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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
3
KBA: the world’s first press manufacturer
First cylinder press, 1812
First inkjet web press, Drupa 2012
• 1807-1812: Friedrich Koenig built the first cylinder
printing press in London
• In 1814 The Times in London became the first
newspaper in history to be printed by machine –
Koenig’s double-cylinder press
• In 1817 Koenig & Bauer started up the world’s first
printing press factory in Oberzell, near Würzburg
• 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
© KBA
KBA: technological leader with strong market position • 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 commercial) approx. €630m
Sheetfed offset approx. €2.7bn
Flexo, gravure, screen approx. €700m
Digital** (presses only) approx. €1.3bn
Market volume in 2015 approx. €5.5bn
Web offset approx. €400m
Sheetfed offset approx. €2.5bn
Flexo, gravure, screen approx. €750m
Digital** (presses only) approx. €1.8bn
**estimated number of toner and inkjet presses for industrial printing plants (excluding copiers, consumables and service)
- 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
07/2013 KBA - Print Promotion - 2014
Strong growth in packaging sector in the near future
* Source: PRIMIR/NPES, World Wide Market for PRINT 2008 - 2014 Update
• Internet is reducing print and advertising market volumes in the newspaper, magazine and catalogue sectors
• The trend to eReader like iPad, Kindle or others is responsible for the decline in book printing • Packaging, label, film printing are classic growth markets and are scarcely affected by the internet and digital printing (apart from labels)
5.5% 6.4%
10%7.4%
5%
29%
36.7%
4.8% 4.6%
9.5%
6.2%4.6%
34%36.3%
0%
5%
10%
15%
20%
25%
30%
35%
40%
Books Catalogues Magazines Newspapers Advertising Packaging Other
20082014
Global print market * by product 2008-2014
KBA - Print Promotion - 2014
KBA - Print Promotion - 2014
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
Does KBA come to mind when looking at these products?
Examples from KBA customers KBA - Print Promotion - 2014
Sheetfed Offset for Packaging
Web printing Bank notes / Security
Marking and
Coding
Flexible
Packaging
Metal /
Coated steel Glass
Machinery business
Construction / Project
business
Construction / Systems
Systems business
Machinery business
Construction / Project
business
Machinery business
• Small-, medium- and large-format presses for packaging, book, poster, display and commercial printers
• Small and medium-sized print runs in premium quality
• Substrates from light-weight paper to corrugated board plus plastics
• Web offset presses for newspapers, inserts, magazines, catalogues, flyers, books, brochures in higher print runs
• Inkjet digital web press for books, direct mail, advertising, newspapers from one copy to medium-sized editions
• Special printing presses with varied printing processes such as intaglio for printing bank notes
• Special security technology and systems for pre-press, quality control, post-press
• Bank note design service
• Inkjet, laser, hot stamping and thermal transfer solutions for marking and coding
• Marking and coding on very varied substrates such as synthetics, plastic film, glass, ceramic, board
• Packaging presses for flexible, non-absorbent materials such as foil
• Varius 80 web offset press for shorter runs
• Flexo presses offered by Flexotecnica for higher print runs
• Solutions supplier for printing, coating, drying and metal sheet logistics
• Systems for air purification
• Application in packaging segments: food, cosmetics, tobacco
• Presses for decorating hollow containers made from premium-quality glass, plastic and metal
• Directly decorated glass containers are mainly used for cosmetics, perfume and spirituous beverages in the top price class
Targ
eted
mar
kets
Pr
oduc
ts
Type
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Special solutions for the packaging sector
Portfolio includes high-tech printing / systems solutions
KBA - Print Promotion - 2014
Sheetfed offset presses for
packaging, book, commercial and poster
printing
Web offset presses for newspaper, magazine, catalogue and commercial printing
Metal-decorating solutions for packaging (coating, printing etc.) made of aluminum and coated steel
Special solutions for
bank note design and production,
security printing
Industrial marking and coding systems on synthetics, film, glass, ceramics, cartons
Services, spare parts, retrofits, upgrades
14
Contribution of market segments to KBA sales
Estimated sales for individual sectors
15%
40%
20%
~ 5%
~ 5%
15%
KBA - Print Promotion - 2014
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!
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
Sheet-fed presses from small to super large format
KBA - Print Promotion - 2014
Innovations for print KBA Rapida 106: world’s fastest press and makeready champion in B1 format
• Medium-format press with the maximum level of automation to support simultaneous makeready processes
• Flying job changes and pre- and post-perfect coating in four-over-four production
• Coater with simultaneous forme change and anilox roller loader
• Maximum rated speed 20,000sph in straight mode, 18,000sph in perfecting mode
KBA - Print Promotion - 2014
KBA speciality: long presses for packaging
• The commercial market is suffering in many countries, the packaging market is still growing
• Historically KBA is very strong in packaging with its medium- and large-format presses
• In 2013 more than 60% of all Rapidas went to packaging printers around the world
• 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
• 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
• 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
• 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 • Networking of press control, nonstop pile changing systems and pallet supply for efficient print
production
• Proven logistics modules, elaboration of customer-specific solutions with RFID-controlled
logistics and warehousing
• 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
• KBA enters the growing flexible packaging market
• The new Varius 80 variable-format web offset press built by KBA-Meprint targets packaging printers with non-absorbent flexible materials
• 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
• Acquisition of Kamman, a German packaging specialist offering screen presses for decorating hollow containers made from premium-quality glass, plastic and metal
• Set up of a cross-process engineering and workflow competence in the packaging production
• Investigation of further printing-related market segments for packaging
KBA - Print Promotion - 2014
Strategic Focus on Packaging
• KBA-MetalPrint has a strong position in metal decorating and is market and technology leader in premium printing and coating systems
• Applications primarily for packaging: food, cosmetics (Nivea tins), cigars etc.
