Prepress

Excellently networked with printnetwork

Tuesday 15. May 2012 - New operating concept optimizes the entire production process

printnetwork by manroland web systems truly lives up to its name – it handles even more networking, control, and monitoring functions in the pressroom for the efficient application of resources.
Printing press technology must be integrated into an efficient workflow to utilize its full capacities. The completely new One Touch operating concept by manroland web systems contributes to this process. The co-operations with ABB and ppi Media, create interfaces between order preparation, prepress, printing, and postpress operations. Other pioneering developments include printnetwork Bridge by manroland web systems and Océ – offering for the first time a continuous digital printing workflow including a folding unit in the finishing stage.
New operating concept – intelligent intuitive control
The unique autoprint functions of manroland web systems now have an equally unique operating concept – One Touch is the general operating philosophy that guides the Web 2.0 generation of press operators. The operator receives all relevant information at a glance and works with intuitive touch control. The entire printing system is controlled from a central control console via touch-screen. Anytime and anywhere. This increases the control speed and taps productivity. The press operator is ultimately elevated to a production process and quality control manager. The manroland developers focused on reducing complexity and creating flexibility – the multi-touch operation of the ControlCenter, the MobilPad as an added mobile control console, and the UnitPad for operating printing units during service work on the presses come together to form an optimally aligned system. The printnetwork system and PECOM process electronics work in the background to create a highly automated printing process. The operating concept is future-proof – individual parts or the entire system can be retrofitted onto older manroland webfed presses.
The press operator can control all aggregates with the ControlCenter. A single multi-touch-screen, the ControlPad, displays the current status of all integrated components in the printnetwork system. Settings can be adjusted directly on the touch-screen, saving time and reducing waste. A second ControlPad can be added for additional equipment. Two screens are optionally available to newspaper press operators for the Softproof display of newspaper pages, allowing the operator to choose between the PressProof screen for the content control of the newspaper product or the TrueColorProof screen for additional color quality check. A special TrueColorProof solution is available for commercial printhouses. Quality management can rely on the SlidePad, the modern successor to keypad-based ink key positioning, which slides along a rail at the bottom of the ControlDesk. It allows the quick adjustment of all product-related register settings (color, water, registers), reducing waste. The operation and display of further inline control systems can also be integrated in the SlidePad.
MobilPad is the control console for on-the-go use. A TabletPC is connected via WLAN to the control console PC. The operator can simply take it along for adjustment operations in the folder superstructure or on the folder. This saves time during production changeovers in the folder superstructure and reduces waste occurring when fine-tuning the folder quality at the delivery. The functions of the control keypads on the individual printing units are taken over by the portable UnitPad with touch-screen. The UnitPad is integrated in the printnetwork system via a data cable, allowing it to reliably receive WLAN signals between the printing units.
autoprint – welcome to the world of full automation
The new operating concept improves the utilization of the autoprint functions by newspaper and commercial printhouses. Everything practically proceeds by itself in the autoprint mode, as the menu guides through the printing process like a navigation device. Background control processes are hidden; the operator can concentrate on controlling standardized product quality. Approximately 80 percent of production runs at an autoprint newspaper publisher do not require any manual interventions. The press operator only optionally intervenes with the production parameters in the expert mode. APL and APL logistics are the basic modules for autoprint systems. They automate plate changes and plate transport within the press and are fully configured, nearly eliminating the need for manual interference by the printer. APL logistics not only governs plate transport in the press, but also controls and coordinates the earlier stage of plate production. With APL sequence, the plates are exposed in the optimum sequence for transport and printing. The operator can also use the monitor to track plate transport using APL control and manually intervene in the process if necessary.
AUROSYS – nonstop material supply
To function efficiently, autoprint automation processes require fast paper supply. The modular AUROSYS system accelerates the material logistics in webfed offset printshops. Starting with automatic truck loading, the system’s performance range includes storage, unpacking, reel preparation for splicing, automatic reel splicer supply, as well as disposal of butt reels, sleeves, and waste. Palette handling can also be automated with AUROlog as the distribution center that networks the individual AUROSYS modules. The PECOM process control is also integrated, providing AUROSYS with the production information. Other integration stages include the networking with the workflow management system printnetwork and through interfaces with external systems such as finance tools or electronic trading systems. For status updates, tracking, and reporting of material logistics.
Everything on the radar with printnetwork Cockpit
The networking software solutions by ABB or ppi Media provide perfect interfaces. The partnerships with these providers resulted in the new printnetwork Cockpit. This tool assists in planning prepress and print jobs as well as finishing and postpress orders. With the Insert Manager module, the printnetwork Cockpit can also record supplement orders, take over the selection of distribution areas and target groups, as well as storage and supplement management. Based on current sales data, the DeliveryPlanner defines the order delivery and transport jobs. The system not only calculates availability, but other key parameters as well, such as the permissible loading weight of transport vehicles.
printnetwork Bridge: integrated postpress processes in the digital printing workflow
printnetwork Bridge by manroland web systems and Océ is the solution for comprehensive digital printing networking. The workflow consistently automates the postpress process, by e.g. integrating one of the new book and signature folders or a digital pin folder by manroland web systems. The cornerstone of the Bridge concept are the automatic job transfer via JDF/JMF, testing these jobs, automatic adjustment of the folding components as well as in the future interfaces to postpress units of other manufacturers or MIS systems. Operation is via a user interface that can be intuitively controlled via touchscreen. What takes place within the digital printing workflow? The Prisma software by Océ uses JDF to provide the printnetwork Bridge with order data including imposition patterns, folding information, print runs, etc. The Bridge software reviews the jobs, while constantly communicating with the workflow of the digital printing press and automatically adopts the settings of the folding system based on the job information. The open interface of the JDF communication offers the option of also integrating components by other manufacturers and offline finishing into the workflow in the future. Integrated tracking solutions will round off the automation process to include the post press stage.