Copyright 2008 KOMORI Corporation. All Rights reserved.

Print Forum 2011Print Forum 2011

Komori with “OffsetOnDemand”Komori with “OffsetOnDemand”

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Todays topics

Komori IntroductionKHS-AIH-UVOffsetOnDemand

Komori IntroductionKHS-AIH-UVOffsetOnDemand

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Komori Introduction For more than 80 years, since 1923, the Komori Group has been producing

offset printing presses.

Employees : 2,471 persons

Main products: Sheet-fed Web-fed Komori Chambon Currency and Security Printing Presses

Komori CZ Office

For more than 80 years, since 1923, the Komori Group has been producing offset printing presses.

Employees : 2,471 persons

Main products: Sheet-fed Web-fed Komori Chambon Currency and Security Printing Presses

Komori CZ Office

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Innovative

Latest Technology to improve profitability and respect the environment

KHS-AI + H-UV = OffsetOnDemand

Latest Technology to improve profitability and respect the environment

KHS-AI + H-UV = OffsetOnDemand

Copyright 2008 KOMORI Corporation. All Rights reserved.

KHS-AIKHS-AI

Latest Technology to improve profitability and respect the environmentLatest Technology to improve profitability and respect the environment

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KHS-AI

Today's issues in the press room Standardize printing procedure Digitize print quality control Reduce waste Reduce lost time between jobs

KHS-AI Concept Standardize the colour matching operation No waste sheets used for color matching Reduce make-ready sheets to 20-30 sheets Get standard density within 20 sheets Limit density change on the run

Today's issues in the press room Standardize printing procedure Digitize print quality control Reduce waste Reduce lost time between jobs

KHS-AI Concept Standardize the colour matching operation No waste sheets used for color matching Reduce make-ready sheets to 20-30 sheets Get standard density within 20 sheets Limit density change on the run

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KHS-AI

Fast Print start - Instant colour and register Pre-Inking - Auto learning Smart Feedback – Density change without paper Register Preset - Auto learning Air Preset - Self learning Smart Sequence – Automatic job change

Fast Print start - Instant colour and register Pre-Inking - Auto learning Smart Feedback – Density change without paper Register Preset - Auto learning Air Preset - Self learning Smart Sequence – Automatic job change

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KHS-AI

The Intelligent Way to Increase Profitability

Productivity with unparalleled performance Lasting performance over press lifetime Automatic Intelligence for smarter production Future proof applicationCost savings on:

Paper Time Inks Chemicals Electricity

Lower cost of production than any similar machineFast return on investment

The Intelligent Way to Increase Profitability

Productivity with unparalleled performance Lasting performance over press lifetime Automatic Intelligence for smarter production Future proof applicationCost savings on:

Paper Time Inks Chemicals Electricity

Lower cost of production than any similar machineFast return on investment

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KHS-AI - Cost Advantages

KHS-AI reduces start-up paper waste by about 80% KHS-AI saves 30 tons of paper a year per machine KHS-AI intelligent pre-setting reduces lost production time KHS AI increases productivity, reduces chemical waste KHS-AI saves electricity KHS-AI reduces ink consumption by 30 to 35 % KHS-AI is a Komori Patent, there is no equal in the industry

KHS-AI reduces start-up paper waste by about 80% KHS-AI saves 30 tons of paper a year per machine KHS-AI intelligent pre-setting reduces lost production time KHS AI increases productivity, reduces chemical waste KHS-AI saves electricity KHS-AI reduces ink consumption by 30 to 35 % KHS-AI is a Komori Patent, there is no equal in the industry

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KHS-AI - Pre-Inking The self-learning function creates an automatic compensation curve

corresponding to the changes in conditions. The self-learning function creates an automatic compensation curve

corresponding to the changes in conditions.

Pre-Inking 2

Basic Ink film formed Ink profile added

% of image

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The compensation curve will change automatically after pushing the update button. Inking, register, press pre-setting are more accurate as conditions change.

