Koenig & Bauer News Feed https://www.koenig-bauer.com/ en Koenig & Bauer AG Thu, 06 Aug 2020 21:44:16 +0200 Thu, 06 Aug 2020 21:44:16 +0200 news-1778 Wed, 05 Aug 2020 11:52:21 +0200 Poland’s first Rapida RDC 106 rotary die-cutter now being used in production at Top-Pol http://iberica.koenig-bauer.com/en/news/detail/article/polens-erste-rotationsstanze-rapida-rdc-106-produziert-bei-top-pol/
  • Used for in-mould label production
  • Pioneer on the Polish market
  • Production output practically doubled
  • Top-Pol in Zbrosławice is the first print company in Poland to use a Rapida RDC 106 rotary die-cutter from Koenig & Bauer. The machine was purchased as part of a project to allow the printing of innovative IML labels in an offset process, and which received funding support from the EU. The rotary die-cutter aims to guarantee production stability and high cutting speeds, alongside significantly reduced makeready times.

    Top-Pol is a family-run company that has been active on the printing market since 1989, and has become a specialist for the production of labels using non-absorbent substrates – primarily plastics – since the end of the 1990s. Co-proprietor Marcel Topolski: “We were one of the pioneers in the use of UV offset technologies for substrates like this. IML labels soon became our flagship product and currently account for 70 to 80 per cent of our production volume. Another key area is the production of lids and covers made from PE, PS or PP for plastic packaging, for example for yoghurt pots.”

    Top-Pol exports 30 to 40 per cent of its production output. The end customers for the labels are primarily companies operating in the food and construction industries. “The systematic development we are pursuing means we are constantly modernising our production machinery, also with regard to finishing processes,” says Marcel Topolski.

    Marcel Topolski (left) has raised the bar for IML production in Poland with the Rapida RDC 106

    High production speeds, fast makeready

    The maximum mechanical output of the Rapida RDC 106 totals 15,000 sheets per hour. The press enables the die-cutting of substrates in thicknesses from 0.03 to 0.6 mm, and is equipped with numerous solutions that were introduced with the Rapida 106 sheetfed offset printing presses. These include, among others, DriveTronic technology with dedicated drives, the sidelay-free infeed DriveTronic SIS, and a camera system to monitor sheet travel at the feeder and delivery.

    One of the key functions of the machine is automatic adjustment of the die-cutting pressure. The pressure can be set separately for each side of the cylinder with a precision of 1 µm. This results in a high die-cutting quality over the entire length of a run. Fast, tool-free forme changes that use a “click & cut” process enable very short makeready times – as little as 5 minutes for repeat jobs. Smooth delivery of the sheets onto the pallet is realised by the dynamic sheet brake and an anti-static system with an extensive range of functions. This also allows further processing to continue immediately when the next step in the production chain starts. There is no need for time-consuming re-stacking ahead of automated further processing. The die-cutting units are equipped with a magnetic cylinder, to which the individual cutting formes are fixed. As a result, a range of processes can be realised in a single unit – from die-cutting to embossing or perforation, along with hole punching. The Rapida RDC 106 is available in a number of different configurations with one to four units.

    Enhanced production and productivity

    “Once again, we have assumed a pioneering role, this time by introducing the Rapida RDC 106 onto the Polish market,” says Marcel Topolski. “As we had already been successful using rotary label die-cutting in the past, the purchase was an ideal opportunity to continue to enhance our productivity and production. After all, our products are quite difficult to produce. The IML labels are made of plastic and also feature indentations to make it easier for the end customer to separate them later on. This makes it a perfect opportunity to broaden our knowledge, both for our own and for the manufacturer's benefit.”

    “Special mention must be made of the level of dedication shown not only by the sales team but also by the technical and service departments, both at our local Koenig & Bauer branch office and at the German headquarters. Integration of the press into the new technological process was completed efficiently and on-time during the first quarter of the year. Our operators have nothing but praise for it, especially in regard to the increased level of process stability and the doubling of production output compared to our previous solution.”

    “Our customers in the food industry, along with our customers in other sectors, expect labels of the highest quality. Accordingly, the solutions we use must also represent the highest standards and the best possible performance that the global market has to offer. The latest investment in the Rapida RDC 106 will more than satisfy these expectations, which are becoming more and more demanding due to changes to the market and to consumer tastes. These aspects are all the more important in the current global situation, which has, of course, also impacted our order volume,” Marcel Topolski concludes.

    Jan Korenc, managing director of Koenig & Bauer (CEE) adds: “This is a first-class solution which requires up to 40 per cent less makeready to complete an entire job. This is why we are confident that it will contribute to the continued growth of Top-Pol as one of the leading print companies in Poland, and play a role in the successful implementation of the new technology project for which the Rapida RDC 106 rotary die-cutter was purchased.”

