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People & Print KBA – Trendsetter in Printing Technology Roland Gebauer, KBA - Sales Manager for UK/ Ireland / South Africa / KBA NOTASYS-Security Printing KBA: the world’s first press manufacturer ã 1807-1812: Friedrich Koenig built the first cylinder printing press in London ã In 1814 The Times in London became the first newspaper in history to be printed by machine – Koenig’s double-cylinder press ã In 1817 Koenig & Bauer started up the world’s first First cylinder press, 1812 printing press factory in Oberzell, near Würzburg ã 200 years after the mechanical printing press was invented the group is moving into the high-growth digital print market with the KBA RotaJET 76 First inkjet web press, Drupa 2012 © KBA 3 KBA: technological leader with strong market position ã ã ã ã ã ã ã Second-biggest manufacturer of printing presses worldwide with sales of some €1.3bn and around 6,000 employees Extensive, highly advanced product portfolio for volume and niche markets Top innovator and technological trailblazer in many areas No. 1 in web offset (newspapers, commercials) No. 1 in large-format sheet-fed offset (no. 2 overall) No. 1 in packaging offset, security printing and metal decorating Mover and shaker in green printing KBA - Print Promotion - 2014 People & Print The today’s market situation Global press market by segments Market volume in 2013 approx. €5.3bn Web offset (newspaper and Sheetfed offset commercial) approx. €2.7bn Flexo, gravure, screen approx. €700m Digital** (presses only) approx. €1.3bn approx. €630m Market volume in 2015 approx. €5.5bn Web offset Sheetfed offset approx. €400m approx. €2.5bn Flexo, gravure, screen approx. €750m Digital** (presses only) approx. €1.8bn - The enhanced productivity of modern, automated presses reduces additional market volume/growth - The digital printing business mainly comprises of over 50% consumables and service contracts - not included here **estimated number of toner and inkjet presses for industrial printing plants (excluding copiers, consumables and service) KBA - Print Promotion - 2014 07/2013 Strong growth in packaging sector in the near future ã Internet is reducing print and advertising market volumes in the newspaper, magazine and catalogue sectors ã The trend to eReader like iPad, Kindle or others is responsible for the decline in book printing ã Packaging, label, film printing are classic growth markets and are scarcely affected by the internet and digital printing (apart from labels) 40% Global print market * by product 2008-2014 36.7% 36.3% 34% 35% 29% 30% 25% 2008 20% 2014 15% 10% 9.5% 10% 5% 5.5% 4.8% 7.4% 6.4% 6.2% 4.6% 5% 4.6% 0% Books KBA - Print Promotion - 2014 Catalogues Magazines Newspapers Advertising Packaging Other * Source: PRIMIR/NPES, World Wide Market for PRINT 2008 - 2014 Update Strategic Core Areas 1. Strategic Focus on Packaging 2. Reorganisation Newspaper & Commercial 3. Entering Digital Printing 4. Strong Base Security Printing 5. Focus on Emerging Markets 6. Becoming a Full Service Provider 7. KBA: The Easiest Company to Deal with KBA - Print Promotion - 2014 Does KBA come to mind when looking at these products? Examples from KBA customers KBA - Print Promotion - 2014 Portfolio includes high-tech printing / systems solutions Special solutions for the packaging sector Web printing Bank notes / Security Machinery business Construction / Project business Construction / Systems ã Web offset ã Special Marking and Coding Flexible Packaging Metal / Coated steel Systems business Machinery business Construction / Project business Glass Type Products Sheetfed Offset for Packaging Targeted markets ã Small-, medium- and large-format presses for packaging, book, poster, display and commercial printers ã Small and medium-sized print runs in premium quality presses for newspapers, inserts, magazines, catalogues, flyers, books, brochures in higher print runs ã Inkjet digital ã Substrates from lightweight paper to corrugated board plus plastics KBA - Print Promotion - 2014 web press for books, direct mail, advertising, newspapers from one copy to mediumsized editions printing