost no mechanical adjustments is proving<br />
especially useful.”<br />
Easy learning curve<br />
“We run the Enthrone on a double day shift,<br />
rotating three operators, all of whom made<br />
an easy transition to using the Enthrone and<br />
all of whom would also testify how simple<br />
the machine is to operate. The E-529P has<br />
many new automated features, including the<br />
very efficient plate-changing system, color<br />
controls and digital workflow. And it is a very<br />
versatile press, especially as we’ve specified<br />
the two-over-three perfecting model, which<br />
gives us the flexibility for quick throughput of<br />
two-over-two jobs and enables us to add a<br />
litho seal or a special color on the fifth printing<br />
unit,” Edwards notes.<br />
“It provides us with a raft of new <strong>Komori</strong><br />
technolog y within a ver y reasonable<br />
investment level. The Enthrone was up and<br />
running within three days of installation and<br />
has quickly reduced our average makeready<br />
time down to just 10 minutes. The potential<br />
it offers is obvious from the superb work it’s<br />
already produced,” Edwards says.<br />
Enthrone key to intercompany growth<br />
At its Hastings plant, which has a customer<br />
base extending across the whole of the UK as<br />
well as clients in Belgium and Holland, Berforts<br />
is aiming to increase turnover from the current<br />
£1.8 million to £2.2 million before the end of<br />
2013, targeting the short run, fast turnaround<br />
market. Having also made recent prepress<br />
investments within the group, including a<br />
Prinergy workflow, it has started utilizing<br />
cross-site facilities to capitalize on commercial<br />
business attracted to its three sites. Adds<br />
Edwards: “Now that we have the Enthrone<br />
here in Hastings, we can <strong>see</strong> the intercompany<br />
production growing, especially on B2 work.”<br />
The other companies within the Berforts<br />
organization offer an exceptional variety of print and related<br />
services. This includes a full book-printing service with an<br />
unusual facility for self-publishers and other customers<br />
requiring very short run lengths as well as market research<br />
and advance copies prior to embarking on full production runs.<br />
“That’s where we truly integrate our digital and offset<br />
production — at times the digital presses even produce oneoff<br />
editions for self-publishers and review requirements, then,<br />
of course, revert to offset for full production,” adds Edwards.<br />
The associated services encompass the reproduction of<br />
previously printed books such as rare or old editions where the<br />
original <strong>file</strong>s or artwork no longer exist. Full finishing options<br />
are also offered — extending to case and leather binding.<br />
Enthrone’s green credentials influential<br />
Across the entire group, Berforts recognizes the importance<br />
of environmental considerations and takes these into account<br />
at all stages of development, marketing and investing. So the<br />
Enthrone’s eco-friendly characteristics of alcohol-free printing,<br />
low paper waste and reduced noise levels were also influential<br />
in the company’s purchasing decision.<br />
Adds Edwards: “Here in Hastings, we’re in the process of<br />
further increasing our sales force. We’ve added a Konica<br />
Minolta Bizhub C8000 and recently a single-color Konica<br />
with in-line finishing. We’ve also added a used four-color B2<br />
perfector — as we believe in gearing up for the increase in<br />
demand to ensure that we don’t have to turn new opportunities<br />
away.”<br />
“In the quick and smooth installation of the Enthrone, we were<br />
immediately impressed by the professionalism shown by the<br />
whole <strong>Komori</strong> team — installation engineers and demonstrators<br />
alike. I have the utmost faith that should we ever need to make<br />
an urgent call to <strong>Komori</strong> UK about any aspect of the Enthrone,<br />
we’d receive an instant and accurate response,” says Edwards.<br />
The E-529P has now been in operation at Berforts for several<br />
months, and as Edwards says, “Ever since the start, in every<br />
respect, it has performed as we’d hoped. Our operators enjoy<br />
using the press, and its fast changeovers — whether from job<br />
to job or between straight printing and perfecting — have<br />
noticeably increased our production flexibility and reduced<br />
our turnaround times.”<br />
“We’ve also <strong>see</strong>n that the <strong>Komori</strong> brand’s reputation with<br />
professional print buyers is impressive and the press has put us<br />
firmly on track to grow the business here in Hastings,” concludes<br />
an upbeat Edwards.<br />
<strong>Komori</strong> On Press<br />
19
User Pro<strong>file</strong><br />
Golden Fall reaps bright future<br />
Zhengzhou Golden Fall Color Printing, Zhengzhou, Henan Province, China<br />
Zheng Wei, General Manager<br />
Zhengzhou Golden Fall Color Printing Ltd. was founded on<br />
May 1, 2000. The company’s name, taken from the golden<br />
fall of harvest season, suggests the bounty that can be gained<br />
through the hard work of the company’s employees.<br />
Twenty years ago, recent graduate Zheng Wei was working<br />
hard in a state-owned enterprise. As Zheng says: “I poured<br />
my energies into the job, but I was unable to advance my<br />
own career.” So in 1995 he opened a data input and copy<br />
service, and Zheng started on the difficult route of founding his<br />
own company. Thirteen years have passed since he launched<br />
Golden Fall, and the exuberant youth and poet is now a business<br />
leader bearing the weight of corporate responsibilities.<br />
Long route to prosperity<br />
From data input and a copy service to light printing, quarto<br />
single-color printing, half-size single-color printing, fourcolor<br />
printing with a Chinese press, color printing on a used<br />
Heidelberg press, and finally to full-service<br />
printing on four of <strong>Komori</strong>’s latest offset presses.<br />
This has been Golden Fall’s path to prosperity.<br />
Growth amid change<br />
Just like many other print houses in China,<br />
Golden Fall experienced rapid growth<br />
amid a climate of change in the vast market<br />
environment and was at times disoriented by<br />
the enormous variety of choices that it faced.<br />
And there were projects in which large sums<br />
were invested that ended up with dreadful<br />
results. Zheng says in looking back on that<br />
period: “It was important not to deviate from<br />
the business plan but to push ahead without<br />
any hesitation.”<br />
20 <strong>Komori</strong> On Press
User Pro<strong>file</strong><br />
“I want to expand<br />
Golden Fall’s existing targets of commercial-scale high-speed<br />
color printing and commercial album printing, making it more<br />