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    news-1771 Wed, 29 Jul 2020 07:15:00 +0200 Koenig & Bauer publishes its H1 report 2020 http://iberica.koenig-bauer.com/en/news/detail/article/koenig-bauer-publishes-its-h1-report-2020/
  • Delivery and pandemic-related revenue decline by 20.1%
  • Order intake 16.2% below prior year, considerably better than industry trend
  • Earnings significantly impacted by low revenue
  • On the cost side, massively counteracted with short-time working from 1 April 2020 and other measures
  • Equity ratio of 32.2%
  • In addition to the general investment restraint on the part of many customers in the corona crisis, travel bans, lockdowns and other restrictions significantly affected the business figures of the Koenig & Bauer group in the first half of 2020. The restrictions caused by the Covid-19 pandemic particularly impeded deliveries of the presses to the international customers as well as the worldwide deployment of the assembly staff and service technicians. At €480.2m, orders were 16.2% lower than in the previous year, although this was better than the sector trend for printing presses published by industry association VDMA. At €404.5m, revenue fell short of the previous year by 20.1%. On the cost side, massive measures were taken to address the effects of the crisis, introducing short-time working from 1 April 2020 alongside other steps. EBIT improved substantially from –€34.9m in Q1 to –€6m in Q2. For the first half of the year, EBIT was –€40.9m after €0.6m in the previous year. At –€44.2m, net earnings as of 30 June corresponds to earnings per share of –€2.68.

    Despite substantially lower trade receivables and higher customer prepayments, the half-year loss and the increase in inventories had major impacts on cash flows from operating activities, which came to –€68.6m (2019: –€96.5m). The equity ratio stood at 32.2% at the end of June 2020.

    The high-end Rapida 106 X press for medium-format sheetfed offset, which was presented at the virtual trade fair Koenig & Bauer Live in June, sets new performance standards in industrial printing (1)

    Segment performance

    Despite the substantial gains with large-format sheetfed offset presses and folder gluers, order intake in the Sheetfed segment declined by 12.9% over the previous year’s figure of €330.6m to €288m due to lower orders for medium and half-format presses. Revenue of €205.5m was 20.6% lower than the previous year’s figure (€258.9m) for delivery-related reasons and due to the effects of the pandemic. With the book-to-bill ratio coming to 1.4, order backlog rose from €261.6m to €265.9m. Due to lower revenue, EBIT of –€17.4m was below the previous year (–€1.3m).

    Order intake in the Digital & Web segment came to €56.7m, down from €89.9m in the previous year, due to lower orders in the web offset press business and for flexible packaging printing. At €51.6m, revenue was down on the previous year (€64.5m). The order backlog contracted from €111.2m to €71.2m. The lower revenue had a significant impact on the EBIT of –€12.1m (2019: –€10.8m).

    The decline in order intake in the Special segment from €175.3m to €150.7m reflects lower orders for security printing, marking and coding as well as glass direct printing. In metal decorating, there was an increase in new business. Revenue fell from €204.9m to €160.1m. The order backlog reached €278.1m after €316m in the previous year. After €6.3m in the previous year, EBIT came to –€10.3m in the first half of 2020 for revenue-related reasons.

    Revenue and orders for the large-format sheetfed offset presses and folder gluers used in the packaging sector also increased during the crisis (2)


    CEO Claus Bolza-Schünemann: “In view of the high volatility and the great uncertainties surrounding the severity and duration of the coronavirus pandemic and the success of health, economic and monetary policies, the further global economic development is uncertain. Given these uncertain underlying conditions, it is currently not yet possible to issue any revenue and earnings guidance for 2020 for our group. The management board is working intensively on the Performance 2024 efficiency programme to increase the operating profitability. We have applied for a KfW loan to supplement the existing syndicated credit facilities. In addition, improvements in working capital and cash flow are at the top of the agenda together with the strategic focus on packaging printing and digital services.”

    Figures at a glance

    The financial statements can be downloaded as a PDF file from here.

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    news-1769 Tue, 28 Jul 2020 12:34:56 +0200 Koenig & Bauer offers Live Remote Video Support App http://iberica.koenig-bauer.com/en/news/detail/article/koenig-bauer-offers-live-remote-video-support-app/
  • Use of different channels for communication
  • Easier communication for fast remote maintenance success
  • Example of consistent implementation of the digitization strategy
  • Visual PressSupport is an App based live video streaming service that Koenig & Bauer now offers for sheetfed presses and other business units. In addition to audio transmission, it enables live videos to be transmitted directly from a mobile device to the hotline technician during remote maintenance. The success rate of classic remote maintenance methods currently used is 80 percent. It is expected to grow further with Visual PressSupport.

    Visual PressSupport is a cutting-edge tool that makes communication much easier for both users and hotline technicians. The hotline technician sees what the press operator or service technician sees on the press. He can be shown processes and procedures live via video and thus gain a quick and comprehensive overview of the situation at the press. This facilitates communication, saves the need for extensive explanations and reduces the risk of misunderstandings compared to a conventional telephone call.

    Visual PressSupport allows you to broadcast live video, mark up still images and share media

    Communication with added value

    But Visual PressSupport can do even more: both the technician on site and the hotline technician can apply markings to the still images generated live. These markers help to carry out function checks or settings on the correct part or to record the current status separately close-up. In this way, it can help to limit malfunctions or be used to transfer operating and setting aids.

    In addition, the operator or technician at the press can share images from the album on their mobile device with the hotline. These can show certain press behaviour that only occurs sporadically and therefore cannot be picked up on live.

    Data security is guaranteed at the same time as the hotline technician can only see the media that has been shared and no other content.