The compensation curve will change automatically after pushing the update button. Inking, register, press pre-setting are more accurate as conditions change.

% of image

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Op

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Update

KHS-AI - Pre-Inking

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KHS-AI - Job Change Control

1. De-inking rollers

1-a.(Ink roller cleaning)

2. Blanket Cleaning

2-a.(Impression cylinder cleaning)

3 ． Plate Changing

4 ． Pre-Inking

5 ． High speed start up

6. Run 30 sheets and wait for OK

All these procedures can be handled automatically by…

KHS-AI "Smart Sequence"

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High Speed Start-up High Speed Start-up at 12,000 sph Time to reach 30th copy Sheets required for Stable Density Sheets required Stable Register

High Speed Start-up at 12,000 sph Time to reach 30th copy Sheets required for Stable Density Sheets required Stable Register

Approx. 40% SavingApprox. 40% Saving

Approx. 60% SavingApprox. 60% Saving

Approx. 60% SavingApprox. 60% Saving

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KHS-AI - Cost Reduction Effect on an LS 29

What If you could reduce just 100 sheets waste per job ?…

Case 1 ： 1 day operation, complete 30 jobs…100 Sheets of 135 gsm paper = 5.5kg x 30jobs x $1.50per kg = $247 cost saving per day

Case 2 ： 25 days operation per month $247 x 25 working days = $6,175 cost saving per month

Case 3: 5 years operation using KHS-AI$6,175 x 60 months = $370,500 in 5 years

+ Power savings (about $300 per month) x 60 = $18,000 in 5 years

Total Saving over 5 Years in Paper and Power = about $388,000

+ Ink & Chemicals savings over 5 years (± $7,000)

KHS-AI can easily save you $395,500 in 5 years

What If you could reduce just 100 sheets waste per job ?…

Case 1 ： 1 day operation, complete 30 jobs…100 Sheets of 135 gsm paper = 5.5kg x 30jobs x $1.50per kg = $247 cost saving per day

Case 2 ： 25 days operation per month $247 x 25 working days = $6,175 cost saving per month

Case 3: 5 years operation using KHS-AI$6,175 x 60 months = $370,500 in 5 years

+ Power savings (about $300 per month) x 60 = $18,000 in 5 years

Total Saving over 5 Years in Paper and Power = about $388,000

+ Ink & Chemicals savings over 5 years (± $7,000)

KHS-AI can easily save you $395,500 in 5 years

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Komori Technology improves the environment and your profitability at the same time

1 tree produces 3 tons of dry wood (2.5 tons of paper) 3 tons of wood makes 37,500 sheets of 40" size coated paper In 1 year a 40" press uses 533 trees (avg. 20million sheets) Average total waste paper is 5% (26 trees) Average start-up waste on a standard press is 200 sheets When we use KHS-AI we can save 160 sheets per start-up Even at only 10 jobs per day you will save 400,000 sheets

(25 tons of paper) or ten trees per year when you use KHS-AI

1 tree produces 3 tons of dry wood (2.5 tons of paper) 3 tons of wood makes 37,500 sheets of 40" size coated paper In 1 year a 40" press uses 533 trees (avg. 20million sheets) Average total waste paper is 5% (26 trees) Average start-up waste on a standard press is 200 sheets When we use KHS-AI we can save 160 sheets per start-up Even at only 10 jobs per day you will save 400,000 sheets

(25 tons of paper) or ten trees per year when you use KHS-AI

Copyright 2008 KOMORI Corporation. All Rights reserved.