presses with varied printing processes such as intaglio for printing bank notes ã Special security technology and systems for pre-press, quality control, post-press ã Bank note design service ã Inkjet, laser, hot stamping and thermal transfer solutions for marking and coding ã Marking and coding on very varied substrates such as synthetics, plastic film, glass, ceramic, board ã ã ã Packaging presses for flexible, nonabsorbent materials such as foil Varius 80 web offset press for shorter runs Flexo presses offered by Flexotecnica for higher print runs ã Solutions supplier for printing, coating, drying and metal sheet logistics ã Systems for air purification Machinery business ã Presses for decorating hollow containers made from premiumquality glass, plastic and metal ã Application in ã Directly decorated packaging segments: food, cosmetics, tobacco glass containers are mainly used for cosmetics, perfume and spirituous beverages in the top price class 13 Contribution of market segments to KBA sales Sheetfed offset presses for packaging, book, commercial and poster printing Web offset presses for newspaper, magazine, catalogue and commercial printing 15% Metal-decorating solutions for packaging (coating, printing etc.) made of aluminum and coated steel 40% ~ 5% Special solutions for bank note design and production, security printing 20% Estimated sales for individual sectors KBA - Print Promotion - 2014 Industrial marking and coding systems on synthetics, film, glass, ceramics, cartons ~ 5% Services, spare parts, retrofits, upgrades 15% 14 Sheet-fed presses from small to super large format Sheetfed KBA Genius 52UV KBA Rapida 75 KBA Rapida 76 KBA Rapida 105 KBA Rapida 106 KBA Rapida 145 KBA Rapida 164 KBA Rapida 185 KBA Rapida 205 Wide range of sheet-fed offset machines: small (360 x 520 mm) to super large format (1510 x 2050 mm) for commercials, books, posters and packaging. KBA Radebeul is the world market leader in large format! KBA - Print Promotion - 2014 Innovations for print KBA Rapida 106: world’s fastest press and makeready champion in B1 format ã Medium-format press with the maximum level of automation to support simultaneous makeready processes ã Flying job changes and pre- and post-perfect coating in four-over-four production ã Coater with simultaneous forme change and anilox roller loader ã Maximum rated speed 20,000sph in straight mode, 18,000sph in perfecting mode KBA - Print Promotion - 2014 KBA speciality: long presses for packaging ã The commercial market is suffering in many countries, the packaging market is still growing ã Historically KBA is very strong in packaging with its medium- and large-format presses ã In 2013 more than 60% of all Rapidas went to packaging printers around the world ã Long presses for UV or Hybrid printing with inline-coating and cold-foil module like this 14-unit Rapida for Bulgaria are becoming more popular in Europe ã In the meantime KBA installed presses with energy-saving HR- and LED-UV dryers, e.g. at commercial printers in France and Benelux Presses like this RA 106 SIS-10+L+T+T+L ALV2 450 mm raised for Bulgaria, with inline-coating and cold-foil equipment, becoming more popular in Europe KBA - Print Promotion - 2014 Innovations for print KBA Rapida 145: fastest large-format press with the shortest makeready times on the market ã ã Maximum rated speed of 17,000sph straight and 15,000sph in perfecting mode Automation modules originally engineered for the world makeready champion Rapida 106, now in large format ã The Rapida 145 and 164 reaffirm KBA’s pole position in large format and packaging printing KBA - Print Promotion - 2014 Innovations for print Enhanced efficiency and flexibility thanks to automation Automatic nonstop systems at the feeder and delivery of the KBA Rapida sheetfed presses, integration in an automated pile-logistics system ã Networking of press control, nonstop pile changing systems and pallet supply for efficient print production ã Proven logistics modules, elaboration of customer-specific solutions with RFID-controlled logistics and warehousing ã Automating pile logistics for bulky substrates (cardboard, corrugated) can