solid overall. We want not only to become the largest scale high-speed print production base in China but also to<br />
standardize printing and develop a national distribution and transportation system.”<br />
— Zheng Wei, General Manager<br />
Lithrone G40: Liberation<br />
In 2011, Golden Fall reflected on its<br />
difficult experience, carefully compared the<br />
alternatives and invested in <strong>Komori</strong>’s latest<br />
four-color Lithrone G40 press. This decision<br />
fundamentally changed the growth model<br />
and the expansion rate of Golden Fall, which<br />
had begun taking online orders and launching<br />
other e-commerce initiatives. Near miraculous<br />
production records were set one after the other:<br />
20 jobs finished and 150,000 sheets printed in<br />
one shift. Eighty small-lot jobs finished in one<br />
shift. With records being rewritten before his<br />
very eyes, Zheng purchased two four-color<br />
Lithrone G40 presses the next year, and<br />
growth began to shoot up at an even faster<br />
pace. The company was liberated from the<br />
headaches of being a low-price, low-efficiency,<br />
high-cost producer.<br />
When Zheng talks about <strong>Komori</strong>, his high<br />
regard for the manufacturer is clear: “<strong>Komori</strong><br />
provides high-efficiency products to users<br />
by continuously upgrading its technologies.<br />
<strong>Komori</strong> presses incorporate ergonomic<br />
principles, and with regard to machine<br />
operability, structural design, and production<br />
processes, the company is far ahead of<br />
its competitors.”<br />
“We have experience in all of the areas that<br />
are vital for success, and Golden Fall Color<br />
Printing is now turning in strong performance<br />
in our regional market. If you ask the people<br />
who work at Golden Fall what their image of<br />
the company is, based on their roughly 15<br />
years of experience, they would say ‘There<br />
is nothing that we lack to complete any job<br />
we are entrusted with. We know that the<br />
only way to win the respect and trust of the<br />
customer is hard work. Continuously taking<br />
an approach of self-criticism — listening to<br />
the views of others, building on strong points<br />
and improving weaknesses — will result in<br />
transcending ourselves.’ This ethos is imbued<br />
throughout our company.”<br />
targets of commercial-scale high-speed color printing and<br />
commercial album printing, making it more solid overall. We<br />
want not only to become the largest-scale high-speed print<br />
production base in China but also to standardize printing and<br />
develop a national distribution and transportation system.”<br />
In his estimates of growth for the industry, Zheng’s selfconfidence<br />
is apparent: “The volume of sales in the offset sector<br />
will tend to decrease in the next five years. However, companies<br />
with a strong position in the market will be the leaders in terms<br />
of purchasing power. In other words, the printing industry will<br />
divide into two sharply contrasting groups.”<br />
Interior and exterior work on a new 16,000-square-meter<br />
plant has just been completed, and Zheng is dreaming big:<br />
“Golden Fall will be a print provider that combines three areas<br />
of competence — individualized digital printing production,<br />
Web-to-print, and industrial cloud printing.”<br />
Raising the status of the industry<br />
“Just a generation ago, we were stigmatized as being retailers<br />
in China, but now I think that we should at least be considered<br />
a successful and respected industry that contributes to the<br />
nation. The enthusiasm I felt at the founding of the company<br />
is slackening, and responsibilities weigh on my shoulders. Yet<br />
there is no change at all in my intentions.”<br />
Dreaming big<br />
Zheng also speaks thoughtfully about the<br />
future: “I want to expand Golden Fall’s existing<br />
<strong>Komori</strong> On Press<br />
21
User Pro<strong>file</strong><br />
GL-840P just right for Varigrafica<br />
Varigrafica, Nepi, Viterbo, Italy<br />
From left: Mauro Adario, CEO; Aldo Adario, President and Owner; Maria Stella Adario, CFO; Vincenzo Cirimele, Managing Director<br />
Varigrafica Alto Lazio near Nepi, Viterbo, Italy, has become the<br />
dynamic company it is today by investing in new technologies<br />
and human resources and by acquiring important new clients.<br />
Its mission focuses on three essential components: producing<br />
high quality printed materials, providing client support and<br />
services, and pursuing research and innovation. The company’s<br />
printing process is based upon a flexible workflow tailored to<br />
clients’ specific needs and providing personalized solutions.<br />
And owing to its managers’ professionalism and extensive<br />
knowledge of the market, the business has achieved the highest<br />
standards of excellence in printing, making it a vital partner<br />
for diverse types of clients. Print quality control has always<br />
been a fundamental element of its production cycle, and<br />
this is why Varigrafica Alto Lazio has implemented an ISO<br />
9001:2000-certified modular, integrated quality management<br />
system. The company is also ISO 14001:2004-certified and<br />
uses FSC- and PEFC-certified paper.<br />
On Press interviewed Mauro Adario, the<br />
company’s CEO, and asked him to describe<br />
the strategies they have implemented to stay<br />
competitive in the market.<br />
What are the company’s origins?<br />
Mauro Adario: The company was founded in<br />
the 1960s by Aldo Adario, a skilled and qualityoriented<br />
entrepreneur. Initially an entirely<br />
family-run business, with three sons joining<br />
the company, it evolved from a substantially<br />
artisan-like company into a modern industrial<br />
group that now employs 70 people and has a<br />
turnover of 16 million euros. Over the years we<br />
have always tried to interpret and anticipate<br />
market trends — with the goal of implementing<br />
suitable marketing policies and investing wisely.<br />
22 <strong>Komori</strong> On Press
User Pro<strong>file</strong><br />
How has your production process evolved<br />
during the years?<br />
We migrated from typographic printing in<br />
the 1960s to offset printing in the 1970s. In the<br />
’80s we added web-printing capabilities and in<br />
the ’90s and early 2000s we finally acquired<br />
five- and six-color 700 x 1,000-mm modern<br />
offset presses. In the last few years we’ve also<br />
been using seven-color HP Indigo presses, and<br />
more recently we upgraded to <strong>Komori</strong>’s new<br />
H-UV technology.<br />
We always wanted to be in a leading<br />
position in graphical arts. We believe from a<br />
technological perspective that our press lineup<br />
today features a unique mix of capabilities in<br />
the market.<br />
At our 12,000-square-meter plant in Nepi,<br />
near Viterbo, we are now operating a full<br />