    Ralf Sammeck – CEO of Koenig & Bauer Sheetfed & Group CDO said “Visual PressSupport is another example of the consistent implementation of our digitization strategy. The focus is on the business benefit for our customers. Everything that contributes to higher availability and productivity and improves communication is of decisive added value for our customers.”

    More details are available at:

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    news-1762 Tue, 21 Jul 2020 11:43:34 +0200 Press demonstration facility upgraded into a global Customer Experience Centre http://iberica.koenig-bauer.com/en/news/detail/article/press-demonstration-facility-upgraded-into-a-global-customer-experience-centre/
  • New building boasting more than 3,000m2 of demonstration floor space in Radebeul
  • Packaging lines with seven printing presses and post-press machines, including workflow integration and production data logging
  • One-stop-shop concept for packaging production with fully automated material flows
  • Koenig & Bauer recently opened its new hall and now offers more than 3,000m2 of floor space for print demonstrations at its Radebeul location, near Dresden. The occasion marked the culmination of a project to upgrade the company’s existing demonstration facility into a global Customer Experience Centre (CEC). For customers and other interested visitors, the CEC offers around one-third more space – packed with the very latest equipment – for press and machine demonstrations, application testing, the development of new technologies and for training purposes. The individual sections focus on the specialised areas of packaging, commercial and label production

    Inauguration of the new CEC in Radebeul (left to right): Dirk Winkler, head of print technology, product management and product marketing, Claus Bolza-Schünemann, president and CEO of Koenig & Bauer, Ralf Sammeck, Koenig & Bauer management board member and CEO of Koenig & Bauer Sheetfed, and Thomas Göcke, head of digital business transformation, hand the new building over to its future users (1)

    The new hall, the Packaging Competence Centre within the CEC, will house three packaging lines comprising three printing presses and four post-press machines once fully set up. Koenig & Bauer will then be able to showcase its one-stop-shop concept for packaging production – with flat-bed and rotary die-cutters, folder-gluers and fully automated material flows. Meeting areas with direct views of the production lines, workstations to illustrate digital workflow integration and a full range of modern media equipment contribute to an atmosphere conducive to tests, production trials, demonstrations, discussions and negotiations.

    The machinery that is already installed and ready for demonstrations includes a latest-generation medium-format sheetfed offset press, this being a Rapida 106 X with seven printing units, double-coating facilities, an additional printing unit after the first coater and the coil foil system FoilTronic, as well as an Omega Allpro 110 folder-gluer and a CutPRO X 106 rotary die-cutter. The next step will see the addition of a Rapida 145 and a CutPRO M 144.

    The first machinery – the brand new Rapida 106 is shown here – is ready for individual print tests (2)

    Koenig & Bauer started construction of the new building in the second half of 2018. Since the beginning of the year, the project has continued with the completion of the interior and installation of the machines, which were shown in action for the first time as part of the virtual event series “Koenig & Bauer Live” from 16 to 25 June. In the meantime, 3,500 cubic metres of earth had been dug and 520 cubic metres of concrete had been poured. Other key parameters of the building are its 38 pre-cast columns, a roof construction featuring glulam trusses and a span of 35 metres, and 1,300 square metres of cladding. Some 250 LED lights were fitted on mounting tracks with a length of almost 600 metres, 30,000 metres of cabling were routed through the facility, and a photovoltaic array was installed on the roof.

    Koenig & Bauer is looking forward to intensive use of the new CEC by customers and other visitors from all over the world over the coming weeks.

    The new building now makes one-third more space available to users and interested visitors for individual print tests and press demonstrations (3)

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    news-1757 Tue, 14 Jul 2020 13:49:10 +0200 Shareholders approve all resolutions http://iberica.koenig-bauer.com/en/news/detail/article/shareholders-approve-all-resolutions/ In addition to details of the group’s business performance in 2019 and in the first quarter of 2020, the numerous product innovations and the successfully launched offensive for digitisation with the service business as a main topic were the focus of the first virtual annual general meeting of Koenig & Bauer AG. The management board reported that the coronavirus pandemic, which has been spreading rapidly since January, has already had a considerable impact on revenue and earnings in the current financial year. CEO Claus Bolza-Schünemann: “Our broad product portfolio with a significant share of revenue in system-relevant packaging printing, the robust, increasingly digital service business and our sound balance sheet with a high equity ratio limit the risk potential. With the corona crisis management established in March, we are working to actively counter this extraordinary situation. The health and safety of our employees, customers and suppliers is our top priority. Our action plan focuses on reliable customer support, cost and investment discipline and securing liquidity. There were almost no restrictions on the supply chain. Short-time working has, however, been in place at different locations since 1 April 2020 due to capacity utilisation. Under the currently uncertain general conditions, the impact on revenue and earnings in the 2020 financial year cannot yet be quantified.“

    Koenig & Bauer AG’s 95th annual general meeting took place as a virtual event for the first time (1)

    Performance 2024 efficiency programme is flanked by applying for a KfW loan

    CEO Claus Bolza-Schünemann: “In parallel to the corona crisis management, we are working intensively on the Performance 2024 efficiency programme, evaluating various scenarios. In addition, improvements in working capital and cash flow are at the top of the agenda alongside the strategic focus on packaging printing and digital services. To strengthen the stability and strategic flexibility of the group, the management board and the supervisory board decided to apply for a flexibly repayable KfW loan with a volume of up to €120m to supplement the existing syndicated credit lines (Direct Participation in Syndicated Loans). Among others, no dividend distributions are permitted during the term of the KfW loan. After the plans for increasing the operating profitability and performance of the group have been adopted, we will report promptly on the targets and costs of the Performance 2024 efficiency programme.”