deliver substantial productivity gains in high-volume production KBA - Print Promotion - 2014 People & Print Strategic Focus on Packaging Strategic Focus on Packaging ã KBA enters the growing flexible packaging market ã The new Varius 80 variable-format web offset press built by KBA-Meprint targets packaging printers with non-absorbent flexible materials ã Acquisition of Flexotecnica, a popular Italian manufacturer of central-cylinder flexo presses for printing on various flexible packaging materials KBA - Print Promotion - 2014 Strategic Focus on Packaging ã Acquisition of Kamman, a German packaging specialist offering screen presses for decorating hollow containers made from premium-quality glass, plastic and metal ã Set up of a cross-process engineering and workflow competence in the packaging production ã Investigation of further printing-related market segments for packaging KBA - Print Promotion - 2014 Strategic Focus on Packaging ã KBA-MetalPrint has a strong position in metal decorating and is market and technology leader in premium printing and coating systems ã Applications primarily for packaging: food, cosmetics (Nivea tins), cigars etc. ã Portfolio: printing, coating, drying and logistics systems for metal sheets, air purification systems ã Activities will be expanded with newly developed products and solutions KBA - Print Promotion - 2014 Strategic Focus on Packaging ã KBA-Metronic has a strong technology position in digital and analogue marking and coding systems ã Growth potential by increased internationalization and new products ã Extension of the product portfolio for packaging systems (Coding, Branding, Marking) KBA - Print Promotion - 2014 Strategic Focus on Packaging (Sheetfed offset presses) ã ã ã ã KBA is the technological and market leader in packaging printing on sheetfed offset presses 60 % of our customers are packaging printers Our target is to expand our leading market position Our philosophy: Customized solutions for packaging printers A straight-on press with 19 printing and finishing units – including cold foil – and a total length of 35 meters at Amcor Tobacco Packaging in Rickenbach, Switzerland KBA - Print Promotion - 2014 Special press configurations / Rapida 106 with 19 units 1. Coating unit (Aqueous / UV) with DriveTronic SFC and Anilox-Loader 2. Dryer units / VariDry hot air / UV 3. ColdFoil Infigo SF110 4. 10 printing units with DriveTronic SPC / PlateIdent / CleanTronic Synchro 5. Coating unit (Aqueous / UV) with DriveTronic SFC and Anilox-Loader 6. Dryer units / VariDry hot air / UV 7. Coating unit (Aqueous / UV) with DriveTronic SFC and Anilox-Loader 8. UV Inert final dryer with KBA AirTronic drum 9. Quality control / QualiTronic Professional 10. KBA VariDry-Technology / - VariDry Blue hot air, UV final dryer + Infra red 10 9 8 7 6 3 5 4 KBA - Print Promotion - 2014 2 1 Strategic Focus on Packaging (Sheetfed offset presses) ã KBA is the technological and market leader in packaging printing on sheetfed offset presses drupa 2000: long perfecting press in South Africa; installed in 2001 First RA 145-6+L in South Africa; installed in 2013 KBA - Print Promotion - 2014 Automation concept for make ready savings Cutting edge technology and constant innovation for top performance, flexibility and economic efficiency State-of-the-art automation modules for saving makeready times, less waste and best quality in print DriveTronic DriveTronic DriveTronic DriveTronic DriveTronic PlateIdent DriveTronic Feeder SIS SPC SFC KBA - Print Promotion - 2014 CleanTronic CleanTronic CleanTronic CleanTronic CleanTronic Synchro Multi UV Re Ink Quality Management ErgoTronic QualiTronic VariDry VariDry IR/ TL VariDry Blu VariDry UV VariDry HR-UV VariDry LED-UV VariDry Inert UV DriveTronic SIS / Sensoric Infeed System USP DriveTronic SIS = Sensoric Infeed System ã ã ã ã No setting errors, as no settings to make Longer period of rest for sheet alignment Reduced make ready time Marking-free Cost advantages through ã Fewer production stoppages and higher productivity KBA - Print Promotion - 2014 DriveTronic SPC / simultaneous plate change system ã All units in ca. 50 seconds ã