production cycle from prepress to binding and<br />
logistics/delivery. Thanks to steady business<br />
growth, our turnover is now split between<br />
Italian (80 percent), European (15 percent)<br />
and other international (5 percent) clients.<br />
We specialize in varied fields such as finance,<br />
telecommunications, utilities, publishing,<br />
marketing and automotive.<br />
What benefits does H-UV technology bring to your<br />
production process? What types of applications is it ideal for?<br />
It’s innovative — using only one lamp per side, very reliable,<br />
user-friendly, cost-effective and, most important, it provides<br />
a superior printing quality. It’s not directed toward specific<br />
printing applications. In fact, it’s ideal for all types of jobs that<br />
need flexibility and high turnover speed. However, if we had<br />
to say where it satisfies us most, it is with plastic substrates and<br />
special and natural paper. The results are really impressive —<br />
the color <strong>see</strong>ms to ‘float’ off the sheet.<br />
Are there any new projects on the horizon?<br />
We’ve invested a lot in plant innovation, production integration<br />
and personnel training. These are three very important<br />
elements of our entrepreneurship and of our goal of obtaining<br />
great results and client recognition. And considering that the<br />
Internet has changed the world so much, we will continue to<br />
pursue a competitive online commercial strategy.<br />
What particular recognition has the company<br />
received from the market?<br />
Without any doubt respect for our<br />
professionalism and trust in the quality of our<br />
product. Our state-of-the-art press lineup<br />
alone would not be sufficient if it were not<br />
for our highly skilled staff, and it’s thanks to<br />
them that we are able to provide high quality<br />
and beautifully finished printed products.<br />
Everything here is done by continuously<br />
monitoring the production process. Plus, our<br />
staff is always engaged in updating their skills<br />
and implementing the latest techniques.<br />
Why did you choose to install the Lithrone<br />
GL-840P with H-UV? What are the main<br />
factors behind this choice?<br />
We chose to install the new <strong>Komori</strong> eight-color<br />
offset press after comparing its technology with<br />
competitive machines. Ultimately we were<br />
convinced by the technological innovations<br />
of this machine. Not to mention, it perfectly<br />
suits our production strategies: the best print<br />
quality, lower operating costs and shorter<br />
printing times. Also, <strong>Komori</strong>’s installation team<br />
provided us with a smooth press setup and<br />
very professional support.<br />
<strong>Komori</strong> On Press<br />
23
User Pro<strong>file</strong><br />
PNB Print pioneers new markets<br />
PNB Print, Riga, Latvia<br />
PNB Print Ltd., based in Riga, Latvia, specializes in book<br />
production printing, finishing and binding with either hard<br />
or soft cover. The company has earned the trust of customers<br />
in Latvia and abroad. That trust is built on consistent quality<br />
ensured by highly skilled personnel and modern technology.<br />
With this guiding principle of achieving customer trust, PNB<br />
is planning further expansion to win ground in the European<br />
and Russian printing markets.<br />
PNB Print signs up for a 16-page <strong>Komori</strong> web at drupa<br />
During the drupa 2012 exhibition, PNB signed up for a<br />
16-page <strong>Komori</strong> System 38S on the <strong>Komori</strong> stand at drupa.<br />
This press runs at 60,000 copies per hour and carries all the<br />
latest <strong>Komori</strong> automation, including the KHS-AI, AI-Link and<br />
Smart Sequence quick job changeover systems, fully automatic<br />
plate changing, fully automated folder changeover, and the<br />
<strong>Komori</strong> splicer, which features an environmentally friendly<br />
regenerative motor system.<br />
PNB has expanded its market into Russia,<br />
Scandinavia and the Netherlands, specializing<br />
in the production of hardbound and softcover<br />
books. This includes books with either flat or<br />
round spines, laminated covers, foil stamping<br />
or relief work, flexi-covers with or without<br />
flaps and employing cardboard or polyester as<br />
well as books that use non-sewing technology,<br />
where the book spine is not sewn but milled<br />
and thermo glued. The printer also handles a<br />
growing volume of commercial work, including<br />
saddle-stitched magazines and brochures as<br />
well as advertising materials.<br />
In December 2010, it installed its first <strong>Komori</strong>,<br />
an eight-color Lithrone S40P perfector. Says<br />
CEO Aleksandr Smoglukov: “What really<br />
impressed us with the LS-840P perfector, and<br />
what strongly influenced our decision to follow<br />
24 <strong>Komori</strong> On Press
User Pro<strong>file</strong><br />
“We concentrated on<br />
what the System 38S web could offer in quick job<br />
changeover, low waste and high quality print.<br />
We also required higher speed in order to produce longer runs when required, which the System 38S can<br />
accommodate efficiently,”<br />
— Aleksandr Smoglukov, CEO<br />
up with a <strong>Komori</strong> web, was its exceptional<br />
output levels, which we attained right from<br />
the start of production. For example, in its first<br />
four months, it delivered 11 million impressions.<br />
In fact, in less than 18 months it has taken us<br />
into new markets with its high print quality,<br />
fast turnaround capabilities, and trademark<br />
<strong>Komori</strong> reliability.”<br />
“Over the last year business has increased<br />
to such an extent that we have needed to<br />
occasionally send work out, and the quality<br />
that came back from <strong>Komori</strong> web houses in<br />
Europe impressed us immensely,” explains<br />
Mr. Smoglukov.<br />
“That prompted us to look more closely at<br />
<strong>Komori</strong> web installations, in particular at<br />
web houses in the US, Japan and Ukraine,”<br />
Smoglukov says.<br />
“We concentrated on what the System 38S<br />
web could offer in quick job changeover, low<br />
waste and high quality print. We also required<br />
higher speed in order to produce longer runs<br />
when required, which the System 38S can<br />
accommodate efficiently,” Smoglukov explains.<br />
Says <strong>Komori</strong>’s Director of Distributor Sales<br />
Tony Carter: “PNB epitomizes how a modern<br />
printer can take advantage of the synergy<br />
between <strong>Komori</strong> sheetfed and web offset<br />
products. A good example of the technological<br />
compatibility between presses is KHS-AI, a<br />
unique makeready feature that has given many<br />
Tony Carter, Director of Distributor Sales (left), congratulates<br />
PNB Print staff.<br />
