Imaging it Directly

Jerry Keller had a problem: His firm's customers needed catalog reruns. That may sound like a good problem for a printer to have—unless you're running 1,000 or 2,000 additional copies at a loss on a 40´´ sheetfed press to keep your customers happy. “We did that sometimes, or we'd farm out the jobs to digital printers,” says Keller, exec. VP of Universal Lithographers Inc. (ULI), a $6-million, high-end commercial printer in Sheboygan, WI. At the end of their business-to-business catalog life cycles, a few thousand reprints are needed on some long-run jobs to hold customers over until the new catalog is ready.

Not wanting to outsource the work any longer, Keller went shopping for a digital press. He browsed at drupa and kicked tires at Graph Expo. “We print-tested here, there and everywhere,” he recalls. Keller shopped more than four years before buying the 4-color Presstek 52DI direct-imaging press, installed in July. The 20.5×14.75´´ direct-to-press device can print up to 20,000 letter-sized pages per hour, complementing ULI's two 6-color, 40´´ MAN Roland 700 sheetfeds.

“The quality of the toner devices wasn't good enough for what we wanted,” Keller says. “There's a joke that 'DI' stands for 'Done In,' especially since Heidelberg pulled the plug on the technology. But then I saw the new 52DI last year.” And that's when his attitude changed.

“It wasn't just the larger sheet size,” Keller notes, “but the speed and resolution—300 lpi and it can print stochastic. We decided the 52DI is the best match to deliver high-quality printing quickly. We now profitably produce fast-turn, short-run jobs from 250 to 15,000 impressions.”

ULI says its regional customers appreciate the press's versatile stock handling. “We can run everything from onion-skin to 24-pt. board, even styrene and vinyl,” Keller says. He and his operators like the big-press features of the Ryobi-engineered machine—the streamfeeder, infrared dryer, closed-loop color profiles/control and on-machine register. “It's really an offset press with digital technology,” he adds. “We fine-tune colors on press like we always have. And because it's dry offset, there are no water or emulsification problems—we've even run sophisticated text papers.”

Presstek's patented DI, computer-to-plate and plate products provide a streamlined workflow in an environmentally sound, chemistry-free environment. Cycle time has been reduced. Keller reports that 4-color, automated makereadies average around 15 minutes—the company's goal is to get three minutes faster.

As with previous DI generations, no external platemaking is required. Direct Imaging (DI) uses 16-micron laser imaging and thermal media to burn digital files to printing plates rolls mounted directly on press. Plates are imaged simultaneously in precise register. This process eliminates the production steps associated with film-based platemaking or the need to separately image plates using an offline CTP process. The design features a single gripper and central impression cylinder.

The 52DI model also automatically adjusts the amount of ink according to the image file data for each plate. “We're getting up to color in about 50 sheets now and want to lower that number, too,” Keller says. The firm runs a Rampage workflow, sold by Fujifilm, and prefers Fuji's pigment-based, dot-generated digital FinalProof for contract proofing throughout the plant—in 2-, 4- and 6-up outputs. “We calibrate everything to FinalProof,” Keller says.

To make EPS, PDF and other incoming files compatible with the new platform, ULI purchased a “shooter,” which converts them into 1-byte TIFFs for the DI server.

Universal Litho is a 42-employee, 39,000-sq.ft. shop that produces high-end graphics for major Midwestern manufacturers, insurance companies, financial institutions, ad agencies and design firms. The company has identified another niche for its DI press: Capturing overflow from customers with in-plant digital print shops who require better quality for their sales and marketing collateral. ULI has produced brochures, invitations and even high-end, pressure-sensitive labels on the Presstek device. “They can't print metallic or a corporate, fifth color on their toner-based printers,” Keller notes. “And there are varnish limitations.” The DI press makes it easy to print PMS colors. Automatic press wash-up and ink key presets expedite changeover back to 4-color print mode.

Additionally, the 52DI allows sales reps to build trust with new and larger customers by initially delivering smaller jobs. “A prospect would rather try us out on a $5,000 order versus a $30,000 order,” Keller says.

Universal's large-volume runs are printed on the 40´´ presses—catalogs, annual reports, casebound books, and fine art reproductions and prints. The pair of 6-color presses use Fuji plates imaged on a Javelin platesetter. Both equipped with inline aqueous coaters, they run everything from vinyl and styrene to MetalFX inks and foil. Bindery/finishing equipment includes Polar and Wohlenberg cutters, Baumfolders, a Stahl folder and a Muller Martini Pony perfect binding line.

The 45-year-old printing company plans to launch an online Web store, within a year or so, offering a higher end, print-on-demand service. And short-run lenticular work may be on the horizon, too. “We think it [lenticular] will be compatible with Presstek's inker,” Keller says.

ONLINE: www.presstek.com/clubdi, manroland.com, fujifilmgs.com, graphics.kodak.com, epson.com, mutoh.com, us.heidleberg.com, baumfolder.com, and colterpeterson.com