People & Print

Trendsetting Topics in today‘s Sheetfed Printing Technology

Stephan Weiser, Area Sales Manager Eastern Africa

KBA Sheetfed Offset
Topics:

Content:

Situation of world printing market today

KBA’s position in this market

Growing market of packaging printing:

solutions and products

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 2

 People & Print

The today’s market situation

Emerging Markets

• Strong growth in Asia and Latin America

• Growth in some border regions of Europe (e. g. Turkey)
• Stagnation/decline in the saturated markets of Western Europe and North America

Worldwide print market by regions 2008-2014

Europe North America Latin America Asia Africa and other

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser Source: PRIMIR/NPES, World Wide Market for PRINT 2009 - 2014 Update 4
Global press market by segments

Market volume in 2013

approx. € 5.3bn

Web offset Sheetfed offset Flexo, gravure, Digital**

(newspaper and screen (presses only)
commercial) approx. €2.7bn approx. €700m approx. €1.3bn
approx. €630m

Market volume in 2015

approx. €5.5bn

Web offset Sheetfed offset Flexo, gravure, Digital**

screen (presses only)
approx. €400m approx. €2.5bn approx. €750m approx. €1.8bn

- The enhanced productivity of modern, automated presses reduces additional market volume/growth
- The digital printing business mainly comprises of over 50% consumables and service contracts - not included here
**estimated number of toner and inkjet presses for industrial printing plants (excluding copiers, consumables and service) 07/2013
(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 5
Strong growth in packaging sector in the near future

• Internet is reducing print and advertising market volumes in the newspaper, magazine and
catalogue sectors
• The trend to eReader like iPad, Kindle or others is responsible for the decline in book printing
• Packaging, label, film printing are classic growth markets and are scarcely affected by the
internet and digital printing (apart from labels)

40%
Global print market * by product 2008-2014 36.7% 36.3%
34%
35%

29%
30%

25%

20% 2008
2014
15%

10% 9.5%
10%
7.4%
6.4% 6.2%
5.5%4.8% 5% 4.6%
4.6%
5%

0%
Books Catalogues Magazines Newspapers Advertising Packaging Other

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser * Source: PRIMIR/NPES, World Wide Market for PRINT 2008 - 2014 Update 6
 People & Print

KBA – the world’s first press manufacturer

KBA: the world’s first press manufacturer

• 1807-1812: Friedrich Koenig built the first

cylinder printing press in London

• In 1814 The Times in London - the first

newspaper in history to be printed by a machine
First cylinder press, 1812

• 200 years after - move into the high-growth

digital print market with the KBA RotaJET 76

First inkjet web press, Drupa 2012

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 8

KBA: technological leader with strong market position

• No. 2 worldwide for printing presses

worldwide with sales of some €1.3bn and around
6,000 employees
• No. 1 in web offset (newspapers, commercials)
• No. 1 in large-format sheet-fed offset
(no. 2 overall)
• No. 1 in packaging offset, security
printing and metal decorating

• Extensive, highly advanced product

portfolio for volume and niche markets
• Top innovator and technological
trailblazer in many areas

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 9

KBA’s global presence

• Sales and services outlets in our primary markets (Europe and North America),
prospective markets Asia (China, Malaysia and Singapore), Australia and Russia
• In addition we maintain an extensive network of agencies providing customer support
the world over – as in Africa

Agencies
KBA branches + subsidiaries

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 12

 People & Print

Product range
Does KBA come to mind when looking at these products?

Examples from KBA customers

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 14
KBA product range: newspaper presses

NEWSPAPER
Offset: single-width
KBA Continent
KBA Comet
Offset: double-width
KBA Commander CL 4/2
and 4/1
KBA Commander CT 4/2
Offset: triple-width
KBA Commander 6/2
KBA Commander CL 6/2
KBA Commander CT 6/2
Offset: waterless
KBA Cortina 4/1, 4/2
and 6/2

KBA is the market leader and a driver of innovation in newspaper

press technology. Our portfolio includes all customary printing
processes, configurations and performance classes, and we also offer
customised systems for paper logistics.

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Sheet-fed presses from small to super large format

Sheetfed
KBA Genius 52UV

KBA Rapida 75

KBA Rapida 76

KBA Rapida 105

KBA Rapida 106

KBA Rapida 145

KBA Rapida 164

KBA Rapida 185

Wide range of sheet-fed offset machines: small (360 x 520 mm) to super KBA Rapida 205
large format (1510 x 2050 mm) for commercials, books, posters and
packaging. KBA is the world market leader in large format!