<strong>Komori</strong> users benefits in saving time and paper. In addition, the<br />
engineering excellence that is applicable to both sheetfed and<br />
web offset products ensures that <strong>Komori</strong> users have possibly<br />
the lowest level of cost of ownership in our industry. “<br />
Open House<br />
Last October, PNB organized an Open House in their factory<br />
to celebrate <strong>Komori</strong>’s newest installation. A great many visitors,<br />
from Latvia as well as abroad, came to this event to congratulate<br />
management and staff, to experience the new equipment in full<br />
production, and to watch musicians and dancers performing<br />
during a laser show around the press. Customers and guests<br />
were obviously impressed with the myriad printing possibilities<br />
that PNB offers.<br />
Laser show at Open House<br />
Performers around the press at Open House<br />
<strong>Komori</strong> On Press<br />
25
User Pro<strong>file</strong><br />
Pro-offset: a real family business<br />
Pro-offset, Bogota, Colombia<br />
From left standing: Pilar Barrera, Assistant Manager; Carolina Barrera, Commercial Director; Yohana Barrera, Quality Director; Teresa Suarez,<br />
Business Associate; Patricia Barrera, Administrative & Financial Director; with Marceliano Barrera, General Manager<br />
Pro-offset is an apt name for a very professional enterprise<br />
in Bogota, Colombia. Its founder tells his inspiring story,<br />
describing his family’s dedication and the key to his success.<br />
Don Marceliano Barrera is an easygoing person who exudes<br />
happiness. A good part of his happiness comes from succeeding<br />
in bringing Pro-offset to a privileged position in the Colombian<br />
graphic arts market as well as having his family play an integral<br />
role in this success.<br />
Colombian Horatio Alger story<br />
Marceliano Barrera’s story is like a Horatio Alger rags-toriches<br />
narrative: through honesty, perseverance and hard<br />
work, a humble but virtuous young man achieves success.<br />
At the age of 10, he began working as a general helper at<br />
the biggest and most prestigious newspaper in Colombia, El<br />
Tiempo. Eventually he worked in all the positions in the paper’s<br />
advertising department.<br />
Not leaving his academic goals behind, Barrera finished high<br />
school and then attained a degree in accounting. He next<br />
joined his friend Hugo Saenz (another very<br />
important <strong>Komori</strong> customer in Colombia), in<br />
starting up a printing company. Ultimately he<br />
went off on his own to create Pro-offset with<br />
the support of his wife and brothers.<br />
Pro-offset was born on October 30, 1980, with<br />
a Mercedes printing machine, a hand-operated<br />
guillotine, and a letterpress machine. Nearly 33<br />
years later, Pro-offset has an impressive array of<br />
machines, 160 employees and a 5,000-squaremeter<br />
facility.<br />
In 1989 during a trip to Tokyo, Barrera was<br />
won over by <strong>Komori</strong>, buying his first <strong>Komori</strong><br />
press, a five-color Lithrone 28 — and never<br />
looking back. He bought another four-color<br />
Lithrone 28 in 1997, a four-color Lithrone<br />
S40+PDC-SII in 2005, and then a four-color<br />
Lithrone S44+PDC-SII last year.<br />
26 <strong>Komori</strong> On Press
User Pro<strong>file</strong><br />
Secret to success<br />
Today, Pro-offset’s biggest customer is El Tiempo, the<br />
same newspaper where Barrera started his early working<br />
career. Barrera has inspired his family and his workers with<br />
his philosophy: deliver what is promised and be completely<br />
transparent. These principles have made Pro-offset the most<br />
respected supplier in the sheetfed printing sector in Colombia.<br />
As he states with pride: “I don’t offer more than I can deliver.<br />
We are not the cheapest. However, our quality and integrity<br />
make us the best.”<br />
One family of printers<br />
During this continuous growth, Barrera not<br />
only received the support of his family but also<br />
had the advantage of their direct participation<br />
in the business. Barrera’s four daughters have<br />
all worked with him and today make up the<br />
managing group of the company, under the<br />
direction of their father. Pilar, Patricia, Yohana<br />
and Carolina share the family devotion to the<br />
graphic arts industry, working in a way that is<br />
similar to Japanese businesses — employed<br />
for life, rotating through the operational and<br />
managerial roles to master the smallest details<br />
of the business.<br />
Each one of them has acquired a<br />
university degree — in advertising, business<br />
administration or international business.<br />
And this second generation of the Barrera<br />
family has also learned the ropes of the<br />
business: solving engineering problems,<br />
installing digital solutions, and creating and<br />
developing new management processes that<br />
have brought Pro-offset to the very forefront<br />
of printing excellence.<br />
Even though the Barrera daughters work in<br />
different areas of the business, they are in<br />
essence sales representatives, following their<br />
father’s mantra that sales are the backbone of<br />
any company.<br />
With this spectacular management team<br />
to maintain the course of Pro-offset, Barrera<br />
strategically guides the company. His capacity<br />
to anticipate the market amazes his family.<br />
Last year’s purchase of the LS-444+PDC-SII<br />
enabled the company to provide solutions to<br />
a market where this particular press size was<br />
difficult to find among Colombian printers and<br />
during a period of recession in the graphic arts<br />
sector of the country and the world in general.<br />
Vision for the future<br />
Barrera feels the competition from digital media and<br />
competes head to head with offers from digital providers. He<br />
<strong>see</strong>s packaging as the sector of graphic arts where Pro-offset<br />
can continue growing, through differentiation with the use of<br />
special in-line finishing and other processes, where <strong>Komori</strong><br />
— as a strategic ally and also as the world leader in supplying<br />
solutions for the packaging market — will continue to support<br />
Pro-offset in its quest for growth and success.<br />
<strong>Komori</strong> On Press<br />
27
User Pro<strong>file</strong><br />
<strong>Komori</strong> is ‘right choice’ for Burke<br />
Burke Group, Edmonton, Alberta, Canada<br />
From left: Barry Burke, General Manager, and Ian Burke, CEO<br />
“We need to be more important to our clients than our clients<br />
are to us,” says Ian Burke, CEO of the Burke Group, located<br />
in Edmonton, Alberta, Canada. The Burke Group has been<br />
focused on this mission for the last 18 months with a series of<br />
huge changes — developing a new business strategy, relocating<br />
to a new facility, and entering the 40-inch printing market. The<br />