Komori H-UVKomori H-UV

Brand newBrand new

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Drying systems used in offset printing

Sheet-fed machines Oxydation: Ink is dried by atmospheric oxygen. IR: Uses expensive IR heat to accelerate oxydation drying Classic UV: Mercury UV light causes photo-polymerisation to cure the ink LED-UV: Special LED-UV light causes photo-polymerisation to cure the ink

Sheet-fed machines Oxydation: Ink is dried by atmospheric oxygen. IR: Uses expensive IR heat to accelerate oxydation drying Classic UV: Mercury UV light causes photo-polymerisation to cure the ink LED-UV: Special LED-UV light causes photo-polymerisation to cure the ink

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Oxydation drying – good points and bad points

Good points Most common system, easily understood. Cost it is low compared to other drying systems

Bad points Lost time waiting for drying. Factory floor space needed for drying paper. Reverse side scratching if drying is not complete. Need to use troublesome spray powder. Need to use small stacks on difficult materials/jobs

Good points Most common system, easily understood. Cost it is low compared to other drying systems

Bad points Lost time waiting for drying. Factory floor space needed for drying paper. Reverse side scratching if drying is not complete. Need to use troublesome spray powder. Need to use small stacks on difficult materials/jobs

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UV Drying - good points and bad points

Good points Instant drying  No need for floor space for drying paper. Easy to turn over and print reverse side No spray powder so clean press environment Small stacks not necessary

Bad points Installation cost and running cost are high Because heat and ozone occurs, rust-proofing and ducting is needed Odour and taint problems can happen

Good points Instant drying  No need for floor space for drying paper. Easy to turn over and print reverse side No spray powder so clean press environment Small stacks not necessary

Bad points Installation cost and running cost are high Because heat and ozone occurs, rust-proofing and ducting is needed Odour and taint problems can happen

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Principle of UV curing system

Classic UV lamp Ultraviolet rays between 200-600nm are output. 254nm wavelength generates ozone, Wave length above 400nm generates heat. Classic UV ink Using a photo initiator with 220nm-580nm reactivity

LED lamp Wave lengths of 365nm, 385nm and 395nm are possible. Manufacturers currently prefer 385nm and 395nm LED-UV ink Current photo initiator wavelength 385nm

Classic UV lamp Ultraviolet rays between 200-600nm are output. 254nm wavelength generates ozone, Wave length above 400nm generates heat. Classic UV ink Using a photo initiator with 220nm-580nm reactivity

LED lamp Wave lengths of 365nm, 385nm and 395nm are possible. Manufacturers currently prefer 385nm and 395nm LED-UV ink Current photo initiator wavelength 385nm

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UV light emitted by Classic UV

Ultraviolet

Infra-red

High energy Low energy

10nm

Electromagnetic wave and x-ray

400nm 780nm

Visible Light

1mm

Radio wave

Copyright - eye graphics

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Merits of LED-UV LED life at least 15 times more than classic UV lamp

Classic UV lamp nominal 1,000 hours, LED 15,000 hours

LED power consumption approx. 20% of classic UV

Heat generation is low, machine stays cool Plastic and other difficult substrates have no register problems

Instantaneous on/off Classic UV start-up 1 minute, cool down 4 minutes

LED life at least 15 times more than classic UV lamp Classic UV lamp nominal 1,000 hours, LED 15,000 hours

LED power consumption approx. 20% of classic UV

Heat generation is low, machine stays cool Plastic and other difficult substrates have no register problems

Instantaneous on/off Classic UV start-up 1 minute, cool down 4 minutes

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UV light emitted by LED-UV

254nm

Ozone occurrence wave length

Heat generation

As for wave length eye graphics make

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LED-UV

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LED-UV tests in Tsukuba

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Problems of LED-UV

Distance between lamp and substrate +/- 20mm Lamp housing less than 15mm causes problems with carton. Must be positioned over a cylinder to be close enough.

UV coating not yet available LED wavelength (385nm) causes coatings to “yellow”

LED lamp cost very high (+/- $200,000 for 1 lamp on 29”) LED lamp life is long, but exchange cost is high ($100,000?).

