Graph Expo 2015 Recap

By DPS Staff

Once again print professionals headed to Chicago, IL this trade show season to see the latest announcements across key industry segments firsthand, including inkjet, digital, offset, flexographic, gravure, hybrid technologies, and products and services for the commercial, transactional, converting and package printing, publishing, mailing, in plant, photo imaging, marketing, and industrial printing industries.

The event was held in Chicago’s McCormick Place from September 13 to 16, 2015, featuring demonstrations across the show floor as well as educational sessions. According to the show hosts, the Graphics Arts Show Company (GASC), Graph Expo 15 featured more than 70 interactive learning sessions and over 50 co-located events. It reports a total 17,941 verified participants, which includes both exhibitors and attendees, and of this 11,534 were attendees/buyers.

Digital Equipment
Digital print, driven by both inkjet and electrophotographic technologies, continue to take over the once offset-heavy show floor. Several leading vendors demonstrated noteworthy equipment in their booths through physical and virtual demonstrations.

Coming right off of its Canon Expo event, Canon U.S.A. demonstrated the new imagePRESS C10000VP Digital press, which offers production print at up to 100 images per minute. The company also represented its recently launched Océ VarioPrint i300 cutsheet inkjet printer and the ColorStream 3000 Z Series high-volume, full-color continuous-feed inkjet system.

Komori America and Screen Holdings Co., Ltd. announced a strategic selling agreement that joins the two companies’ sales organizations. Through the partnership, Komori America becomes the sole U.S. distributor of Screen’s new Truepress Jet520HD.

Konica Minolta offered several pre-production previews in its booth on a variety of different technologies, including KM-1 high-speed inkjet technology. The company also showcased the bizhub PRESS C71cf digital label printer.

MGI Digital Technology demonstrated the Meteor DP1000 XL high-speed digital production press. The device is integrated inline with the DF pro finishing system as well as a new digital toner foiling solution, the iFOIL T.

For the first time in the U.S., Xerox showcased the iGen 5 and Rialto 900 Inkjet Press.

Additionally, Hewlett-Packard (HP) highlighted the HP PageWide Web Press portfolio, OKI Data debuted the C942 digital production printer, Pitney Bowes introduced the AcceleJet roll to cutsheet printing solution, and Ricoh showcased the updated Ricoh Pro 8100e monochrome printer series.

Among wide format offerings, Mimaki showcased prototyping capabilities made possible with a combination of its printing and cutting solutions.

A variety of finishing vendors were on hand to demonstrate products and services that enable quality and productivity across a range of applications.

C.P. Bourg showcased its print finishing machines including the Bourg BSF Sheet Feeder in a tandem configuration.

Duplo and Ricoh partnered to introduce the 350R In-Line Booklet System, a print and booklet making solution that integrates the Duplo DBM-350/T booklet maker and trimmer with Ricoh Pro C7100/8100/9100 production printers.

Graphic Whizard unveiled six new machines, including the PT 335SCC Multi—an all-in-one finishing solution.

Scodix launched Scodix Foil, an inline digital foiling station for the Scodix Ultra Pro. Using a patent foiling process, Scodix digitally produces professional results.

Standard Finishing Systems featured a range of capabilities including die cutting, perfect binding and trimming, creasing and folding, saddle stitching, inspection systems, and roll-fed print solutions. In addition to end-to-end demonstrations, the company unveiled a smart-sheet processing system from Horizon of Japan, and also debuted a new dynamic perforating and punching module from Hunkeler of Switzerland.
Many other finishing solutions were demonstrated on the show floor. See the following page for additional highlights.

Change of Scenery
Next year, Graph Expo moves to Orlando, FL from September 25 to 28, 2016 at the Orange County Convention Center.

According to GASC, the relocation offers exhibitors and attendees the benefits of an “affordable destination during a business-focused time of year in Orlando.”

Once again, we plan to be on hand next Fall to cover the latest technologies, products, and services. dps

Maximizing MPS

By Lisa Guerriero

Managed print services (MPS) transcend basic hardware management. Vendors offer comprehensive solutions that streamline the paths of business documents. A combination of strategies and tools ensure that each MPS customer’s solution is customized for cost savings and efficiency.

Among market leaders, this holistic approach is often known as managed document services (MDS). Industry analysts like Quocirca and Gartner identify market leaders as Canon, Hewlett-Packard (HP), Lexmark, Ricoh, and Xerox, as well as Konica Minolta, Kyocera, and Toshiba.