company was founded in 1905 as Douglas Printing and over<br />
the years earned a solid reputation as a first-rate printer. Burke<br />
joined the company in 2004 as a partner, and in 2005 bought<br />
the company from the Douglas family. Since Burke took the<br />
helm, the company has tripled its sales and started down a<br />
path to change the way they do business.<br />
A transformational move<br />
Getting all its businesses under one roof was the first<br />
step in building the new business model. The company’s<br />
various divisions — Douglas Printing, the general commercial<br />
division; Douglas Express, the digital printing business; Target<br />
Express, the direct-mail arm of the company; and Maximum<br />
Imaging, wide-format printing — had been spread between<br />
several facilities. “The move to the new facility was really<br />
transformational for us,” says Burke. “The ability to have all our<br />
businesses and our people under one roof was the first step<br />
in maximizing our efficiency, and has made a<br />
massive change in our organization.”<br />
The new business strategy focuses on three<br />
key areas: diversifying the product offering,<br />
reducing costs, and improving efficiency.<br />
One of the changes Burke wanted to make<br />
was about timing — when the company gets<br />
involved with its customers: “Typically printers<br />
tend to get a job after the marketing budgets<br />
have already been finalized. You get hired to<br />
print a brochure or some specific collateral,<br />
and you need to come in at the lowest price.<br />
It’s transactional. We wanted to get further<br />
upstream in the planning process, and help our<br />
customers achieve their goals by becoming a<br />
true partner in their business.” The company’s<br />
Print Management System is the backbone to<br />
this approach. Burke explains: “We examine<br />
our clients’ print needs and their marketing<br />
goals, and come up with a comprehensive<br />
plan to help them maximize their budgets by<br />
eliminating redundancy, providing a consistent<br />
brand across all media, and reducing costs.”<br />
28 <strong>Komori</strong> On Press
User Pro<strong>file</strong><br />
Burke says this new approach is paying off:<br />
“When you can help a client examine where<br />
they are spending their marketing dollars and<br />
their time, and offer a variety of products and<br />
programs to help them maximize their results,<br />
you become more than just their local printer<br />
with the lowest price.”<br />
Goal: cut cost per job by 75 percent<br />
Burke says the company’s goal is not primarily<br />
to grow sales, but to be more profitable by<br />
making more money on their existing sales. He<br />
credits a new estimating system with helping<br />
the company understand the cost of a print job:<br />
“We’re the first company in North America to<br />
use this new system and it is truly amazing. It’s<br />
easy to use and has helped us become much<br />
more analytical about our business.” With print<br />
runs getting shorter, Burke says it’s critical to<br />
reduce the cost of each job to remain profitable:<br />
“One of the biggest things I learned from Bob<br />
Douglas, the former owner, was the importance<br />
of knowing your hourly rate. Most companies<br />
assign an arbitrary number or an industry<br />
standard number, but that really doesn’t let<br />
you understand your business. With our new<br />
system, we plug in our numbers and we know<br />
down to the penny what our costs are. It takes<br />
time to get all the data entered, but we didn’t<br />
want to be a company, like so many, that invests<br />
in software and then doesn’t utilize it to the<br />
maximum.” Burke says the company has set a<br />
goal of reducing their cost per job by 75 percent.<br />
“It may be a crazy number, but we’re working on<br />
it. We’re focused on it. We’re trying to reduce<br />
the number of touches an order has before it<br />
gets to the press. Then the press takes over,”<br />
Burke explains.<br />
demonstration was extremely impressive: “The automation<br />
on the press was superior — and <strong>Komori</strong> completed the jobs<br />
in half the time it took the Heidelberg. We decided that for<br />
our productivity and profitability goals, the <strong>Komori</strong> was the<br />
right choice.”<br />
GL40: ‘best decision we ever made’<br />
As Ian Burke says, “The purchase of the GL40 was one of the<br />
best decisions we ever made. It’s done absolutely everything<br />
we were told it would do. We utilize all the automation, and<br />
print to the numbers on every single job. The press runs fast, it<br />
runs well. It’s been a great experience all around.”<br />
How does Burke <strong>see</strong> the printing industry changing in the next<br />
several years? “I think you’ll <strong>see</strong> more online printers. We’re<br />
an online society. Run lengths will continue to get shorter and<br />
customers will demand faster turnaround times. I think we’ll<br />
<strong>see</strong> growth in direct mail as clients become more focused on<br />
targeting marketing to their customers.”<br />
Burke feels his company is well positioned for the future: “We<br />
made the right investments at the right time. We’ve got a broad<br />
product offering from offset to digital to large format and mail<br />
and fulfillment. We’ve got great people. I think we’re headed<br />
in the right direction.”<br />
<strong>Komori</strong> finishes in half the time<br />
One of the biggest changes in the company<br />
was its entry into the 40-inch press market.<br />
“If our goal was profitability, we needed to<br />
invest in technology that was going to get us<br />
there,” Burke says. They were looking seriously<br />
at Heidelberg and <strong>Komori</strong>, but it was their<br />
experience at <strong>Komori</strong> America’s GraphiCenter<br />
that led them to purchase a six-color Lithrone<br />
G40 with coater. “We came up with a plan<br />
for both manufacturers to run ten 500-sheet<br />
jobs — and they weren’t easy jobs. We went to<br />
Heidelberg and the demo was good. And I’ve<br />
got to say, I left there thinking we were going to<br />
buy a Heidelberg,” says Burke. But, according<br />
to General Manager Barry Burke, the <strong>Komori</strong><br />
<strong>Komori</strong> On Press<br />
29
User Pro<strong>file</strong><br />
First H-UV press in Germany<br />
Fritsch Druck, Leipzig, Germany<br />
From left: René Fritsch, Managing Director, and Martin Saeger, Plant Manager<br />
Last year was not good for Saxony’s local printing industry.<br />
Some printers in Leipzig and Dresden, the two major cities<br />
in this state in eastern Germany, fell into insolvency due to<br />
a fiercely competitive regional market. But a few weeks ago,<br />
Fritsch Druck GmbH, a small printer in Leipzig, had better<br />
news to share: The company had installed a brand new fivecolor<br />
Lithrone G40+Coater+H-UV in its printing shop in the<br />