Distance between lamp and substrate +/- 20mm Lamp housing less than 15mm causes problems with carton. Must be positioned over a cylinder to be close enough.

UV coating not yet available LED wavelength (385nm) causes coatings to “yellow”

LED lamp cost very high (+/- $200,000 for 1 lamp on 29”) LED lamp life is long, but exchange cost is high ($100,000?).

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A system which can cure LED-UVA system which can cure LED-UV ink using just one ozone-freeink using just one ozone-free UVUV lamplamp

LED

Black

LED

Cyan

LED

Mag

LED

Yell

Ozone less UV lamp

The Hybrid UV system proposed by Komori

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Hybrid UV performance tests in Tsukuba 4 lamps on, 16,000sph printing OK 3 lamps on, 16,000sph printing OK 2 lamps on, 16,000sph printing OK 1 lamps on, 16,000sph printing OK

1 lamp at 50% power, 16,000sph printing OK

4 lamps on, 16,000sph printing OK 3 lamps on, 16,000sph printing OK 2 lamps on, 16,000sph printing OK 1 lamps on, 16,000sph printing OK

1 lamp at 50% power, 16,000sph printing OK

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UV spectrum comparison of Komori Hyper UV

As for wave length eye graphics make

254nm

Ozone occurrence wave length

Calorification territory

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Advantages of Komori Hyper UV system Reduced initial cost (opposite of LED-UV)

Less than half price of LED-UV

Reduced lifetime cost of UV lamp (opposite LED-UV) Lamp life is shorter than LED-UV lamp but exchange cost is cheap,

Power consumption same as LED-UV plus compact power source Hyper UV15.8kw (lamp 10.2kw and water cooling 4.6kw on 32”).

Heat generation is low Dryer area + 4-5°

Ozone free Ozone generation wavelength (254nm) is cut.

Easy to print carton board Distance between lamp and substrate same as classic UV

Environmentally friendly printing LED ink has no VOCs No need for heat blower Reduction of CO2 emission

Reduced initial cost (opposite of LED-UV) Less than half price of LED-UV

Reduced lifetime cost of UV lamp (opposite LED-UV) Lamp life is shorter than LED-UV lamp but exchange cost is cheap,

Power consumption same as LED-UV plus compact power source Hyper UV15.8kw (lamp 10.2kw and water cooling 4.6kw on 32”).

Heat generation is low Dryer area + 4-5°

Ozone free Ozone generation wavelength (254nm) is cut.

Easy to print carton board Distance between lamp and substrate same as classic UV

Environmentally friendly printing LED ink has no VOCs No need for heat blower Reduction of CO2 emission

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Development concept of Hyper UV Komori investigated the best solution to printers in both price and

technology wise at this stage, we would like to contribute benefit to printers

Installation and running cost is low, allowing UV development into commercial printing.

Cost advantages between lamp life and exchange cost.

Overcomes a major defects with LED-UV, UV coating, no scratching on carton.

Komori investigated the best solution to printers in both price and technology wise at this stage, we would like to contribute benefit to printers

Installation and running cost is low, allowing UV development into commercial printing.

Cost advantages between lamp life and exchange cost.

Overcomes a major defects with LED-UV, UV coating, no scratching on carton.

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LS-440 (conventional) Remarks

Number of operating days

288 days Per year

Actual operating time

11.5 hours 12 hour working

Average run 3,000 sheets Per job

Production quantity

12.8 jobs Per day

Sales price 4,000 Yen Per edition

Ink cost 10 Yen Per colour /1 s

20% image

Electric power 92kw

Lamp change expense

0 Yen

Annual profit 26,158,548 Yen

LS-440 (H-UV) Remarks

Number of operating days

288 days Per year

Actual operating time

11.5 hours 12 hour working

Average run 3,000 sheets Per job

Production quantity

16.6 jobs Per day

Sales price 4,000 Yen Per edition

Ink cost 28 Yen Per colour /1 s 20% image

Electric power 131kw

Lamp change expense

2.2 times change 1,500hr life

Annual profit 27,122,908 Yen 964,360 Gain

Considering a 30% productivity increase

H-UV Profitability - compared to Conventional printing

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LS-440 (conventional) Remarks