Plate changing parallel to other make ready processes possible: - washing of printing and coating unit - format settings - all preadjustments KBA - Print Promotion - 2014 Overview of KBA washing device CleanTronic CleanTronic Synchro Designation No. of washing bars Process System CleanTronic 1 mobile washing bar blanket & impression Serial blanket & rollers synchronous 2 washing bars blanket & impression synchronous 1 x blanket Blanket & rollers synchronous 1 x impression blanket, impression, rollers synchronous CleanTronic Synchro KBA - Print Promotion - 2014 CleanTronic ReInk USP Roller washing is now absolute independent ã High speed roller washing with auxiliary drive ã Duration between 1 - 1,5 minutes* ã Option: operation during production Roller washing possible during ã Blanket washing ã Impression cylinder washing ã Coating form change ã Production KBA - Print Promotion - 2014 KBA VariDry dryer technology - overview IR/ Hot Air- Dryer for conventional inks and water-based varnish ã UV-dryer for UV inks and UV varnish (UV, GA-UV, OzonFree-UV) ã Combination dryer for hybrid presses (IR/TL/UV) ã Special UV-dryer for high reactive inks (HR-UV, LED-UV, UV-Inert) ã KBA - Print Promotion - 2014 People & Print Rapida 106 – Concept for energy saving KBA VariDryBlue Rapida 106 / KBA VariDryblue USP KBA VariDryblue: Lowest energy consumption in its class ã Still unsaturated hot air from Modules 1 and 2 returned to Module 3 ã Reduction of power consumption and waste air volume by approx. 50% ã Heat register integrated in the extension (short distance to the hot air knifes) KBA - Print Promotion - 2014 Comparison of dryer efficiency Production forme ã Pantone 4975 + Pantone 1665 + CMY + conventional coating ã Ink coverage: 53.65% ã Production speed: 13,000 sheets / h ã Anilox roller 100 L/cm; Volume 12.0 cm³/m² ã ã Dryer: 30°C temperature in pile Substrate: GD2 300 g/m² Rapida 106-9+L SW4 KBA - Print Promotion - 2014 Example calculation without obligation Comparison dryer efficiency KBA VariDry Blue Standard dryer 251 251 3 3 7,4 7,4 5.015 5.015 KBA VariDry Blue Standard dryer 33 70 165.495 351.050 Energy costs in € pro kWh 0,10 0,10 Energy costs per Jahr in € 16.550 € 35.105 102,10 216,6 Planned capacities Working days per year Shifts a day Working hours per shift Production hours per year Measurement results Measured energy consumption (kWh) Energy consumption kWh/ year CO2-emission (t/Jahr) Possible savings Energy saving (kWh/ year) Energy saving (%) Cost saving (€/year) CO2-reduction (t / year) KBA - Print Promotion - 2014 KBA VariDry Blue 188.555 - 53 - 18.555 - 114,5 Example calculation without obligation People & Print Quality Management Innovations for print Enhanced efficiency thanks to inline quality control Cutting-edge inline quality measuring technology – closed loop system QualiTronic Professional inspects the sheets and tags faulty images Online - ErgoTronic Register Control ErgoTronic ACR ErgoTronic ICR Color Control Inspection KBA - Print Promotion - 2014 Inline - QualiTronic QualiTronic ICR ErgoTronic ColorDrive ErgoTronic ColorControl QualiTronic ColorControl DensiTronic PDF QualiTronic Professional People & Print KBA Services – Complete workflow solutions Process Automation – JDF/JMF Networking KBA Services: Complete production workflow A special printhouse workflow cannot be bought – it needs to be developed! MIS KBA - Print Promotion - 2014 Complete workflow solutions – Summary ã Job data passed through from the branch software to the press console ã Single point of data acquisition and input, no errors due to multiple points of input ã Full control and analysis of the production process in real time ã Increased productivity through faster makeready ã Exact consumption records enable optimized materials management ã Precise statistical cost accounting and effective controlling ã Optimum integration of KBA presses into a continuous JDF workflow Profitable production through efficient processes! KBA - Print Promotion - 2014 KBA: The Easiest Company to Deal with! KBA - Print Promotion - 2014 People & Print Thank you! Any interest? Please contact us! Koenig & Bauer AG www.kba.com