• Portfolio: printing, coating, drying and logistics systems for metal sheets, air purification systems
• Activities will be expanded with newly developed products and solutions
KBA - Print Promotion - 2014
Strategic Focus on Packaging
• KBA-Metronic has a strong technology position in digital and analogue marking and coding systems
• Growth potential by increased internationalization and new products
• Extension of the product portfolio for packaging systems (Coding, Branding, Marking)
KBA - Print Promotion - 2014
• 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
Strategic Focus on Packaging (Sheetfed offset presses)
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
3 1 9 5 10 2
4 6 7 8
KBA - Print Promotion - 2014
• 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
Strategic Focus on Packaging (Sheetfed offset presses)
KBA - Print Promotion - 2014
Automation concept for make ready savings
CleanTronic
CleanTronic Synchro CleanTronic Multi CleanTronic UV CleanTronic Re Ink
Quality Management
ErgoTronic QualiTronic
DriveTronic
DriveTronic Feeder DriveTronic SIS DriveTronic SPC DriveTronic PlateIdent DriveTronic SFC
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
VariDry
VariDry IR/ TL VariDry Blu VariDry UV VariDry HR-UV VariDry LED-UV VariDry Inert UV
KBA - Print Promotion - 2014
DriveTronic SIS / Sensoric Infeed System
DriveTronic SIS = Sensoric Infeed System • No setting errors, as no settings to make • Longer period of rest for sheet alignment • Reduced make ready time • Marking-free Cost advantages through • Fewer production stoppages and higher productivity
USP
KBA - Print Promotion - 2014
DriveTronic SPC / simultaneous plate change system
• All units in ca. 50 seconds
• 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
Designation No. of washing bars Process System
CleanTronic 1 mobile washing bar blanket & impression blanket & rollers
Serial synchronous
CleanTronic Synchro 2 washing bars 1 x blanket 1 x impression
blanket & impression Blanket & rollers
synchronous synchronous
blanket, impression, rollers synchronous
CleanTronic CleanTronic Synchro
KBA - Print Promotion - 2014
CleanTronic ReInk
Roller washing is now absolute independent • High speed roller washing with auxiliary drive • Duration between 1 - 1,5 minutes* • Option: operation during production Roller washing possible during • Blanket washing • Impression cylinder washing • Coating form change • Production
USP
KBA - Print Promotion - 2014
KBA VariDry dryer technology - overview
• IR/ Hot Air- Dryer for conventional inks and water-based varnish
• UV-dryer for UV inks and UV varnish (UV, GA-UV, OzonFree-UV)
• Combination dryer for hybrid presses (IR/TL/UV)
• Special UV-dryer for high reactive inks (HR-UV, LED-UV, UV-Inert)
KBA - Print Promotion - 2014
People & Print
Rapida 106 – Concept for energy saving KBA VariDryBlue
Rapida 106 / KBA VariDryblue
KBA VariDryblue: Lowest energy consumption in its class • Still unsaturated hot air from Modules 1 and 2 returned to Module 3
• Reduction of power consumption and waste air volume by approx. 50%
• Heat register integrated in the extension (short distance to the hot air knifes)
USP
KBA - Print Promotion - 2014
Production forme • Pantone 4975 + Pantone 1665 + CMY + conventional coating • Ink coverage: 53.65% • Production speed: 13,000 sheets / h • Anilox roller 100 L/cm; Volume 12.0 cm³/m² • Dryer: 30°C temperature in pile • Substrate: GD2 300 g/m²
Comparison of dryer efficiency
Example calculation without obligation
Rapida 106-9+L SW4
KBA - Print Promotion - 2014
Comparison dryer efficiency
Planned capacities KBA VariDry Blue Standard dryer Working days per year 251 251
Shifts a day 3 3
Working hours per shift 7,4 7,4
Production hours per year 5.015 5.015
Measurement results KBA VariDry Blue Standard dryer Measured energy consumption (kWh) 33 70
Energy consumption kWh/ year 165.495 351.050
Energy costs in € pro kWh 0,10 0,10
Energy costs per Jahr in € 16.550 € 35.105
CO2-emission (t/Jahr) 102,10 216,6
Possible savings KBA VariDry Blue
Energy saving (kWh/ year) 188.555 -
Energy saving (%) 53 -
Cost saving (€/year) 18.555 -
CO2-reduction (t / year) 114,5 -
Example calculation without obligation KBA - Print Promotion - 2014
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 Inline - QualiTronic
DensiTronic PDF
ErgoTronic ICR
ErgoTronic ACR
ErgoTronic ColorDrive
ErgoTronic ColorControl
Register Control
Color Control
Inspection
QualiTronic ICR
QualiTronic ColorControl
QualiTronic Professional KBA - Print Promotion - 2014
People & Print
KBA Services – Complete workflow solutions Process Automation – JDF/JMF Networking
KBA Services: Complete production workflow
MIS
"A special printhouse workflow cannot be bought – it needs to be developed!"
KBA - Print Promotion - 2014
Complete workflow solutions – Summary
• Job data passed through from the branch software
to the press console
• Single point of data acquisition and input, no errors
due to multiple points of input
• Full control and analysis of the production process
in real time
• Increased productivity through faster makeready
• Exact consumption records enable optimized
materials management
• Precise statistical cost accounting and effective
controlling
• 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
Koenig & Bauer AG www.kba.com
Thank you! Any interest? Please contact us!
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