Number of operating days

288 days Per year

Actual operating time

11.5 hours 12 hour working

Average run 3,000 sheets

Production quantity

12.8 jobs Per day

Sales price 4,000 Yen Per edition

Ink generation 10 yen Per colour /1s

20% image

Electric power 92kw

Lamp consumption expense

0 Yen

Annual profit 26,158,548 Yen

LS-440 (H-UV) Remarks

Number of operating days

288 days Per year

Actual operating time

11.5 hours 12 hour working

Average run 3,000 sheets

Production quantity

15.3 jobs Per day

Sales price 4,400 Yen Per edition

Ink generation 28 yen Per colour /1s

20% image

Electric power 131kw

Lamp consumption expense

2.2 times change per year

1,500hr life

Annual profit 30,291,281 Yen 4,132,733 gain

Considering Productivity + 20% and Sales Price +10%

H-UV Profitability - compared to Conventional printing

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H-UV ink Supplied by TOYO worldwide World-wide expansion with alternative ink suppliers Price comparable to regular UV Coverage 20% more than conventional ink Better colour hold-out (no dry back) Superior high gloss coatings

H-UV ink Supplied by TOYO worldwide World-wide expansion with alternative ink suppliers Price comparable to regular UV Coverage 20% more than conventional ink Better colour hold-out (no dry back) Superior high gloss coatings

H-UV INKS

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Classic UV Expensive installation and high running cost Produces ozone and heat (bad for m/c and environment)

LED-UV Overcomes a few of the issues with classic UV printing Expensive hardware, difficult to make a profit.

H-UV New printing technology using H-UV lamp and H-UV ink Lots of merit points compared with other UV processes. Superior printing quality and lowest production costs

Classic UV Expensive installation and high running cost Produces ozone and heat (bad for m/c and environment)

LED-UV Overcomes a few of the issues with classic UV printing Expensive hardware, difficult to make a profit.

H-UV New printing technology using H-UV lamp and H-UV ink Lots of merit points compared with other UV processes. Superior printing quality and lowest production costs

Summary

Copyright 2008 KOMORI Corporation. All Rights reserved.

KHS-AI + H-UV, adding Twenty MatchingKHS-AI + H-UV, adding Twenty Matching

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A system which matches a press sheet to a proof within 20 sheets of start-up

No change in quality after 20th sheet

A system which matches a press sheet to a proof within 20 sheets of start-up

No change in quality after 20th sheet

Twenty Matching - System

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Commercial sector Based on target density standards Using international printing standards Factory with environment control H-UV or conventional process inks

Commercial sector Based on target density standards Using international printing standards Factory with environment control H-UV or conventional process inks

Twenty Matching – Target Segment

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And when we combine KHS-AI, H-UV and Twenty Matching

We get !

And when we combine KHS-AI, H-UV and Twenty Matching

We get !

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Offset-On-Demand New business model for offset printers Competes with digital (Print On Demand) Three 200 copy jobs in 15mins Only 20 sheets waste (20 matching) Instant finishing

New business model for offset printers Competes with digital (Print On Demand) Three 200 copy jobs in 15mins Only 20 sheets waste (20 matching) Instant finishing

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Offset-On-Demand Can be used on straight or perfecting m/c Can be used with almost any substrate More profitable than digital over 400sheets Combined with near-line finishing equipment Can be combined with web-to-print

Can be used on straight or perfecting m/c Can be used with almost any substrate More profitable than digital over 400sheets Combined with near-line finishing equipment Can be combined with web-to-print

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Thank-you for your attention,

(See you soon for the demonstration)

Thank-you for your attention,

(See you soon for the demonstration)