    In his address to the shareholders, CEO Claus Bolza-Schünemann touched upon the latest product innovations and the already successfully launched offensive for digitisation (2)

    High approval from shareholders

    With a large majority, the shareholders confirmed the management and supervisory boards' proposal to suspend the dividend payment for the financial year 2019 and to carry forward the retained profit generated by the holding company Koenig & Bauer AG to new account. Alongside the discharge of duties with regard to the members of the management and supervisory board, shareholders elected PricewaterhouseCoopers in Frankfurt am Main as public auditors and group auditors in 2020. In addition, they elected Professor Gisela Lanza to the supervisory board. As well as this, the proposed amendments to the articles of association were adopted.

    The individual voting results can be found at https://www.koenig-bauer.com/en/investor-relations/annual-general-meeting/

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    news-1753 Thu, 09 Jul 2020 15:15:34 +0200 Koenig & Bauer stands by the drupa trade fair http://iberica.koenig-bauer.com/en/news/detail/article/koenig-bauer-steht-zur-branchenmesse-drupa/
  • Participation in drupa 2021 is not in question
  • Stand in Hall 16 remains as planned
  • Broad portfolio will be shown
  • Although digital formats are gaining in importance, they are only a supplement in customer communication
  • Many visitors and machines in action at drupa 2016. drupa 2021 should also be an experience for visitors

    Koenig & Bauer reaffirms its commitment to participate in the world's largest trade fair for the printing industry, which has been postponed until April 2021. The company is well positioned and the stand in Hall 16 will be retained.

    Since drupa was founded in 1951, the company has maintained an uninterrupted presence and welcomed customers from all over the world, even in times of crisis.

    "We continue to see drupa, the world's leading trade fair, as an important building block in the graphic arts industry and we see it as our responsibility to support this industry. We want to do our part to continue to provide important impulses locally in personal discussions," says Claus Bolza-Schünemann, Koenig & Bauer CEO and drupa president, explaining the company's position. "We have confidence in Messe Düsseldorf's hygiene concept and in the sense of responsibility of all visitors.”

    Ralf Sammeck, Koenig & Bauer board member, adds: "Trade fairs will not be the same as they were before COVID-19, and Koenig & Bauer is also supplementing communication with its customers with virtual formats and customer-specific events, for example in our new Customer Experience Center. Nevertheless, these formats can only convey the performance capabilities of the broad product portfolio to a limited extent. Nothing beats experiencing the latest technologies up close in action with the public and the trade fair feeling."

    "For Koenig & Bauer there is no more suitable platform to present the product diversity from digital, offset and flexo printing to intelligent digitalization and service solutions to an international audience", adds Christoph Müller, member of the board at Koenig & Bauer.

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    news-1748 Wed, 08 Jul 2020 11:23:36 +0200 “The press has immense potential” http://iberica.koenig-bauer.com/en/news/detail/article/die-maschine-hat-immenses-potenzial/
  • Shortest job makeready times – including the coater
  • Printing times practically halved
  • High print quality on uncoated papers
  • Growth edging upwards despite a challenging environment
  • The five-colour Rapida 76 with coater and extended delivery is highly valued at Schmidt & Buchta for its outstanding performance potential (1)

    Matthias Herrmann, managing director of the Schmidt & Buchta printing company based in the small town of Helmbrechts in northern Bavaria, paid a visit to Koenig & Bauer Grafitec in July last year to learn more about the Czech factory in which his Rapida 76 was manufactured. This highly automated five-colour press with coater and extended delivery has now been used for routine production for more than six months.

    Schmidt & Buchta has seen any number of changes since the arrival of its Rapida 76. Investment in a new hall has tripled the available production floor space from 500 to 1,500m2. And the Rapida 76 has far exceeded Matthias Herrmann’s original expectations: “I never imagined that the press would have such an impact. It has immense potential.” Makeready times have been reduced tangibly, and the company is now printing an average of two to three additional jobs every day.

    Jobs which previously required printing time of between 36 and 42 hours are now completed, along with all the requisite plate changes and makeready processes, within 21 to 24 hours. The consistently high production speed represents another contributing factor. While a print job used to last for 1.5 shifts, Schmidt & Buchta has now been able to condense its operations to one single shift only. Even so, monthly output has increased by around 500,000 sheets – despite the fact the predecessor press was also from the 16,000sph generation.

    Fully automatic FAPC plate changers make a significant contribution to faster makeready times (2)

    Consistent high quality

    “On the old press,” Herrmann recalls, “we sometimes had to drive with the handbrake on, so to speak, in order to keep the quality up to the required level.” This is now a thing of the past. The Rapida 76 reliably delivers consistent results, irrespective of production speed or substrate. QualiTronic PDF, in particular, can take the credit for this. The system comprises not only inline colour control and sheet inspection with continuous production monitoring, but also a comparison of the printed sheets with the pre-press PDF. This functionality allows the company to promise a consistently high quality, as required by pharmaceuticals companies, for example.

