Offset Printing
printservices success story: Retrofits and Upgrades – for increased service life and optimized performance
Thursday 23. October 2014 - manroland web systems ensures the economic viability of newspaper production with retrofits and upgrades
“An unavoidable yet successful heart surgery”, is how Carlo Hoffman, Production Manager at Imprimerie Saint-Paul in Luxembourg City, refers to the retrofit of the 17-year old COLORMAN system. “The investment did not increase the size or speed of the press, but it is the prerequisite to ensure reliable production for at least 10-15 years. And all this at a fraction of the cost of a new purchase.”
Reliability and custom-made solutions fulfill long-term production needs
The Imprimerie Saint-Paul, a medium-sized publishing house that mainly publishes the Luxemburger Wort newspaper with a daily circulation of around 67,000 copies, is not the only company to take this step. An increasing number of operators of high-quality newspaper press systems from manroland web systems are relying on retrofit projects to maintain their production facilities in the long run and to pave the way for the sustainable further development of their core newspaper business. Their first choice is always manroland web systems as the manufacturer of the systems. The technical expertise and reliability coupled with the large range of customizable package solutions offer advantages that speak clearly in favor of the world market leader for webfed printing systems. The dependable construction quality is another plus: “The new system works reliably and to date, there has not been a single technical defect,” states Hoffmann about his experience with the retrofitted COLORMAN one year after conclusion of the work.
PECOM PressManager (PPM):
Putting the production manager in charge of all planning and controls
Kurt Kribitz, Managing Director of print group Styria in Austria, had similar positive experiences. The company decided one year ago to retrofit its newspaper printing presses. “As a leading publishing house we need high production reliability to maintain our printing quality and improve the production cost structure. That’s why we have developed a retrofit program in collaboration with manroland web systems.” The printing house’s presses will be equipped with the latest PECOM control systems. In addition, individual quality assurance measures are introduced. This improves press availability and allows all data to be consolidated in the PPM. This enables the production manager to plan and control the technical workflow. Günter Braun, Service Manager for Northern and Eastern Europe at manroland web systems, developed the concept in cooperation with Styria: “At Styria, networked thinking is important; that means including all locations in an integrated planning approach. In this project, we worked very closely with the customer to understand their production needs and recommend the best possible features.”
Best-selling e-retrofits from manroland web systems
“Control and operation retrofits are currently especially popular among users of the newspaper printing presses from manroland web systems,” explains Anton Happacher, who is in charge of customers in Germany, Austria, and Switzerland.
The hardware and electronics, as well as the software of the drive control and operation, becomes technically outdated much faster than the mechanical components that are designed for decades of continuous use. This is why manroland web systems has developed retrofit packages especially for this need. An offer that has been well received. During the past 3 years alone, the PECOM controls, operating elements, drives and their controls, Interbus loops, or diagnosis and control systems of more than 30 customers were brought up to date. “This allows customers to reliably operate their print systems for the next 10 to 15 years. In many cases, an e-retrofit manages to replace a new investment,” says Happacher.
Global success
The majority of manroland web systems’ service projects are for small and medium-sized printing houses. As the world market leader for webfed printing systems, manroland web systems also has the expertise and the capacity to reliably and successfully carry out large retrofit projects around the globe within the required deadlines. For example, the Australian News Corp decided to replace all control systems and control panels of the COLORMAN and NEWSMAN 40 presses in Brisbane, Sydney, and Townsville. The conversion was implemented in a 2-shift operation to ensure punctual publishing of the daily newspapers.
Turning one into four
Another large retrofit and update project is currently underway in Australia at Fairfax Newspapers. The publishing house is distributing the modules of the COLORMAN system of Melbourne across a total of four locations, one of which is based in New Zealand. At the same time, the presses are equipped with completely new controls, and made ready for additional production options such as heatset printing while the web width is adjusted to current requirements. The project is expected to be completed in 2015.
From broadsheet to tabloid
Similarly, De Telegraaf, the Netherlands’ only nationwide popular newspaper, follows the current trend of the newspaper sector and is investing in more product diversity based on the existing COLORMAN systems. The ultimate aim is to be able to utilize the production facility more flexibly. With the press-update it has recently ordered from manroland web systems, De Telegraaf is optimally set up for the future, even with decreased print runs. Among other changes, the main production will be switched to the modern, reader-friendly tabloid format, while broadsheet production remains available. “This way we not only strengthen our profitability, but also set a clear signal for printed newspapers as our core business,” says a speaker for De Telegraaf. In addition, the printing capacity will be adjusted to the changing requirements. After restructuring, the ten printing lines will be converted to seven, all of which will then produce in full color.
Comprehensive possibilities
The portfolio of upgrades and retrofits from manroland web systems includes all mechanical, electronic, and print technology components of a press system. This ranges from the update of the operator control, new register control systems for reliably optimized printing quality, new control console or operating concept solutions, up to the complete reconfiguration of existing systems. Decreasing web widths and the conversion from broadsheet to tabloid production are also included in the scope of services, as is the general overhaul of folding systems, cylinders, and bearings for newspaper and commercial printing systems.
Sustainable solutions – designed individually
“We want our customers to enjoy continued success. This is why we team up with our customers to develop creative solutions that ensure and optimize the long-term performance of their systems and that are precisely matched to the individual requirements of a printing company,” emphasizes Anton Happacher. “In addition, we naturally also offer short-term services. The primary aim is to secure the production reliability for our customers at all times.”