northeast of the city. The press is 15 meters long, weighs 40<br />
metric tons and is packed with the latest <strong>Komori</strong> technology<br />
for sheetfed presses. The total investment was 1.5 million euros.<br />
High quality even with tight deadlines<br />
In the past, tight deadlines and high quality<br />
were mutually exclusive at Fritsch Druck. But<br />
not any more. Now, thanks to the innovative<br />
H-UV curing system, the printed sheets are<br />
completely dry and immediately ready for<br />
finishing procedures. Production is much<br />
more efficient than before. H-UV eliminates<br />
all quality losses related to drying like blocking<br />
and ink drydown as well as issues related to<br />
powder spraying. The sheet surface is scrub<br />
resistant and a protective varnish almost<br />
not necessary.<br />
The in-line coater offers Fritsch Druck several<br />
new options for effects like high-gloss, softtouch<br />
and drip-off coating to satisfy the<br />
increasing demands for higher quality and<br />
added value among clients. Fritsch Druck<br />
is a full-service provider of sheetfed offset<br />
and digital printing, prepress, postpress,<br />
lettershop service and graphic design.<br />
Products range from commercial printing to<br />
high quality magazines.<br />
Focused on growth<br />
Fritsch Druck, founded in 1990, moved to<br />
a modern facility in an industrial park in the<br />
northeast of Leipzig in 2006, and today has<br />
eight employees. From the very beginning, the<br />
company was focused on growth. Thanks to<br />
the enormous productivity of the new GL-540,<br />
management says that its new middle-term<br />
target will <strong>see</strong> a doubling of annual sales to<br />
1.8 million euros and the company plans to<br />
recruit new staff.<br />
Crucial factor: H-UV<br />
The new GL-540 combines high-performance specifications:<br />
a maximum printing size of 710 x 1,020 mm, five units, a<br />
thickness range up to 1.0 mm and an in-line coater for different<br />
added value coatings. Furthermore, it’s the first H-UV press in<br />
Germany and the innovative curing system was a crucial factor<br />
in the investment. Managing Director René Fritsch explains:<br />
“Compared to conventional UV systems, energy consumption<br />
is cut by one third and CO 2<br />
emissions are reduced. The system<br />
does not discharge ozone and only a small amount of heat,<br />
which improves both the printing environment and quality.”<br />
The investment gives Fritsch Druck important advantages<br />
in the competitive regional market: shorter turnarounds,<br />
higher quality and more added value. “Our customers are<br />
very demanding and we will continue our strategy to improve<br />
print quality,” emphasizes Mr. Fritsch.<br />
30 <strong>Komori</strong> On Press
User Pro<strong>file</strong><br />
GL-640+C for IPC ‘first in Mexico’<br />
Impresos Profesionales del Centro, Celaya, Guanajuato, Mexico<br />
From left: Gabriela Solís Mosqueda, Financial Director; Maria Eugenia Mosqueda Nieto, CEO; Luis Raúl Solís Mosqueda, Operations Director<br />
Impresos Profesionales del Centro (IPC) was founded in<br />
1979 by Raúl Solís Gomez and Maria Eugenia Mosqueda Nieto<br />
with a focus on commercial printing. In 1990 Mr. Solís began<br />
expanding into the folding carton market. With increasing<br />
sales and promising success in this area, he decided to invest<br />
in a new sheetfed press with four units.<br />
Move to high quality cartons<br />
In 2000 Solís invested in prepress equipment to attract<br />
customers who had special requirements and high print quality<br />
demands. As Solís says, “We wanted to increase our sales in the<br />
folding carton market and also in the litho-laminated carton<br />
market for the food processing and automotive industries.”<br />
Six-color Lithrone G40+C now working three shifts<br />
“In 2011 after a detailed analysis of different brands, we decided<br />
to buy the new <strong>Komori</strong> six-color Lithrone G40 plus coater. It<br />
was the first of its kind in Mexico,” Solís continues. “We bought<br />
the <strong>Komori</strong> press for its versatility in changing from paper to<br />
cardboard and its printing quality on different substrates. Also,<br />
the integration between the KHS-AI integrated control system<br />
and CIP4 data enables a very quick makeready, depending on<br />
substrates and colors.”<br />
Solís concludes: “We are convinced that we made the right<br />
choice. And with the support of Grupo Sanchez,<br />
press operation has been problem-free. The<br />
GL-640+C has become the most important<br />
press in our printing shop. It’s so user friendly<br />
that our crew learned how to operate it in a<br />
very short time. Currently, we operate the press<br />
for three shifts every day. But with this kind of<br />
success, we are naturally thinking of investing<br />
again — now we are looking to offer services in<br />
prepress, sheetfed offset and graphic design.<br />
And <strong>Komori</strong> will likely play an important role<br />
in our continued success.”<br />
<strong>Komori</strong> On Press<br />
31
Tokyo<br />
[<strong>Komori</strong> service]<br />
Topics<br />
<strong>Komori</strong> Service<br />
Service Lineups to Fit the User<br />
<strong>Komori</strong>’s Techno Service Center in Tokyo is constantly <strong>see</strong>king new and better ways of helping customers<br />
profit from their <strong>Komori</strong> machines and systems. Not every case is the same, and the Center offers different<br />
approaches to fit the needs of the customer, which can vary by location, type of equipment, and the maintenance<br />
capabilities of the on-site staff.<br />
Remote access<br />
benefits U.S. printer<br />
The Techno Service Center worked with<br />
a large printer in the U.S. for eight months<br />
in an effort to improve performance and<br />
cut waste and downtime. The printer<br />
was running two <strong>Komori</strong> web presses,<br />
and management was very pro-active<br />
with regard to optimizing maintenance<br />
to achieve greater productivity and fewer<br />
breakdowns. Moreover, the presses were<br />
equipped with a remote access function<br />
that allowed <strong>Komori</strong> to download<br />
detailed information on machine<br />
utilization and downtime for analysis.<br />
The calculation of working efficiency<br />
showed a clear improvement during<br />
the period. The considerable degree of<br />
fluctuation in the data was smoothed<br />
out with an approximation curve that<br />
showed an acceptable albeit less than<br />
stellar boost in productivity.<br />
Downtime was analyzed by the cause<br />
— press, ink, paper and so on, and of<br />
course, preventive maintenance itself<br />
requires downtime. The analysis showed<br />
that when preventive maintenance was<br />
significantly increased, downtime caused<br />
by a press error or anomaly was halved.<br />