    Matthias Herrmann is still as fascinated by the automatic regulation of colour densities shown on the console monitor as the press starts up as he was on the very first day. He has calculated that the automatic control has enabled waste to be reduced by up to 50 per cent. The benefits are particularly apparent when restarting the press following stoppages or when running work-and-turn jobs.

    Printer Tobias Krauß at the console of the Rapida 76. The comprehensive measuring and control systems that the press employs comprise inline colour control, sheet inspection with continuous production monitoring, and comparison of the printed sheets with the pre-press PDF (3)

    Ingenious features

    The print quality on uncoated papers is likewise much better than anything the previous press produced – even without an LED-UV process. “We were already getting very good results beforehand, but the Rapida has elevated us to an even higher quality,” says Matthias Herrmann. Dot sharpness on the Rapida 76 is simply superior.

    The sidelay-free infeed is another feature that Matthias Herrmann considers ingenious. Printing on thin and sensitive substrates is much more straightforward, as DriveTronic SIS does not subject the sheets to mechanical stress during alignment. This dispels any concerns about buckling or marking by the side lay. In addition, there is no need for manual adjustments when changing substrates. Even a switch from 80 to 300g/m2 is an amazingly straightforward process.

    The coater is another feature which has made a similarly good impression on everyone at Schmidt & Buchta. Coating plates are changed in two to three minutes. In the past, a change usually took around ten minutes longer. Furthermore, changing the coating type necessitated manual washing of the unit, which took a further 15 minutes. The effective cleaning time for the Rapida 76 is negligible, as it is conducted at the same time as other makeready processes in automatic mode. Where the work requires frequent coating changes, the time savings are, of course, considerable.

    Nor is anyone prepared to forego parallel washing processes in the printing units any more. Matthias Herrmann: “We had no idea that so many tasks could actually run simultaneously.”

    New press technology and a new production hall. At Schmidt & Buchta, all the signs are pointing to growth (4)

    Press contributes to continued growth

    The printers at Schmidt & Buchta were working alone on the new Rapida 76 after just two weeks of familiarisation training. It is now making a significant contribution to the continued growth of the 13-man company. Matthias Herrmann considers the press to be on an absolute par with its 3b counterparts, the only difference being that it prints in a smaller format.

    Even if Schmidt & Buchta were also affected by the usual order volume failing to materialise in March and April due to COVID-19, Matthias Herrmann is nevertheless optimistic about the future. By combining commercial work for the regional economy, the cultural sector, food and pharmaceuticals companies and furniture manufacturers, not to mention its unique specialisation in so-called “sample hangers” for the textile industry, he is well equipped to cope with any shifts in market demands. In fact, turnover at Schmidt & Buchta actually increased by two to three per cent in the first three months of 2020, despite the lockdown and all the negative consequences it had for the advertising industry.

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    news-1740 Mon, 06 Jul 2020 13:01:00 +0200 Responsibility and sound judgement in times of pandemic http://iberica.koenig-bauer.com/en/news/detail/article/mit-verantwortung-und-augenmass-durch-die-corona-zeit/
  • Challenges facing the industry due to the coronavirus crisis
  • Safeguarding operations as a partner to system-relevant companies
  • Reaction to the postponement of our flagship fair drupa
  • Success story in large formats
  • Koenig & Bauer Report No. 56 is out now. The latest issue of the Group’s customer magazine shines a spotlight on the latest news and innovations that will allow the industry to continue to take important steps forward despite the coronavirus pandemic. Spanning about 56 pages, it reports on interesting developments relating to sheetfed and web offset, post-press technologies, digital and flexo printing, and a broad spectrum of special applications.

    The latest 56-page issue of Koenig & Bauer Report spotlights current news, innovations and trends from the print industry

    In his editorial, president and CEO Claus Bolza-Schünemann refers to the challenges currently facing the industry and the still incalculable consequences to be overcome by companies all over the world in the wake of the CoVID-19 pandemic. Koenig & Bauer immediately implemented measures to safeguard its delivery capabilities, service readiness and spare parts supplies. As a printing press manufacturer, it was particularly important to be well prepared, as many customers are direct partners to the food, pharmaceuticals and beverage industries, and can therefore be classified as absolutely system-relevant. “This responsibility is additional motivation to work to the best of our ability and to keep production running for our customers,” Bolza-Schünemann writes.

    Koenig & Bauer Report also reflects on the postponement of drupa, which would normally have come to an end a few days ago. The decision to postpone the print industry’s biggest trade fair and exhibition until April 2021 was accepted with respect and full understanding. Aside from the new fair dates, the magazine informs readers about product innovations such as the ultra-compact Evo XC, the decades-long success story for Koenig & Bauer in large-format sheetfed offset, and the development of the digital VariJET press together with joint venture partner Durst.

    Koenig & Bauer Report is published in German, English, French, Spanish and Italian. Printed copies can be requested from our local regional offices or from the central marketing department of Koenig & Bauer AG

    tel.: +49 931 909-4567
    fax: +49 931 909-6015
    e-mail: marketing(at)koenig-bauer.com.