The approach caught on, in part because MPS customers are discerning veterans. Quocirca reported in 2014 that among large U.S. enterprises it surveyed—those with 1,000 or more employees—over 85 percent either used MPS or planned to implement it in the next year.

Most market leaders perceive an opportunity to migrate existing MPS users to a more comprehensive second- or third-generation solution. These customers require greater productivity and optimization from existing implementations.

Other MPS customers are first-time adopters, especially among small and mid-sized enterprises. Vendors strive to offer comprehensive solutions for these customers as well. New adopters benefit because MPS optimizes their printed output needs.

To ensure a thorough solution that increases productivity over time, MPS providers break the service into multiple stages. These stages generally fall into three categories—development, implementation, and maintenance.

Here we highlight a selection of prominent MPS providers and discuss how each vendor’s solutions ensure effective print management.

Spotlight on Solutions
Canon U.S.A., Inc. considers its offering to be managed services rather than straight MPS. The company helps customers graduate beyond output-focused services and derive more value than they did with earlier-generation MPS.

For companies considering MPS, Dennis Amorosano, VP/GM, marketing division, Business Imaging Solutions, Canon U.S.A., Inc., recommends investing in solutions that can provide true efficiencies.

“Basic MPS delivery is facing the threat of commoditization, a cost-per-print ‘decimal war,’ largely due to its inherent narrow scope of services. Expanding to a managed services model that solves real end-customer business challenges is the next logical step,” he says.

The company breaks its services into five stages, Discover & Analyze, Design, Deploy & Transition, Support & Manage, and Evaluate & Review. Canon gathers insight and data about the enterprise’s output environment and activity and reports back to the customer.

Canon’s team then develops a plan based on the assessment as well as the customer’s goals and needs.
The implementation phase includes the physical movement and replacement of equipment.

Once the solution is implemented, support and management are key. “A poorly maintained output environment is costly not only in numbers, but in employee productivity. Canon’s tools for service delivery are advanced and designed so that you can stay focused on your core business, instead of thinking about support issues,” notes Amorosano.

Evaluation and review are performed on an ongoing basis to ensure continuous business process improvement.

Although solutions vary depending on the vertical market and each business’ needs, Canon believes its structure ensures productivity for all clients.

“Canon’s five-phase methodology, inclusive of quarterly business reviews, clearly defines return on investment (ROI) in addition to identifying new opportunities to solve real customer challenges and deliver better business outcomes,” notes Amorosano.

HP specializes in several industries, including financial services and insurance; healthcare; manufacturing and distribution; communications, media, and entertainment; and the public sector.

The key to successful MPS is taking a broader and more modernized view at the factors that influence document pathways. “Initially, largely a cost reduction story, MPS today is about increasing employee and IT productivity and performance, and continuous improvement through increased transparency and control,” explains Todd Gregory, director, Print and Personal Systems, HP.

To be effective, MPS must address security, the digital influence on workflow, and the client’s need for a flexible solution that adapts when the business changes.

“Many organizations don’t know the true cost of their imaging and printing print spend, much less the opportunity to drive down the number of pages printed through best practices and end user acceptance. Certainly, most organizations are not aware of security considerations—including secure disposal of old equipment,” says Gregory.

An effective MPS solution addresses timely factors like device management, content capture, and mobile printing. Printers and multifunction products (MFPs) are “smart” devices that interact with corporate data and are effectively an on-ramp to the network. Interest in secure print solutions increased across nearly all segments and regions, notes Gregory. In response, HP released JetAdvantage Security Manager, which helps customers detect and protect their print infrastructure.

By addressing all of these areas of MPS and providing regular reporting to track the solution’s efficacy, HP ensures ROI.

Konica Minolta’s Optimized Print Services (OPS) combines consultancy, hardware, and software implementation and operation to improve print management.

The OPS concept focuses on five areas—fleet, process, financing, security, and “green.” It links three essential functions—consult, implement, and manage.

Lexmark cites double-digit growth in MPS, with particular growth from the government and healthcare segments. It also provides solutions for banking, education, insurance, manufacturing, and retail. The company’s goal is not just to manage printers, but to leverage print infrastructure to optimize and streamline workflows and business processes, says Kyle Farmer, VP/GM, managed print services, Lexmark.