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 17

Rapida 185 - 205

• Largest sheetfed offset press in the world (max. substrate format: 151 x 205 cm)

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 18

KBA: No.1 in large-format sheetfed offset

The World‘s largest Atlas, printed on KBA Rapida 205-5+L in Italy at Litorama

© KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 19

 People & Print

Rapida 75
Highlights of the Rapida 75
Technical data and features

Technical data Rapida 75

RAPIDA 75 2-colour up to 8-colour and high gloss coating unit

Substrate
Maximum sheet format 530 x 750 mm
Maximum print format 510 x 735 mm
Substrate thickness 0.04 – 0.6 mm (CX: 0,8mm)

Production speed
Maximum (up to 8 printing units + coater) 15,000 sph
HighSpeed package 16,000 sph

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 21

 People & Print

Rapida 105
Winning features
Technical data of the new Rapida 105 (B3)
Rapida 105
Max. substrate size 720 x 1.050
Max. substrate size (Option) 740 x 1.050

Thickness of substrate* (paper) 0.04 – 0.7 mm

Thickness of substrate (board-handling) (Option) 1.2 mm

Thickness of substrate (corrugated board) (Option) 0,1 - 1.6 mm

Maximum speed 16,000 sph

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser S = Standard 23

O = Option
 People & Print

Rapida 106
The innovation in the high-performance class
Technical data and features
Rapida 106
Max. substrate size 740 x 1.060
Max. substrate size (Option)

Thickness of substrate* (paper) 0.04 – 0.7 mm

Thickness of substrate (board-handling) (Option) 1.2 mm

Thickness of substrate (corrugated board) (Option) 0,1 - 1.6 mm

18,000 sph
Maximum speed
20,000 sph

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 26

Automation concept for make ready savings

 Cutting edge technology and constant innovation

for top performance, flexibility and economic efficiency
 State-of-the-art automation modules for saving
makeready times, less waste and best quality in print

DriveTronic CleanTronic Quality VariDry

Management
DriveTronic Feeder CleanTronic Synchro VariDry IR/ TL
DriveTronic SIS CleanTronic Multi ErgoTronic VariDry Blu
DriveTronic SPC CleanTronic UV VariDry UV
QualiTronic
DriveTronic CleanTronic Re Ink VariDry HR-UV
PlateIdent VariDry LED-UV
DriveTronic SFC VariDry Inert UV

KBA - Print Promotion - 2014 271

DriveTronic SIS / Sensoric Infeed System USP

DriveTronic SIS = Sensoric Infeed System

• No setting errors, as no settings to make
• Longer period of rest for sheet alignment
• Reduced make ready time
• Marking-free

Cost advantages through

• Fewer production
stoppages and higher
productivity
DriveTronic SPC / simultaneous plate change system

• All units in ca. 50 seconds

• Plate changing parallel to other make ready processes possible:
- washing of printing and coating unit
- format settings
- all preadjustments

KBA - Print Promotion - 2014 291

Make ready comparison – full automation

Rapida 106 Competitive press

Highest automation with DriveTronic SPC and CleanTronic

Competitive press
Plate change Fully automated 1:45
Blanket washing 3:00
Impr. cyl.washing 4:00
Roller washing 5:00
t [min] 2:00 4:00 6:00 8:00 10:00 12:00 14:00
Rapida 106
Plate change DriveTronic SPC
Blanket washing CleanTronic Synchro 2:00
Impr. cyl. washing CleanTronic Synchro 3:00 time savings

Roller washing CleanTronic SRW 1:30

30 Example calculation without obligation

 People & Print

Packaging Printing
Strong growth in packaging sector

40%
Global print market * by product 2008-2014 36.7% 36.3%
34%
35%

29%
30%

25%

20% 2008
2014
15%

10% 9.5%
10%
7.4%
6.4% 6.2%
5.5%4.8% 5% 4.6%
4.6%
5%

0%
Books Catalogues Magazines Newspapers Advertising Packaging Other

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser * Source: PRIMIR/NPES, World Wide Market for PRINT 2009 - 2014 Update34
 Global print volume by market sector and process

Publications
printing 30% 50% 8% 12%
(32% of the volume)

3% 2% Sheetfed offset
Web offset
Packaging printing 34% 38% 23% Flexo
(25% of the volume) Digital
Other

Advertising and
45% 28% 17% 10%
commercial printing
(43% of the volume)

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser Source: Pira, Jakoo Pöyry, Primir, Global Insight, Heidelberg, estimate for 201135
KBA presses_ Ready for packaging printing

Be flexible with your printing machine!