    Koenig & Bauer Report will also be available in the next few days as a digital web magazine (in all the aforementioned languages as well as in Portuguese). The digital magazine is available at http://report.koenig-bauer.com/ and can be downloaded from https://www.koenig-bauer.com/downloads/koenig-bauer-report/.

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    news-1738 Thu, 02 Jul 2020 14:12:40 +0200 Rapida 106 X – the new performance benchmark in industrial printing http://iberica.koenig-bauer.com/en/news/detail/article/rapida-106-x-der-neue-leistungsmassstab-im-industriellen-druck/

    • Numerous functions for even higher productivity and for autonomous processes
    • Machine design: superior and visionary
    • Plate logistics: from the platesetter directly to the changer without manual intervention
    • World première: 20,000 sheets/hr in perfecting mode
    • High-end quality control
    • Smart operating concepts
    • Comprehensive services for increased availability and enhanced performance

    With the Rapida 106 X, Koenig & Bauer is unveiling a new high-performance sheetfed offset press for the medium format 740 × 1060mm. It meets every conceivable demand that today’s market makes of a press in terms of automation, digitisation and workflow solutions, thereby making it the latest in a line of trendsetting developments defining the future of industrial offset.

    Typical commercial press: Rapida 106 X as an eight-colour press with perfecting unit for 4-over-4 production and an additional coater (1)

    Superior, dynamic and of lasting value – these are properties that the Rapida 106 X embodies with its new award-winning design. Glass side panels, a new touchscreen operating concept and an expressive design language immediately identify the press as an ultra-modern automated printing system. What becomes evident with just a glance is that this is the most powerful Rapida that the market has ever seen.

    The new Rapida 106 X series aims to lend performance a further boost in order to make companies even more profitable. There are five criteria that play an especially decisive role in this:

    1.     Shorter makeready times – faster into print

    To avoid wasting even a second during makeready, the Rapida 106 X incorporates a host of pioneering and precisely coordinated features. These range from simultaneous plate changing in less than a minute with unbent and process-free plates to a multitude of parallel makeready processes, and also includes autonomous printing of a whole sequence of jobs with automatic activation of the good-sheet counter (AutoRun). At this level of automation, the Rapida 106 X is truly a perfect automatic printing system.

    As soon as the sheet counter reaches the specified run length for the current job, the impression is thrown off and the Rapida 106 X automatically begins the job changeover. Once makeready is completed, printing resumes for the next job without any intervention by the operator. The measuring and control systems detect when the specified print quality has been attained and re-activate the sheet counter. After printing the required number of sheets for the second job, the press switches back into job changeover mode. This process is then repeated as often as is necessary to complete the whole sequence of jobs.

    A Rapida 106 X on raised foundations for packaging production, with seven printing units, double-coating facilities, an additional printing unit after the first coater and the cold foil system FoilTronic (2)

    Plate logistics right up to the printing unit

    A similarly high level of automation characterises the new PlateTronic plate logistics system. It can be incorporated into the new Rapida 106 X upon request. It has been designed as a modular system and exhibits the versatility to adapt to the requirements of each individual print company.

    From job preparation in the PPS system LogoTronic Professional to plate exposure and delivery up to the designated printing units on the press, as well as the removal of the old plates, the process is completed without any manual intervention whatsoever. Assignment of the plates to the individual printing units is managed by the logistics system, meaning that the order in which the plates actually reach the press can be varied as required. The Koenig & Bauer logistics system guides the plates directly into the plate changers. The operator’s work consists solely of process monitoring.

    At commercial printing companies with short runs and frequent language or section changes in particular, the plate logistics system offers key benefits in terms of productivity. Imagine printing a job with a run length of around 350 sheets requiring removal of the old plates from eight or more changers, and loading of the same number of new plates ready for subsequent mounting, all while the job is proceeding – an operator could only keep pace with the press for a short time. The technology provides a distinct advantage in this case, and helps to ensure that the Rapida 106 X is always back in production as quickly as possible.

    New: PlateTronic plate logistics right up to the loading channels on the press. From the platesetter to intermediate plate storage and even the plate changer, all processes run fully automatically (3)

    2.     Higher speed – even faster in production

    As a world first, the Rapida 106 X reaches production speeds of up to 20,000 sheets per hour in perfecting mode. It thereby opens the door to entirely new levels of performance for perfector presses. Commercial printers that use eight-colour presses for 4-over-4 production will be delighted, as they now have access to the same high-performance technology as companies working with straight presses only.

    Optimising job sequences offers additional potential for raising the daily output of sheetfed offset presses. With this in mind, Koenig & Bauer is launching a brand new tool together with the Rapida 106 X: the Job Optimizer. This tool acts as a link between MIS and PPS, and optimises the order of the jobs preset in the MIS scheduling module in accordance with technological or press-related considerations. The former include aspects such as the sheet format, substrate weight, type of coating and quality levels of complex formes. Examples for the latter are the option of implementing parallel processes, or formes that are suitable for use of the print-clean function rather than resorting to more time-consuming washing processes. An optimised job sequence can shorten makeready times by a further 30 to 50 per cent, depending on the parameters of the specific job.

