High-volume production of commercial print in inkjet web with offset-class print quality and material diversity – Service & Print Group Haberbeck lives up to this claim thanks to a Ricoh PRO VC60000 inkjet web printing system. The printed web is subsequently cut very efficiently using a versatile in-line configuration from Tecnau.
At the headquarters of Service & Print Group Haberbeck in Lage, mid-way between Hannover and Dortmund, digital web printing operates alongside heatset web offset on three web presses, sheetfed offset on two presses and digital sheetfed on three systems. The group employs 250 people at three German facilities and is a cross-media, full-service “digital” company for all advertising channels, with a portfolio covering everything involved in the development and production of marketing campaigns, including conception and design, through IT services as well as printing and finishing to logistics and fulfillment. Its business activities are focused on retail marketing for clients in the automotive, textiles & fashion and telecommunications industries. The production of supplements, inserts, catalogs, brochures, mailers and POS products is therefore the order of the day. Since most of Haberbeck’s customers sell through networks of branches or franchises, many of its high-volume products have to be highly personalized or versioned.
“It was back in 2011 that we first started thinking about digital web production –print runs for supplements were in decline and also, demand was increasing for personalized and variable printing,” reports Christian Haneke, Head of Technical Transformation at Service & Print Group Haberbeck. “It really took off starting in 2014. Ricoh gave us a solution that met all our requirements for offset-compatible print quality and a broad array of substrates. Hybrid products, for instance, which we print in runs of several hundred thousand copies, are an important pillar for us. The personalized cover is digital but the content is produced in sheet-fed or web offset. There mustn’t be any visible difference in quality between the two.”
Productive efficiency in-line
Haneke explains why Haberbeck decided to combine the inkjet system, which was commissioned in April 2016, with Tecnau products: “We were looking for a market-ready solution and the cooperation between Ricoh and Tecnau was far advanced. What’s more, Tecnau’s in-line processing equipment had already demonstrated what it was capable of at the European pilot user of the Ricoh PRO VC60000. The fact that Böwe Systec, who was traditionally well-established with us, was also responsible for servicing Tecnau machines was another strong argument.”
The 36-meter line, comprised of the inkjet system and various Tecnau machines, runs with a single operator per shift. A Tecnau Unwinder 550 feeds rolls up to 52 cm wide to the Ricoh PRO VC60000. Equipped with a heavy paper kit, the Tecnau unwinder can handle paper types weighing anything from 40 to 250 g/m2 and is thus optimally matched to the printing system. “We exploit the possible paper type and weight ranges to the full,” Haneke emphasizes. “About three quarters of our output is printed on matt or glossy art paper, though we also use newsprint, uncoated offset papers and occasionally inkjet papers.”
Flexible processing options with Tecnau
Roll-to-roll production for finishing by an external service provider is handled simply by a Tecnau Rewinder 555, which is arranged at a right angle.
In most cases, however, the web is supplied to the cutter, passing first through a Tecnau Buffer 530 before entering the Tecnau Cutter c23. Output may be slit into 2-up or 3-up streams in addition to simple 1-up production. The Tecnau Stacker s20 then stacks the sheets. “This workflow is a particular advantage when products with a large number of pages have to be printed in short runs, like catalogs or manuals that are printed on demand. The option of printing single copies means we can deliver collated products that are ready for perfect binding,” Haneke continues.
Alternatively, the Tecnau installation can cut sheets (even posters) up to 52 x 100 cm in size and stack them in piles. In this case, after sheeting in the Tecnau c23 cutter, the sheets are fed to a Tecnau h10X high pile stacker, where they are stacked on pallets before being folded or processed in another way.
“Service & Print Group Haberbeck opted for one of our versatile machine configurations; it dovetails with the Ricoh PRO VC60000 optimally in terms of productivity and the papers that can be processed,” says Robert Gubo, Tecnau Sales Manager for Germany and Switzerland. “From personalized, high-volume jobs to short, print-on-demand runs, the Tecnau solution lets Haberbeck cut flexibly and efficiently in-line, so that they meet the requirements of the various downstream processing steps in every respect.”
In-line production at speeds of up to 120 m/min, which is also the maximum for the press, can be achieved regardless of the operating mode set on the Tecnau line. “The Tecnau components make a perfect complement to inkjet production printing. The entire line enables streamlined, high-quality digital production, seamlessly integrated into our overall workflow,” Haneke concludes.
The Ricoh PRO VC60000 inkjet web printing system, equipped with in-line finishing equipment from Tecnau, is supplied with roll paper by a Tecnau Unwinder 550.
Service & Print Group Haberbeck prints a wide variety of products, covering a similarly diverse range of paper types and weights, on the inkjet system.
After sheeting in the Tecnau Cutter c23, the sheets are fed to a Tecnau High Pile Stacker h10X.
Commercial Printing, Graphic Arts.
Catalogues or Manuals, Brochures to Large Format Posters
Ricoh PRO VC60000 inkjet web printing system
Flexible combined inline solution with multiple options:
- Roll 555 Roll-to-Roll with Unwinder 550 & Rewinder 555.
- Stack 2320: Unwinder 550, Cutter c23, Stacker s20 on 90° conveyor.
- Stack h10: Unwinder 550, Cutter c23 to High Pile Stacker h10.