“An exciting aspect of the evolution of MPS is helping our customers grow their business with their customers, rather than just helping them reduce costs and build efficiencies,” he observes.

The company looks at MPS in three stages, starting with infrastructure optimization. Next, in the proactive management stage, Lexmark provides a single-system of the infrastructure, ensuring uptime.

The final phase is streamlining/business optimization. Lexmark digitizes and simplifies critical processes. The data collected during the second stage now serves to improve processes in the back office and public-facing environments.

“Our closed-loop governance process ensures that we meet established ROI targets at every phase of the engagement. This includes monthly measurement reporting, quarterly strategic business reviews, and an annual satisfaction survey,” says Farmer.

Lexmark offers an integrated platform. Because it owns its technology, the company is able to unify output, content, and process management. “These technologies enable us to solve unstructured content problems that span both paper, such as documents, forms, and notes; and digital, such as email, images, video, and electronic forms formats,” he explains.

Toshiba views MPS as having three types of customers, late adopters, existing MPS users looking for a better solution, and “customers who think they are doing MPS, but are really just buying toner and service,” explain Kathy De Santi, program manager, and Jon Hafey, director, Strategic MPS Business Development, Toshiba America Business Solutions.

These groups have disparate needs and goals, but the common thread is the need for mature processes for implementation and execution. “Many clients are still waiting to actually achieve the benefits that MPS has promised. As a result, many are focused on refining their current programs and products to better realize the full potential of MPS,” say De Santi and Hafey.

Early stages of Toshiba’s program include assessing legacy devices and optimizing placement and reallocation prior to procuring new equipment.

The company designs its document output and device management solutions to protect and control print volumes and expenses. It strives to simplify and optimize fleet management and workflow.

During development, Toshiba works with the customer to establish strategic, financial, and operational goals for the engagement. After implementation, both Toshiba and the client have tools to evaluate the program’s success.

“During meetings and quarterly strategic business reviews, we review progress against those targets and continuously identify opportunities for improvement. In addition, Toshiba customers have access to tools to help manage their fleet, with extensive data on all critical aspects of the fleet,” note De Santi and Hafey.

Xerox combines classic MPS services with sophisticated components like data analytics, mobile access, and security. It offers a suite of services, allowing clients to select a program suited to their needs and expectations.

The company strives to provide a modernized version of core MPS services, like document lifecycle management. Xerox drills down to establish who created a document, where the document originates, how many people used it, and how long it lasted. This level of scrutiny gives the company insight into the customer’s workflow and how best to re-engineer document pathways. “We can find and process hot spot inefficiencies,” observes Kirk Pothos, VP, MPS offering development, Xerox Corporation.

The customer’s devices must also be analyzed to ascertain their condition and how they were used. This allows Xerox to show the client what environment is ideal for the equipment, and vice versa. It also ensures ROI later in the process. Usage patterns come under the microscope. A printer may produce 1,000 pages a month, but how that number is reached affects the MPS. If only two users hit the 1,000 with sporadic, high-volume printing, it’s different than five people using it regularly for smaller jobs.

When devices are eliminated, the customer relies more on the remaining equipment. Understanding these machines and properly maintaining them is important. “We want to make our devices better MPS citizens,” explains Pothos.

Device and document data serve another purpose—analytics. Xerox utilizes the information to track the customer’s progress and make adjustments to maximize efficiency. The company recently released a third analytic platform focused on the user. Called CompleteView User Analytics Tool, it evaluates users’ non-essential printing, how often they print, and the time of day they use the device.

Xerox also focuses on mobility—access as well as security. “We do see that customers want to work using mobile devices,” notes Pothos.

MPS Evolves
Print and document management needs continue to grow. New enterprises seek solutions, especially in segments where MPS penetration is low. Moreover, the market is ripe with early adopters looking for a more comprehensive solution.

Vendors approach MPS differently, but there is a common thread among market leaders. They take a broader view of their services. While programs manage devices and documents, they also play a role in efficient workflow and business practices.

Changes in business practices and IT affect the MPS landscape. Vendors are already adjusting their solutions because of greater mobile use, security concerns, and the demand for data analytics. MPS strategies that meet these needs will have the most success in the future. dps

Saddle Up

By Lisa Guerriero

High-speed finishing solutions offer customization and automation to streamline high-volume digital print operations served by inkjet. Saddle stitching systems are designed to handle these volumes, enabling applications including financial and healthcare documents, direct mail, and brochures, as well as testing booklets and other educational materials.