Print on

• cardboard up to 1.2 mm
• corrugated board up to 1.6 mm

samples

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 36

KBA presses – Ready for Packaging Printing
Sheet transfer: Double sized cylinders/ transferters
Drive concept: Continuous gear train
Gripper system: Large diameter of gripper shafts. Strong gripper holding forces
Bearings: Play-free cylinder bearings
Substructure: Box frame cast in a single piece for maximum torsional rigidity

RA 105/ 106
sheet guiding system

RA106 cylinder bearings

RA106 Drive concept

RA106 Grippers RA106 one-piece box frame

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 37

Gripper system

Reinforced gripper shaft

(35 mm) enhances
gripping power

Firmer grip thanks to new
pad geometry

No need to set universal gripper
bars during substrate change

Narrow gripper margin of 10 mm

Benefits:

Optimum register precision with
all substrates

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 38

Rapida 106 / Automated coating forme change

KBA SAPC for fast and automated coating forme change

Change time approx. 1 min

39
 People & Print

KBA VariDry dryer technology

 KBA VariDry dryer technology - overview

• IR/ Hot Air- Dryer for conventional inks

and water-based varnish
• UV-dryer for UV inks and UV varnish
(UV, GA-UV, OzonFree-UV)
• Combination dryer for hybrid presses
(IR/TL/UV)
• Special UV-dryer for high reactive inks
(HR-UV, LED-UV, UV-Inert)

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 41

Rapida 106 / KBA VariDryblue
KBA VariDryblue: Lowest energy consumption in its class
• Still unsaturated hot air from Modules 1 and 2 returned to Module 3
• Reduction of power consumption and waste air volume by approx. 50%

KBA - Print Promotion - 2014

 People & Print

Quality Management
 Measurement Systems

Online Systems Inline Systems

Density and Lab values (spectral) Continuous Measuring & control of ink density
On every single sheet!

 Ensures consistant quality of your printed product!

441
 People & Print

Example of packaging product

Finishing Effects / Typical Inline Finishing Applications

RA 105 - 6 + L

Unit 6 Unit 5 Unit 4 Unit 3 Unit 2 Unit 1

blank blank conventional conventional conventional conventional

yellow magenta cyan black

Coater Result

Iriodin varnish
(solid)

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 46

 People & Print

Strategic Focus on Packaging

- The future already today
Strategic Focus on Packaging (Sheetfed offset presses)

• KBA is the technological and market leader in packaging printing on sheetfed offset presses
• 60 % of our customers are packaging printers
• Our philosophy: Customized solutions for packaging printers

A straight-on press with 19 printing and finishing units – including cold foil – and a
total length of 35 meters at Amcor Tobacco Packaging in Rickenbach, Switzerland

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 48

Special press configurations / Rapida 106 with 19 units

1. Coating unit (Aqueous / UV) with DriveTronic SFC and Anilox-Loader

2. Dryer units / VariDry hot air / UV
3. ColdFoil Infigo SF110
4. 10 printing units with DriveTronic SPC / PlateIdent / CleanTronic Synchro
5. Coating unit (Aqueous / UV) with DriveTronic SFC and Anilox-Loader
6. Dryer units / VariDry hot air / UV
7. Coating unit (Aqueous / UV) with DriveTronic SFC and Anilox-Loader
8. UV Inert final dryer with KBA AirTronic drum
9. Quality control / QualiTronic Professional
10. KBA VariDry-Technology / - VariDry Blue hot air, UV final dryer + Infra red

3
10 9 8 7 6 5 2 1
4

KBA - Print Promotion - 2014

Strategic Focus on Packaging

New Inline Coldfoiling unit on KBA Rapida

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 50

Innovations for print
Hybrid production offset - digital
• Combination of offset and inkjet inline for brand protection, marking defective sheets, coding
and personalisation
• KBA QualiTronic MarkID: an inkjet unit with 2 heads (KBA-Metronic, Atlantic Zeiser) and an UV
dryer were integrated into a KBA Rapida 105

Varnishing Printing Units QualiTronic MarkID

KBA Rapida 105-5+M+L

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 51

Brand Protection – Copy Detection Pattern

Holograms for security and authenticity marks

There are different kinds of holograms offering different levels of security. Some of them
contain invisible marks which can only be read with special equipment.

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 52

What we did not speak about:

More aspects to become efficiant:

• Complete workflow solutions / integration of
CIP3, CIP4, MIS, JDF
• Closed loop quality control
• Pile logistics
• … and much more

(C) KBA for PrintPromotion 2014/ Nairobi -- Stephan Weiser 53

 People & Print

Specialized Open House Events at KBA:

• Packaging Printing: 14 May 2014

• Label Printing: 13 June 2014

• Commercial Printing: 27 June 2014

Thank you! Any interest? Please contact us!

Koenig & Bauer AG

www.kba.com