Druckerei Preuss, Germany.

Speedmaster XL 75-5 with LED drying.

The machine replaces two older machines from a different manufacturer and results in significantly increased capacity growth.

Industrialization on a small-scale.

In addition to a high setup and production speed of up to 15,000 sheets per hour, the most impressive feature of the new Speedmaster XL 75 is its extremely short makeready times. There are virtually no waiting times when switching between a high number of short run jobs, thus leading to an enormous increase in productivity. “After the first few weeks, it is evident that the machine really is extremely fast, whether it be with complete job changes or signature changes,” reports Alfred Preuß of Rossimedia. The increased throughput of the Speedmaster XL 75 must be handled well, as the company produces more than just standardized printed products on 135 g paper – up to nine different types of paper are used every day. “With the Speedmaster XL 75, we print 12 to 13 gangs in three to four hours, and each of these gangs has a different type of paper,” explains Alfred Preuß. This diversity of small jobs plays a large part in ensuring profitable use of the machine. However, a prerequisite for profitability is job costings based on sound business principles, as well as corporate organization that is as optimized as possible. It is not easy to ensure that these requirements are met in a small family company. “Perfect coordination, from punctual provision of the substrate and the printing plates to processing in-house or at service providers, is the be-all and end-all for successful deployment of a high-performance machine such as the XL 75,” says Alfred Preuß.

At the beginning of May, the print shop based in Ratingen commissioned a new five-color Speedmaster XL 75 with LED UV drying. With the new press, the company replaced two older machines from a different manufacturer that were operated in a single shift.

Rossimedia is particularly proud of the enhanced range of services brought about by the production of high-end products with highly-embellished motifs, for example with relief coating and gold print. The DryStar LED UV dryer configuration has proven to be the right choice as the results are extremely impressive. “Thanks to LED drying, even natural papers that are challenging in terms of haptics produce bright colors and we achieve good image contrasts, including on paper with open pores,” reports Alfred Preuß. He adds, “The exceptional quality on these papers has meant we have been awarded jobs that we wouldn’t have got with conventional technology.”

Another advantage of LED technology is fast ink curing and ozone-free production without any radiant heat. Furthermore, printing powder is not needed and fast processing is achieved at all times. Yellowing caused by the coating is also a thing of the past, ensuring that the surface of the paper maintains its bright whiteness. However, the merits of the new technology have to be accompanied by a systematic rethink of the daily processes, as this technology acts completely differently than is the case with conventional printing without an LED dryer. “With traditional offset printing, my printers controlled the ink-water balance with a great deal of sensitivity, using their extensive experience and by assessing the printing result. But LED UV technology means that some of the well-rehearsed routines are no longer needed. The printing result is perfect in a great many respects and the ink is always dry,” explains Alfred Preuß. “However, this means that several warning signals for unsatisfactory process workflows are also missing. We’re therefore no longer willing to do without another feature. The Prinect Inpress Control 2 inline color measurement and control system.” The spectrophotometric measuring technology not only detects even the most minor color deviations in process and spot colors and constantly corrects them; the high-performance process computer also provides ongoing information about dot gain and issues a warning if tolerances are exceeded. The register is checked at the same time and readjusted if necessary. Measurement and control during production allows for continuous production monitoring, thus resulting in a print run with excellent color fidelity, produced within very tight limits. And this automation also naturally has a positive impact on the amount of paper waste. Today, Alfred Preuß expects 180 sheets of paper waste with complicated motifs, whereas salable products are produced with as little as 70 to 90 sheets with simple motifs, such as periodicals, whereby several similar gangs run in succession.

Druckerei Preuß has focused on printing quality for more than 50 years and provides its customers with an extensive portfolio of different printed materials. Included in the range of services of the full-service company are the creation of the print data, the entire prepress and high-performance postpress. The medium-sized company now employs 10 people and its customers include numerous renowned industrial clients and advertising agencies. In contrast to large-scale print shops, the Druckerei Preuß team places a great deal of importance on individual customer wishes by providing an exhaustive diversity of paper and inks to choose from. Customers can therefore give free rein to their creativity, without any stumbling blocks. The company produces a wide range of printed materials, from simple flyers to high-quality embossed and punched company reports.

Druckerei Preuß, Germany

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