    Information on compliance with OEE criteria, used for overall equipment efficiency, is provided by the new LogoTronic Cockpit. Just-in-time analyses are performed on all production data and times, and the results are presented in clearly structured diagrams. It is possible to compare the current production performance and makeready times with reference settings at just a glance. At the same time, production data can be used in costing analyses to enable comparisons with the planned values. Profits and losses are quantified in real time.

    Smart operating concept: the ErgoTronicApp makes the control console mobile (4)

    3.     Reliable processes – stable in production

    When it comes to measuring systems, too, Koenig & Bauer has set the benchmark. A single camera system (with two cameras on perfector presses) covers three functions: inline colour control, sheet inspection with continuous production monitoring, and comparison of the printed sheets with the pre-press PDF.

    QualiTronic ColorControl measures the ink densities in colour bars on every single sheet. The system uses the measured values to calculate corrections to the ink settings every ten sheets. In conjunction with the fast reaction by inking unit of the Rapida 106 X, jobs are brought into colour in next to no time – the number of waste sheets at start-up and after production stoppages decreases tangibly: just 25 to 50 sheets, depending on the job and quality parameters.

    QualiTronic PrintCheck upgrades inline colour control by adding a production monitoring function. When printing starts, the system scans a set number of good sheets to generate a reference. All printed sheets are subsequently compared with this reference. Any deviations that are detected are displayed on the monitor and can also be marked in the pile by using an optional tag inserter. All these processes require no makeready and run fully autonomously.

    A comparison of the printed sheet with a customer PDF is performed using QualiTronic PDFCheck. This system allows flaws to be detected before the actual production run even commences – a major bonus, especially for Internet or packaging printers. The PDF comparison is performed for every single sheet during production, at a scan resolution of 100dpi. If the system spots any differences between print and PDF, the operator is alerted and is prompted to intervene. A report is created to document the print quality.

    QualiTronic PDF HighRes conducts sheet inspection with even greater precision. The content of each printed sheet is checked at a resolution of 290dpi. Even the tiniest flaws and deviations as minute as approx. 90µm can be detected, visualised and logged. To this end, two additional cameras are installed on the Rapida 106 X.

    Smart tools for intuitive processes

    Once the colour is within the specified tolerances, the Traffic Light function provides information about the overall quality of the production. Three different quality levels can be defined. If a green light is displayed, the quality meets the specifications and the good-sheet counter is activated automatically. Traffic Light allows waste to be reduced while printing in a defined, comparable quality and maintaining effective control over the whole length of a run.

    Koenig & Bauer is offering a pair of smart tools for the print process in the form of the Rapida LiveApps. ErgoTronicApp allows the entire press to be visualised on a mobile device. Printers can view all job data for the current and next job, production times, notifications and maintenance instructions, including support, to enable them to carry out the work. This makes the press console mobile. The ProductionApp can be used to manage store inventories, track consumables batches and much more. The app provides an accurate overview of which print jobs were produced with which batches of substrates, inks and consumables, even after the job is finished.

    The design of the Rapida 106 X embodies superiority, dynamism and elegance – right down to the tiniest detail (5)

    4.     Less maintenance – more time in production

    Data-driven services and digital business processes lay the foundations for optimised maintenance processes for sheetfed offset presses from Koenig & Bauer. Most of the customer-oriented services are based on performance data from the presses and their log files.

    PressCall improves communication with the remote maintenance service and optimises communication by eliminating language barriers. Visual PressSupport increases the scope of services that can be provided by remote maintenance by enabling direct insight into the press using the operator’s smartphone. Photos, videos, audio and a comment function help provide a much clearer description of the situation that results in a remote maintenance call, and also make it easier to provide assistance in relation to process technologies or mechanical press components.

    A monthly performance report shows performance data and key performance indicators of presses in an easy-to-understand graphic form. In addition, performance data can be compared internally and externally with those from presses used in a similar manner – anonymously, of course.

    DriveTronic dedicated drive technology (here in the form of the sidelay-free infeed DriveTronic SIS) offers unique functionalities (6)

    5.     Digitalization – top in profitability

    Thanks to artificial intelligence and by making use of sensor data from the presses, a steady stream of features has been, and continues to be, developed to ensure the Rapida 106 X operates with ultimate productivity, to increase its production availability and to promote a detailed exchange of information between users and the manufacturer using digital channels. What we call our Customer Community is the central point of contact. This is where new tickets can be created, open tickets and performance reports can be viewed, and a range of other digital services can be accessed. Users and the manufacturer can access an identical information database, meaning that they are all on the same page when working together. In future, the Customer Community will unite all digital services under one and the same roof.

    Sensor data from the press are becoming increasingly important as a means of localising faults before they result in actual press downtime. Using methods incorporating artificial intelligence, it is possible to analyse sensor responses to distinguish between normal and abnormal press behaviour. As soon as abnormalities are detected, bots intervene in operations and automatically generate a service ticket. The service engineer responsible then takes a defined series of measures and, if necessary, contacts the user without delay to discuss scheduled maintenance and avert any unplanned downtime.

    LogoTronic now features a new and versatile, operating and press data-based reporting tool, the Performance Analytics Plus option, which will be able to be accessed by means of the Customer Community in future. Performance Analytics Plus enables print companies to analyse processes from different perspectives in order to maximise the performance of their Rapida technology. Job histories, production time records and much more can be visualised ad-hoc in configurable dashboards that adapt to individual requirements. Even complex trend analyses that allow the user’s own long-term strategies to be monitored can be generated with just a few clicks.