The Center concluded that even without<br />
setting aside a large amount of time<br />
for maintenance, downtime could be<br />
reduced to a tolerable level as long as<br />
the program was continued.<br />
Paper waste was also checked and<br />
analyzed to determine the causes and<br />
ways to reduce the level of waste. The<br />
analysis showed that while run waste<br />
was steadily declining, makeready waste<br />
Changes for the Better<br />
Total Productivity<br />
Higher rate of machine utilization, shorter<br />
makereadies, reduced operator workload<br />
and quicker job turnarounds.<br />
Time and Materials Losses<br />
Less paper waste, reduced machine<br />
downtime, fewer missed deadlines and<br />
lower running cost.<br />
was actually rising. Further, within the<br />
makeready waste category, print startup<br />
waste was increasing. Narrowing down<br />
the part of the total process that was<br />
generating waste allowed the service<br />
engineers to recommend a series of<br />
preventive maintenance measures to<br />
cut this category of paper waste.<br />
In addition, the remote access function<br />
was utilized to obtain the machines’<br />
error history and, in particular, the<br />
Full-APC-related errors. This yielded<br />
data that indicated one particular unit<br />
was responsible for the overwhelming<br />
majority of the errors. On the basis of this<br />
report, <strong>Komori</strong> America recommended<br />
an inspection and service regimen that<br />
gave priority to this unit.<br />
Service lineup items and parts<br />
The total plant evaluation paradigm<br />
Another paradigm provided by the<br />
Techno Service Center is shown in the<br />
case of a Japanese printing company that<br />
operates internationally and sought a<br />
full-scale evaluation of its plant with a<br />
view to measures that would improve<br />
both productivity and quality. The focus<br />
in this assessment covered all facilities<br />
in the plant as well as manpower,<br />
processes and technology utilization.<br />
This proved to be so useful to the printer<br />
that moves are under way to have the<br />
Techno Service Center carry out the<br />
same type of full-spectrum evaluation<br />
and make recommendations for three<br />
overseas plants that are operated by the<br />
same printer.<br />
Higher productivity, reduced material<br />
losses and less downtime are in the cards<br />
thanks to the expertise and planned,<br />
preventive approach to maintenance and<br />
service that <strong>Komori</strong> has developed. And<br />
<strong>Komori</strong> is ready to design customized<br />
diagnostic plans and service proposals<br />
that meet specif ic applications<br />
and situations.<br />
32 <strong>Komori</strong> On Press
Tsukuba<br />
[KGC]<br />
<strong>Komori</strong> Graphic Technology Center<br />
KGC’s Four Functions at Three<br />
Having just celebrated the third anniversary of its opening, the <strong>Komori</strong> Graphic Technology Center (KGC) at<br />
the Tsukuba Plant has become a busy hub of training, R&D and demonstrations that more and more <strong>Komori</strong><br />
customers and their employees recognize as invaluable to their success. The Center consists of four components<br />
that are equipped and staffed to meet the different objectives of KGC’s overall mission.<br />
Demonstration<br />
Center<br />
Printing<br />
College<br />
Technical<br />
Training Center<br />
Printing<br />
R&D Center<br />
Demonstration Center:<br />
Live demos served daily<br />
The Demonstration Center’s primary<br />
activity is running demonstrations of<br />
<strong>Komori</strong>’s range of machines so that<br />
prospective customers can observe<br />
the performance of the press that they<br />
are interested in and also holding open<br />
house events. Demonstrations of added<br />
value printing, high-productivity onepass<br />
printing, fast print startup, print<br />
quality verification and standardized<br />
printing as well as eco-friendly and<br />
efficient printing are carried out for both<br />
domestic and overseas users. The Center<br />
will continue to conduct demonstrations<br />
to meet the changing demands and issues<br />
of customers.<br />
Printing College: Building users’ skills<br />
The Printing College offers a diverse<br />
curriculum that provides skill sets<br />
meeting the needs of various positions<br />
in the printing company — starting with<br />
training in basic press operation for<br />
beginners and proceeding to courses<br />
for operators or chief operators <strong>see</strong>king<br />
to upgrade their abilities, and even<br />
including programs for managers. In<br />
addition, courses that enable participants<br />
to actually experience the stages in the<br />
printing workflow — submission of data,<br />
image editing, press and postpress — as<br />
well as color management courses are<br />
part of the training course lineup.<br />
Technical Training Center:<br />
Instruction for the service network<br />
KGC’s Technical Training Center<br />
offers training on both sheetfed and<br />
web offset presses for <strong>Komori</strong>’s own<br />
service specialists and for the engineers<br />
of Japanese and overseas dealers.<br />
In addition, customized training for<br />
printing companies that meets specific<br />
requirements, such as special courses<br />
for press operators and personnel in<br />
charge of maintenance, are also offered.<br />
The Center’s texts and training courses<br />
have been improved over the past three<br />
years, and a fuller training curriculum has<br />
been developed.<br />
Printing R&D Center:<br />
Seeking answers to today’s issues<br />
The Printing R&D Center endeavors<br />
to find answers to the new needs and<br />
issues confronting users and responds<br />
with research and development such<br />
as collaboration with various other<br />
manufacturers and the development of<br />
printing software. In the past three years,<br />
the Center has worked principally on the<br />
development of the H-UV system and on<br />
the promotion of standardization based<br />
on printability tests aimed at optimizing<br />
printing materials such as blankets, inks,<br />
varnishes, coater plates, cleaning fluids,<br />
and dampening solution additives.<br />
Research results are communicated both<br />
throughout the <strong>Komori</strong> Group and to<br />
outside parties.<br />
These functions within the <strong>Komori</strong><br />
Graphic Technology Center — integrated<br />
into the state-of-the-ar t design,<br />
development and manufacturing<br />
environment of the Tsukuba Plant<br />
— are daily raising the level of skills,<br />
know-how and printing software<br />
that are indispensable to getting the<br />
most out of <strong>Komori</strong>’s industry-leading<br />
hardware. The steady, incremental<br />
improvement of operation, maintenance<br />
and management of the worldwide<br />