“Inkjet print providers need a saddle stitching solution that can take a pile of cutsheet product or a pre-printed roll from the press and automatically process it into a sellable, finished product with much less labor requirements and at much higher throughput rates,” says Andy Fetherman, director of digital solutions, Muller Martini Corp.

Inline and nearline stitching solutions produce between 4,500 and 14,000 booklets per hour. Robust construction and automation enable this productivity, even in 24/7 pressrooms.

Saddle stitching solutions expedite finishing for variable data workflows, providing controls like tracking and validation. Additionally, these systems are available for a variety of print operations, including hybrid environments comprised of digital and offset capabilities.

Accountability and Accuracy
Many saddle stitching systems incorporate validation and integrity solutions well suited to the variable nature of inkjet production. Barcodes, cameras, and other tracking functions provide accuracy.

“Many print providers are looking to produce products on inkjet with as few as four pages, or up to 200 pages or more—with or without a cover from a separate print stream. Tracking every page and every book is a feature that is requested due to personalization,” notes Neal Swanson, director, marketing communications, Standard Finishing Systems.

Tracking and validation capabilities allow print providers to ensure customized data is stored correctly and assigned to the right book. They enable books with varying page counts, check that pages are in the right sequence, and provide automated rejection or ejection of incomplete books.

“When dealing with variable data or jobs that require ultra-high integrity, a printer should be sure that the saddle stitcher can track book progress and accuracy,” suggests Ryan Manieri, marketing coordinator, MBO America.

For many booklet and small-book applications, the accountability of saddle stitchers is essential to delivering information securely. It’s not only a question of best practices, but of meeting legal requirements.

“Healthcare and examination booklets must only contain data specific to the recipient. In healthcare, there are severe penalties for mixing one person’s medical information with another in a booklet,” explain Don Piontek, digital finishing specialist, and John Cracknell, managing director, IBIS Bindery Systems, Ltd.

Focused Finishing
Saddle stitching is a cost-effective method of book binding, offering fast output for materials with a relatively short shelf life. However, these stitching systems must also be capable of applications where longevity and quality are important.

Flat, light books are in demand—whether a travel catalogue personalized for one individual or a periodical with a run size of several thousand.

“The advantage of saddle stitching is the method used to fold and stitch booklets. By scoring and plough folding, a saddle stitcher can produce much flatter booklets,” notes Anthony Gandara, product manager, Duplo USA.

Saddle stitchers’ narrow focus allows them to produce small books effectively, but limits print providers to one binding method for most devices. This precludes the square-bound books and booklets that some customers want.

Although saddle stitchers are capable of higher page counts than in the past—up to 200 pages—this method is still restricted to smaller books. The layflat quality sought by buyers is lost if the page count is too high or the paper stock too thin.

“If you can imagine a Bible or textbook being held together by staples along the spine, you’ll understand why saddle stitching really doesn’t make sense for a book of that size,” observes Manieri.

Thinner substrates are ideal for many small book applications. Companies looking to minimize mailing costs use lighter media, which is usually better suited to saddle stitching systems.

The drying systems often used in inkjet printing tend to leave paper susceptible to cracking and flaking, especially with heavier stock. Digital saddle stitching systems feature specialized scoring and creasing processes designed to limit cracking. Lighter media can also help mitigate the risk of cracking during finishing. Drying also causes static, which some stitchers address by including an anti-static component.

Stitching Solutions
Solutions are available to suit a variety of inkjet printing environments.

Duplo’s iSaddle system produces up to 4,500 booklets per hour and 400,000 per month. By adding two options—the DKT-200 Two Knife Trimmer and the Gutter Cut Module—productivity increases up to 9,000 booklets per hour for some two-up applications. It produces books up to 120 pages and features a loading capacity of 2.56 inches. The suction-based collating system features four towers that can be connected to maximize productivity.

The device and its folding and stitching method target high-speed inkjet production environments. “The iSaddle System neatly and accurately jogs each set prior to scoring and plough folding to ensure consistent and accurate folding,” says Gandara.

The system’s PC Controller software saves an unlimited number of jobs, which can be recalled to perform job changeovers in seconds with little or no operator intervention. The software controls air flow and vacuum for each bin to ensure consistent, reliable feeding. It also comes standard with the Intelligent Multi Bin Feed feature. It allows the operator to select which bins to feed from, set or change how many sheets feed from each bin, and in what sequence. The feature enables custom feeding, including pre-collated digitally printed documents.

