Web's Got a Friend

By partnering with other processes, web offset reaches its maximum productivity value.

by Jessica Millward, Associate Editor

THE QUALITY OF web offset printing has never been in question; its economy, however, has had its naysayers. But the new generation of web offset looks to be fueled by interdependence: using offset in conjunction with other processes to provide high quality while rationing costs. Given its in-line capabilities and speed advantage, web offset's doors may soon open to many more printers.

The move to multi-process was certainly witnessed by last year's Labelexpo attendees. RDP Marathon, for example, highlighted its LF-series of variable repeat web presses, which employs interchangeable print inserts available in hybrid combinations of litho, flexo, screen, waterless, and gravure.

Brian Ivens, RDP's director of international marketing, believes, "Such print flexibility allows the appropriate printing process to be used according to the needs of each job—offset for process printing, flexo for special coatings, screen for high ink deposition, gravure for metallic effects, etc."

Nilpeter, a combination web offset veteran, recently introduced the 20˝ M-5200 model as a first cousin to the 13˝ M-3300 unit. These presses feature a platform slide-in system to allow printing cassette changes without tooling, as well as off-line job preparation. Stressing the ability to change set-ups from job to job, Nilpeter offers UV flexo and UV screen versatility, in addition to laminating, embossing, stamping, and diecutting.

Offset seems to have found its natural print partner in UV flexo, which often provides better large-area, solid color coverage than offset. Michael Aumann, North American sales manager for Brandtjen & Kluge, agrees, counting the newly offered UV flexo capacity on the Kluge web press system as one of the most significant developments of his company's presses. as it will significantly expand the amount of work the press can produce.

Investigating improvements

Web offset has recently become better acquainted with the sheetfed business, given the Gallus-Heidelberg alliance forged in 1999. Detlef Janke, marketing director for Heidelberg's sheetfed Speedmaster 102 press, remarks, "In-line technologies, including printing, hot foil stamping, window patching, and diecutting, offer opportunities to our new and existing customers."

Janke explains Heidelberg's original hesitation regarding web offset was the process' gravity toward long runs and difficult changeovers. Meanwhile, the Gallus TCS250 intermittent web press is ideal for small and medium-sized runs, complete with individual print modules that support letterpress or screen options. Because the TCS250 requires no format-dependent accessories, order-specific outlay is reduced.

Press suppliers are ready to provide various all-round print improvements. Stevens International's President Richard Stevens notes, "Printers are specializing…many require more colors and more special, signature colors. Also, we see demand for special coatings and higher resolution." In response, Stevens has enhanced its web management systems for better register. Also, in some models, Stevens has added larger rolls in the ink train to reduce misting.

Dry times for dry offset?

Buoyed by a near tidal wave of hype, waterless offset seemed poised for greatness in the early '90s. The elimination of water-ink balance worries, reduced VOC/HAP emissions, and sharper print ability made the waterless resumé fairly impeccable. However, the buzz began to simmer down as Toray, the sole possessor of the analog waterless plate patent, strained to meet growing demand. Press downtime caused many a printer to abandon the pursuit of dry offset altogether, and the monopoly on the plate market didn't do much to encourage new users.

Waterless' fortunes may soon change, as suppliers hasten to render it more appealing. Ted Barry, VP, Sales for Matik North America, which represents Codimag's new Viva 340 press, believes strongly in waterless' potential, considering "the expiration of Toray's patent—which should drive plate costs down, and the greater availability of waterless inks." Sanki, too, is banking on dry offset's cogency. Their new press offers waterless printing in combination with flexo and rotary screen, and a host of post-print options including cold lamination, hot/cold stamping, and others, all in one web pass.

Another chief concern in waterless printing is heat generation caused by the friction of milling the ink through the rollers. Vital on-press temperature control systems maintain constant temperature and stabilize ink viscosity. Accordingly, the Viva 340 employs separate cooling circuits for the ink trains and UV driver bases, as well as individual plate cylinder chilling.

But improvements in traditional wet offset just might rain on the waterless parade. RDP Marathon's Director of Intenational Marketing Brian Ivens says, except for specialty printing applications, the company has witnessed a drop in interest for waterless capability. He suggests the newer, improved roller coverings and blanket materials on wet offset presses have gone a long way toward resolving ink/dampening issues. He also argues combined process capabilities compensate for any edge in print quality dry offset may have had.