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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 />

I<br />

D<br />

I<br />

A<br />

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

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