The IBIS Smart-binder, models SB-2 and SB-3, create up to 7,000 books per hour, or 14,000 in two-up mode. Monthly volume is about one million. The system creates books of up to 200 pages on 70 gsm stock.

The solution folds each sheet individually for better layflat characteristics, rather than as a set, and varies the number of pages in each book automatically. It uses barcode or Datamatrix codes printed on each sheet for sheet and booklet tracking. “The IBIS Smart-binder includes a sophisticated embedded data tracking and logging system on the sheet level, which ensures 100 percent booklet integrity. If a booklet is rejected, data is provided upstream to allow it to be reprinted,” note Piontek and Cracknell.

The Smart-binder offers a built-in alternative, the ISG cold-gluing system. It replaces stitching wire with micro-dots of cold glue, giving end customers a staple-free option. It offers the same productivity as the stitching process on uncoated stock. Optional features for the Smart-binder include a sheet buffer module for inline use with IJ printers, offline sheet feeding, insert feeding, cover feeding, sheet perforation, and booklet stacking.

MBO’s offerings include Muller Martini’s Presto II Digital—which it recommends for commercial, digital, and hybrid workflows—and IBIS’ Smart-binder, for digital, variable data, and highly sensitive data. Both integrate with MBO’s digital finishing modules.

The company also advises using an upstream camera inspection system for jobs with sensitive information. “Systems like the Xcam from Baumer HHS can be integrated with nearly all MBO finishing solutions and can detect blank sheets, match patterns for accuracy, or read codes,” suggests Manieri.

Muller Martini’s Presto II Digital produces up to 9,000 copies per hour (cph) with pages up to .375 inches thick, while the Primera Digital produces 14,000 cph, with pages up to .5 inches thick.

A hybrid configuration is available for both models. It allows for handling variable content products from either a pile or a roll, while also processing traditional offset signatures with standard feeders on the same line. The solutions ensure the cover and content match for variable data production.

A barcode printed on every signature and cover contains a product ID that defines the job, a copy ID that ensures the correct sequence of the signatures, and a bundle ID for stacking. “These systems deliver customized products, which are optimally sorted by the various mailing routes on pallets to customers at very high production speeds,” explains Fetherman.

Standard’s Horizon StitchLiner6000 creates books up to 200 pages. It produces up to 6,000 per hour for books up to 24 pages. Integrated with the company’s Hunkeler UW6 unwinder and CS6 rotary cutter, the solution functions inline with continuous-feed inkjet and digital presses or offline when the application calls for feeding pre-cut sheets or stacks from another nearby print engine.

Based on the StitchLiner technology platform, the system offers inline cover feeding and non-stop booklet production on a range of paper stocks at up to 600 feet per minute. It produces variable sheet-count booklets using barcode scanning or mark reading.

The StitchLiner6000 features an icon-based color touch screen control and a fully automated setup, including folder roller gap settings. It is designed for ease of use, allowing the same operators who run the printer to easily manage post-press functions. Precise stepper motors drive the solution’s systems—including end stops, side guides, and stitching heads—to the exact location for the sheet size and finish style selected.

VITS International offers a single- or double-web system that integrates with saddle stitchers from any manufacturer. The Sprint Variable Data Saddle Finishing System (VDSFS) increases throughput by running multiple webs into the stitcher. It allows printers to take one or two preprinted rolls, slit and merge ribbons, cut and deliver, and collate directly onto the saddle.

Depending on the width and number of webs, each cut of the cutting cylinder can deliver a four-, eight-, 12-, or 16-page signature to the stitcher. The system increases the rate of book production, allowing for maximum utilization of the stitching device.

“The Sprint VDSFS is a VITS exclusive, as no other finishing manufacturer delivers multiple webs in register direct to the saddle stitcher. This technology offers printers the ability to increase productivity and open new markets for saddle stitched products,” says Nick Gerovac, director of sales and marketing, VITS International.

Binding for Efficiency
Saddle stitching systems feature speed, automation, and variability to complement the growing high-speed production inkjet market. “Inkjet technologies have breathed new life into a well-established form of finishing. Inkjet web allows for the personalization and variability that marketers covet, and integrating this with a proven format can be powerful,” observes Gerovac. dps