DIGITAL'S FAMILIAR FACE

The integration of digital print into conventional press formats sets the road to the future in comfortable surroundings.

by Jessica Millward, Associate Editor

AS YET, DIGITAL print isn't installed in an overwhelming number of packaging plants. Suppliers realize, however, that the nature of the market will require the integration of digital techniques in the not-too-distant future, and are preparing accordingly.

"The converter is being forced by their customers to advance print capabilities to match market demands," observes Chris Faust, digital sales manager, Chromas Technologies. He identifies the common reason for investing in digital print capability as the pressure to deliver packaging on-demand, with new graphics or variable information.

The eternal search for sufficient skilled labor also acts as a persuasive force in digital adoption's favor. As Faust notes, "Digital print will allow for converters to produce high-quality products, on demand, with minimal operator influence."

In the offset market, too, digital becomes a more attractive alternative as run lengths shrink. Heidelberg USA Product Manager/Direct Imaging Jörg Dähnhardt adds interest in direct imaging has sprouted with the increased market for test marketing pieces, such as sample packages or labels.

As a testament to suppliers' convictions about digital print's future, the evolution of better, easier-to-adopt-and-use digital print abilities has continued in research labs, even through a stagnant economy.

Suppliers who do otherwise shoot themselves in the proverbial foot, Faust reasons, because "… most manufacturers see the future as being digital, and any slowdown [in research activity] now will deeply affect them in the future."

Flexo's intro

For the flexo community, digital/conventional combo technology permits printers to exploit strengths of both processes, both in terms of cost and process capability. Faust cites an order with metallic or fluorescent color outlining a four-color process image. While the metallic or fluorescent would be printed through conventional flexo or gravure, the process image could be economically achieved digitally, with high quality and tight registration.

Historically, the prime challenge facing hybrid presses has been web transportation. Faust lists several web issues press designers must face: 1) Do the webs have the same travel path? 2) Is one intermittent while the other one is continuous? 3) Do the two systems have similar web tension requirements? 4) Do the two system's speed capabilities match each other?

Press manufacturers have made serious strides further in producing a truly integrated press. The Chromas Argio SC Ink Jet Printing System is a 7.5˝-wide unit ready for retrofit onto existing conventional presses, and reaches speeds to 100 fpm.

Set to premier at Labelexpo Americas in September, the Mark Andy/Barco digital ink jet printing system features a digital unit which integrates directly into a 13˝ Model 2200 press.

"For digital printing to be successful in the world of flexography, the equipment must be easily adaptable to the flexo printing operator's environment, especially from a workflow standpoint," asserts Ken Daming, product manager, Mark Andy. Therefore the new digital module prints at speeds to 80 fpm, and the system offers a full range of in-line converting options. Traditional flexo stations can be placed both before and after the ink jet module.

Acquainted with offset

In offset circles, the digital migration has moved further along, buoyed by commercial print's demand for quicker turnaround. Aspects of digital integration continue to be works-in-progress, however.

Heidelberg's Dähnhardt remarks on the snares inherent on the shop floor. Laser heads are sensitive, and, as he points out, in a press environment they come in close contact with such volatile materials as water, powder, inks, and solutions. Dähnhardt also emphasizes the need for stable, fast, and reliable data transfer on direct imaging presses.

On Heidelberg's Speedmaster 74 DI, Dähnhardt maintains, these issues have been addressed. The press produces offset quality imaging, with no color cracking, and is food-packaging friendly. Additionally, the UV CoCure process is possible, and the press uses conventional offset inks, coatings, etc.

MAN Roland has dipped into digital technology in various ways, from the DICOpack web-based packaging/label press to its new DICOweb unit, which employs an imaging cylinder that is laser-imaged, then erased, so the press can print job after job directly from digital data.

The just-commercialized DICOweb press is currently offset-based, but has the capability to swap processes with its modular inker. Marketing Director Christian Cerfontaine notes while the press has not been purchased by a package printer yet, it handles a multitude of substrates, "so it's just a matter of time."

A recent Open Day for the packaging and labels division of MAN Roland, held at its German headquarters, revealed plans to further the DICOpack concept with in-line and off-line finishing solutions, and to possibly combine the DICOweb and DICOpack systems in the future for full-blown toner/ink jet/flexo/gravure print systems.