VLF OFFSET:
TECHNOLOGY
FOR GREATER DIFFERENTIATION,
HIGHER PROFITS
Joerg Daehnhardt, Director of Product Management, Heidelberg USA
“Immense” describes both the size and market potential of the newest
very large-format (VLF) offset printing systems installed in packaging
environments. The right press, optimally equipped and maintained,
also can be the key to improved profitability for packaging printers
whose volume and job mix can justify the investment.
The Magazine
8
6.2013
In North America roughly 75% of VLF offset presses are used to produce
folding cartons, with the remainder used in point-of-purchase and pointof-sale and W2P. The largest of these systems, including Heidelberg’s
64-inch Speedmaster XL 162 series presses, compete with high-volume
web offset, gravure, and screen printing. For fast, efficient production on
a smaller scale, at 57-inches VLF presses go beyond the volume reach of
41-inch presses and are the best choice for independent folding carton
producers in search of market differentiation and higher profits.
We’ll focus our discussion here on the folding carton market served by
independent (non-conglomerate) packaging printers, as defined by
outputs averaging around 40-plus million sheets per year produced on
a large-format sheetfed offset press in a 24/7 environment, topping
out at around 70–80 million sheets annually. At volumes like these,
and under the right circumstances, large-format capacity can be a key
differentiator in a market crowded with 41-inch offset presses.
Why Invest?
Packaging printers planning to invest in a new VLF press may be
looking to replace existing large-format equipment that is older than
fifteen years. They may want to add large-format capacity or grow
up from a 41-inch press as part of a strategic plan for growth into a
lower-cost, higher-volume business. In all cases the aim is to enable
users to enter new markets, grow their share of current customers, and
drive new business. Whatever the reason, business volume is a major
component of the investment decision, though hardly the only one.
Assuming the volume is sufficient, printers transitioning from a
41-inch platform face a complex undertaking that involves not just the
installation of a VLF press, but also modifications to the physical plant
to accommodate both the press and additional floor space for larger
pallets, as well as additional upgrades to prepress (CtP) and postprocessing capabilities. Again, given the volumes involved, in-house
sheeting capabilities are a “must have” to optimize sheet layout and
minimize waste.
Caution is advised. Just because a press fits into your building doesn’t
mean it fits into your business. With the cooperation of the prospective
press supplier, a careful analysis of the undertaking should be carried
out beforehand to avoid creating upstream or downstream bottlenecks
associated with work-in-process increases.
Fast, Flexible, Productive
VLF presses have been around a long time. However, the new technologically advanced presses represent a vast improvement over the
slow operating speeds and lengthy makereadies of their nonautomated predecessors. Designed for production flexibility while
also being faster and easier to prep, key elements of this newest
generation of VLF offset presses include:
• Integrated press control technology. Inline Lab color and
register measurement and adjustment; and a high-performance
press console offering control of press, peripherals, and color.
• S ystematic makeready savings. Fast, automatic, or synchronous plate changes, high repeatability, and easy ink washup
procedures with ink fountain foils; parallel washup of blanket and
impression cylinder; and comprehensive preset capability.
• L atest generation press design for highest speed. Feeder
technology with inline adjustment; drying technology capable
of high-speed applications; and automatic non-stop operation in
both feeder and delivery.
• In addition, look for design features that combine easeof-use with easy maintenance with minimal production
downtime. This will typically be six hours per week in a 24/7
environment. These include integrated peripherals; fast roller
settings; parallel procedures; an automatic lubrication system;
and fast changing of consumables such as cleaning cloths.
TECHNOLOGY
It Pays to Take a Systematic Approach
While it’s wise not to overlook the size of your local support organization, ready access to factory-trained technicians and spare parts is just
one element in a systematic approach to keeping your VLF press performing at its peak. It’s well to remember that just because your press
is running doesn’t mean it’s performing at its best. Availability and
reliability also can be optimized by means of remote monitoring for
diagnosis and analysis of potential problems, as well as by a comprehensive program for maintenance such as Heidelberg’s Systemservice
36 and periodic productivity monitoring to gather key performance
data on a regular basis.
If you have your eye on higher profits that come from improved efficiency and productivity, and if a careful analysis of your business strategy reveals that VLF is the way to go, it’s time to talk to your supplier.
If you buy a press, have a clear understanding of what to expect. Agree
with your supplier on what makeready times, running speeds, and
waste to anticipate. Then decide on clear remedies for noncompliance.
Choose a supplier that offers not only a high-performance press but
also a systematic approach to keep it running at its productive peak. In
evaluating a new press, ensure that the differences you are looking at
are repeatable on your shop floor with your people at all times.
Aside from the production capabilities of your chosen press, the ability
of your sales and service team to react quickly to customer demand
will be a key differentiator in your success with VLF. Unlike the largest
conglomerates that manufacture their own stock, you will not be the
lowest-cost provider, but you will be more flexible. The VLF press you
choose should enable you to capitalize on that flexibility in all the ways
noted above.
To learn more visit www.heidelberg.com or email Joerg.Daehnhardt@
heidelberg.com.
Will you be
attending PRINT 13?
We are too.
Come visit the Printing Industries
of America Booth #4855. We will be
showcasing our resources for the
printing and graphic arts industry.
Learn about our upcoming events
and training opportunities.
Browse the onsite bookstore,
Printing Industries Press, and get
“show special” pricing.
Free Giveaway—booth bookstore
visitors receive a free downloadable publication.
Demo the new Integrated Print
Center (IPC) to learn the full benefits
of its resources.
FOR MORE INFORMATION
Sample Chapter from Printing Plant Layout and
Facility Design by John Geis
(PDF Download—Member Login Required)
http://prnt.in/ZuR
Sample Chapter from Materials Handling for the
Printer by John Geis
(PDF Download—Member Login Required)
http://prnt.in/ZuD
For updated news and information
about our presence at PRINT 13, visit
www.printing.org/print13.
The Magazine
9
6.2013