Print in a Diversifying
Media World
ERA Annual Conference
Munich
October 17-18, 2011
Josef Aumiller
Vice President Sales
Web Offset Presses
manroland AG
Potential of High Volume Web Offset
Presses in Publication Printing
2 ERA Annual Conference 2011 © manroland AG, Oct 2011 Josef Aumiller
Perspective print
Market dynamics
New champions like Apple,
Google and Facebook
Traditional business model
PRINT is changing
and partially substituted.
3 ERA Annual Conference 2011 © manroland AG, Oct 2011 Josef Aumiller
Perspective print
Market dynamics
Technological progress
Higher automation and
productivity reduce demand.
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Perspective print
Market dynamics
Overcapacities amongst
printers and manufacturers
Irrational price competition.
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Perspective print
Market dynamics
Digital printing becomes
more and more competitive
Quality and productivity
improvements of digital
printing make inroads into
offset markets.
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European paper consumption in industrial-scale
webfed printing
11.1
mill. t
2009
13.3
mill. t
2008
Source: EMGE & Co.
11.7
mill. t
2010
Heatset Web Offset and Publication Gravure
11.3
mill. t
2011
Forecast
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Magazines: general trends
Magazine titles with runs in the millions
are losing ground
The trend is towards short to medium runs
Shorter production times, shorter time to market
Still a high number of new publications
Higher product value (paper, cover)
Approx. 45 % of volume
8 ERA Annual Conference 2011 © manroland AG, Oct 2011 Josef Aumiller
Catalogs: general trends
Splitting of “big books” into thinner,
special-interest catalogs in shorter runs
Faster to the customers
Higher product value (paper, cover)
Mutations: magalogs
Approx. 20 % of volume
9 ERA Annual Conference 2011 © manroland AG, Oct 2011 Josef Aumiller
Inserts: general trends
4 to 48-pages, wide variety of layouts
(formats, types of fold, glueing)
Market very stable and slightly growing
Short production and distribution times –
time to market generally between
24 and 48 hours
Approx. 25 % of volume
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Requirements for future publication printing
Cost per copy
Flexible press systems
Constant high printing quality
Environmental friendly production
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What was discussed 4 years ago in Verona?
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Investment in Commercial Web Offset Presses in
Europe
197 171
60
62
98
104
0
50
100
150
200
250
300
350
2000 - 2004 2005 - 2010
up to 1000 1000 to 1480 1480 to 2860
Number
of presses
Source: manroland
Web width in mm
High Volume Presses 48 – 96 pages
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What was discussed 4 years ago in Verona?
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Productivity increase by higher speed
Since 2007: 12
LITHOMAN presses in
the market with
50.000 rev/h
production speed
1980 1990 2000 2005
50 000
25 000
´rev/h
14.6 m/s
17.2 m/s
30 000
35 000
42 500
50 000
2007
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Flexible production concepts for the widest variety of
requirements
number of pages
run length
LITHOMAN 32/48/64/72/80/96 pages long grain
LITHOMAN 32/40/48/96 pages short grain
ROTOMAN S 24/32 pages
ROTOMAN 16 pages
EUROMAN 32/48 pages
Gravure
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3.06
2.72
Million pages/h
2.4
2.16
72 pages
45,000 [1/h] 64 pages
45,000 [1/h]
32 pages
85,000 [1/h]
16 pages
65 / 70,000 [1/h]
48 pages
50,000 [1/h]
24 pages
90,000 [1/h]
80 pages
45,000 [1/h]
3.6
1.04/ 1.12
Press concepts – long grain
Output in number of pages/h
2,250 mm
1,2
40
mm
96 pages
2,860 mm
4.32
45,000 [1/h]
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Flexible production concepts in commercial web
offset
Available formats
Double circumference:
Cylinder circumfer-
ence [mm]
1,260.0
1,240.0
1,197.0
1,190.0
1,156.0
1,140.0
1,105.2
1,066.8
1,016.0
990.0
984.25
968.0
939.96
904.2
900.0
889.1
+
Crossfold production Crossfold production
+
quarter-fold production
Modular folder range
UWWO
Unique
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Commercial printing systems
autoprint commercial
autoprint already features fully-automated job changeover and system start-up,
which ensures run length flexibility, efficient planning and fewer waste.
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autoprint
We are designing the fully automated press
The machine controls itself
The operator becomes process controller
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What does it mean for the production process?
Standardization and automatisation of the fundamental phases of the
production processes
Press stop
Change over
Press start
Printing
Quality proof
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autoprint – the total is more than the sum of its parts
InlineControl Systems
Quickstart
APL
AutoJobChange
Magnetic Brake
Postpress stopps the press
Quality definied ramp up
autoprint
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AutoJobChange LITHOMAN 48/64 pages:
Changeover times & start-up waste
PE
CO
M p
rod
uctio
n c
ha
ng
e
Quick
Stop
APL
2 min.
good copies
pre
ss s
peed
Values valid without
start-up wash
waste
≤ 7 min. at
900 revs. waste
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The first autoprint LITHOMAN 64 pages
24 jobs with autoprint
Average makeready time: 5 min. 42 sec.
Average waste: 998 rev./h
29 jobs in 48 hours
5 without autoprint
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DynaChange – flexible opportunities
4/4 with imprint function
4/4 with imprint function and varnishing
6/6
special color
varnish
varnish
5/5 with imprint function and special color
5/5 with special color and varnishing
special color
special color
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Product Value Product Value Production Efficiency Production Efficiency
Increased Turnover Increased Turnover Cost Reduction Cost Reduction
Sustainable Production, Ecology Sustainable Production, Ecology
Competitiveness in Commercial Web Offset
Sustainable Profit Sustainable Profit