fleet of <strong>Komori</strong> printing presses is the<br />
direct result of the courseware offered<br />
at KGC and the tireless dedication of<br />
its top-ranked demonstrators, trainers<br />
and researchers.<br />
<strong>Komori</strong> On Press<br />
33
e<br />
Show Reports<br />
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-8.MAR.2013<br />
Frankfurt<br />
Baumann Launches Partnership<br />
with Open House<br />
Only the best quality and innovative technology will give printers an edge in the markets<br />
of the future.<br />
A three-day Open House that attracted more than 450 visitors was held by Baumann, the<br />
new <strong>Komori</strong> distributor in Frankfurt am Main, Germany. Baumann took over <strong>Komori</strong> sales in<br />
the southern and southeastern part of the country and will now be selling <strong>Komori</strong> presses<br />
and a broad lineup of prepress and postpress technology.<br />
President and CEO Yoshiharu <strong>Komori</strong> of <strong>Komori</strong> Corporation came all the way from Tokyo<br />
to Frankfurt to attend Baumann’s Open House. Masaru Tsukamoto and Neil Sutton of <strong>Komori</strong><br />
International management as well as newly appointed <strong>Komori</strong> International Europe President<br />
Akihiro <strong>Komori</strong> were also in attendance. President <strong>Komori</strong> spoke to an audience of more<br />
than 100 visitors, pointing out that Baumann will be an important keystone in <strong>Komori</strong>’s global<br />
network. He emphasized the importance of the printing industry and made clear that only<br />
the best quality and innovative technology will give printers an edge in the markets of the<br />
future. Christian Baumann, managing director of the Baumann Group, also spoke, stressing<br />
that <strong>Komori</strong>’s economic power is crucial for Baumann’s success in a competitive market<br />
environment and that <strong>Komori</strong>’s corporate philosophy — Kando: Beyond Expectations — is<br />
the perfect match for his business.<br />
Information on New Distributors<br />
Baumann Partners with <strong>Komori</strong> in Germany<br />
Heinrich Baumann Graphical Centre, Frankfurt, Germany<br />
From left: Jeroen Hulshoff and Neil Sutton of<br />
<strong>Komori</strong> International Netherlands; Christian<br />
Baumann, Managing Director, and Uwe<br />
Wagner, Sales Manager, Baumann Group<br />
On January 1, 2013, the Heinrich Baumann Graphical Centre of Frankfurt am Main<br />
began selling sheetfed offset machines from <strong>Komori</strong> Corporation. Previously a<br />
manroland sheetfed distributor, Baumann sells a wide product range from well-known<br />
manufacturers in the print processing sector. They also have a successful record in<br />
the prepress sector, representing players such as Agfa and Kodak.<br />
Managing Director Christian Baumann says: “Business means constant change if you<br />
want to be successful. The new partnership with <strong>Komori</strong> is a big opportunity for our<br />
company, and for existing and future customers. We are grateful and proud to now be<br />
able to work together with the third-largest printing press manufacturer in the world.”<br />
Neil Sutton, European Managing Director at <strong>Komori</strong> International Netherlands in<br />
Utrecht, says about the new partnership: “We are looking forward to working with<br />
Baumann and are confident that we will now be able to install our new and innovative<br />
<strong>Komori</strong> installations across a wider area. We believe that the Baumann Group, with<br />
its long history and devotion to its customers, will prove a most reliable partner for<br />
us for the future.”<br />
34 <strong>Komori</strong> On Press
a<br />
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-8.FEB.2013<br />
TSUKUBA<br />
Tsukuba Open House Draws a Crowd<br />
Three full-spec machines flex their muscle while demonstrating state-of-the-art<br />
color management solutions.<br />
<strong>Komori</strong> held an Open House at the Tsukuba Plant on February 7 and 8 to introduce<br />
three of the hottest machines in the lineup and also brief printers on the company’s<br />
strategy going forward. The demonstrations featured the debut of the H-UV-equipped<br />
Lithrone GX40RP 4/4 Reverse Printing dedicated double-sided press and also<br />
presented an H-UV version of the LA37 as well as the Impremia C80 digital printing<br />
system that was shown at drupa 2012.<br />
<strong>Komori</strong> Achieves High Success<br />
at PrintPack India 2013<br />
“We featured the new <strong>Komori</strong> LA-437, which is matched to the Indian market,”<br />
says Sangam Khanna, director at Insight.<br />
N<br />
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28.FEB.2013<br />
NEW DELHI<br />
The event was PrintPack India 2013 and the press was the new Lithrone A37 introduced<br />
at drupa 2012. Insight Communications, India’s largest graphic art equipment distributor<br />
and now all-India partner of <strong>Komori</strong>, showcased the new technologies from <strong>Komori</strong>,<br />
in particular the innovative H-UV printing system and the LA37 at this exhibition. “We<br />
featured the new <strong>Komori</strong> LA-437, which is matched to the Indian market,” says Sangam<br />
Khanna, director at Insight. Ajay Aggarwal, founding director and CEO of Insight, notes:<br />
“H-UV is the future of UV printing. UV printing was the exclusive domain of packaging<br />
printers and it is now possible for commercial printers to adopt UV technology due<br />
to the tremendous benefits of economical H-UV printing technology.”<br />
Insight Takes Charge of India<br />
Insight Communications, New Delhi, India<br />
Insight Communications was founded in 1991 and today is one of the largest<br />
organizations selling graphic art equipment in India. Insight partnered with <strong>Komori</strong><br />
to promote <strong>Komori</strong> presses in the North of India in 2006. In the space of just six years,<br />
Insight has turned the <strong>Komori</strong> brand into the top seller of new offset presses in India,<br />
with 80 presses sold up to now. Now Insight has taken charge of <strong>Komori</strong> sales and<br />
support for the entire country. Sangam Khanna, director of the company, says, “Insight<br />
really went to town in February, closing 10 <strong>Komori</strong> press orders, including three at<br />
the recent PackPrint India 2013.” Insight founding director and CEO Ajay Aggarwal<br />
adds: “The value proposition of the LA-437 is just too good. The rising yen and the<br />
slow market conditions were holding Indian printers back from adopting this press.<br />
As soon as the prices became reasonable, the value became clearly visible, and the<br />
recent spurt in orders is just an example of how Indian printers can quickly shift gears.”<br />
Sangam Khanna, Director<br />
<strong>Komori</strong> On Press<br />
35
ONPRESS78 en JPN 36P Apr. 2013 10.8K HP