    All these details add up to make the Rapida 106 X the most powerful and most efficient medium-format Rapida that the market has ever seen.

    Coating plate changes are similarly automated on the Rapida 106 X and can be completed without the need for tools in under two minutes thanks to SAPC (7)

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    news-1733 Fri, 26 Jun 2020 09:35:16 +0200 Koenig & Bauer LIVE: Print also functions online http://iberica.koenig-bauer.com/en/news/detail/article/koenig-bauer-live-print-funktioniert-auch-online/
  • World première of the new Rapida generation
  • Virtual live demonstration of a complete packaging workflow
  • Presentation of digital services
  • Innovations in digital web printing and for the processing of corrugated board
  • Live insights into the broad portfolio of Koenig & Bauer
  • New developments from the joint venture Koenig & Bauer Durst
  • Koenig & Bauer has drawn wholly positive conclusions at the end of its first entirely virtual fair. Under the banner “Koenig & Bauer LIVE”, the press manufacturer presented product innovations, digital applications and new service solutions for the print industry through a series of online events between 16th and 25th June. Daily streams enabled partners, customers and all other interested print professionals to learn more about the innovations which Koenig & Bauer has developed for the industry.

    The chosen dates were no coincidence. “These were precisely the two weeks which we were all planning to spend at drupa,” as Claus Bolza-Schünemann, CEO and president of Koenig & Bauer, explains. Like so many other major events this year, the world’s biggest trade fair for the printing and graphics industry also fell victim to the coronavirus pandemic. New dates have already been found. The next drupa will now take place in April 2021. Koenig & Bauer didn’t want to leave this extra time unused. “Our preparations were close to completion when the news broke that drupa would be postponed,” says Dagmar Ringel, head of corporate communication and marketing at Koenig & Bauer. “But we didn’t want to wait another year before revealing our latest innovations to the printing world.”

    The highlight of the virtual fair was the world première of the new Rapida generation (2)

    Presentation of the new Rapida generation

    The highlight of Koenig & Bauer LIVE was the unveiling of the new Rapida generation. Redesigned from the ground up, with additional features and a new modern appearance, the flagship in the sheetfed offset segment was proudly presented by group board member Ralf Sammeck and his team. The medium-format Rapida 106, with production speeds of up to 20,000 sheets per hour in perfecting, flying job changes and highly automated plate logistics, is the most powerful Rapida the market has ever seen. The Rapida 76, too, boasts all the features of its larger sister press and has set a new milestone in the B2 format.

    Post-press – From print to the finished packaging

    In the field of post-press solutions, Koenig & Bauer introduced its new CutPRO family of die-cutters – the flat-bed die-cutter CutPRO Q 106 from Spanish subsidiary Koenig & Bauer Iberica and the rotary die-cutter CutPRO X 106. During the live session, sheets printed on the previous day were embossed, creased, die-cut and stripped on the CutPRO X 106. The Omega Allpro 110 folder-gluer from Koenig & Bauer Duran then converted the blanks into a finished product as part of a similarly live demonstration.

    Digital solutions for the packaging market

    Robert Stabler, managing director of the joint venture Koenig & Bauer Durst, gave an insight into the innovations for the digital packaging market. Alongside enhancements to the Delta SPC 130 and CorruJET 170 machines, it was above all the development of the new VariJET 106 which stole the limelight. This innovative press integrates inkjet technology into the high-performance sheetfed offset platform of the Rapida 106.

    With Koenig & Bauer LIVE, the company held its first entirely virtual fair (1)

    Digital services – Valuable applications in times of crisis

    Against the background of the coronavirus pandemic, the virtual fair also turned attention to the value of digital services. When the lockdown suddenly rendered technician assignments and customer visits impossible, necessary exchanges were shifted into other formats. Koenig & Bauer has already been using video-based service tools such as Visual Press Support for a number of years. Already existing augmented reality solutions and possibilities for preventive maintenance also helped customers to overcome restrictions imposed by the coronavirus. In addition, Koenig & Bauer has developed various industry-specific service packages.

    Insights into digital print and web offset

    On behalf of the Digital & Webfed segment, board member Christoph Müller and his team described the possibilities for use of the RotaJET press in digital web printing, for example for décor or packaging production. They also reported on the return to the market for corrugated board processing with the machines CorruCUT and CorruFLEX. Here, the company is responding to the fast-growing demand for packaging solutions, for example from brand owners and food producers. Luigi Magliocchi, the new managing director of Koenig & Bauer Flexotecnica, presented the Evo XC directly from the factory in Tavazzano in Italy. The ultra-compact 8-colour press builds upon the success of the established Evo series. It is available in two different versions with maximum repeat lengths of up to 850 mm and production speeds of up to 400 m per minute.

    Diversity of print products from the Koenig & Bauer world

    Short clips shown during the live sessions shone a light on the many other fields covered by Koenig & Bauer’s broad product portfolio. For example, the responsible specialist subsidiaries presented solutions for the decoration and finishing of metal substrates, glass and hollow containers. The audience also learned how an AI application can be integrated into coding applications, and why banknotes remain a safe and indispensable means of payment even in today’s day and age. 

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