Quick pressroom retrofit of Grapho Metronic IDC system

Closed loop color controls added to Kala Jyothi’s Komori heatset

InkZone Inline IDSm 1280x1191

In 2006, Kala Jyothi installed a new Komori System 38S heatset press at its web offset plant in Kondapur near Hitec city in Hyderabad for printing magazines and newspaper supplements. The press has been running well with excellent service on the whole over the years. From the outset, it had a KHS-AI (Advanced Interface) preset system for shortened makeready, which remembers ink and dampening preset and corrections from previous runs and incorporates these in current runs.

However, when Kala Jyothi’s KHS-AI system stopped working about 5 or 6 years after the press was commissioned, Komori was unable to fix it although the request was well within 10 years of the press installation. The company spoke of the requirement for a new software purchase at considerable cost and was also unable to put in a modern closed loop color at a cost-effective price or convincing time frame saying that the solution had to be redeveloped for what it described as an older generation press.

However, the German press manroland web systems together with a Swiss interface supplier was ready to retrofit and upgrade Kala Jyothi’s Komori System 38S press with a Swiss interface and a manroland web systems Grapho Metronic Inline Density Control system – a closed loop color density and control system. Kala Jyothi director Kartik Alapati says, “They said they were ready to make it work, and we said if you can make it work you can have the order. Remarkably the manroland web and Swiss interface combination didn’t even ask us for an advance although it was the first time they had done this interface on a Komori System 38S. They were quite confident and we were very pleased to see a German company that is ready to provide not just a new press but every type of accessory and upgrade together with engineering service in case you need just another unit or some modification or let’s say an improvement in your quarter folder. This was super interesting.”

“We understand that life is competitive nowadays,” says Kala Jyothi director Ramnath Alapati, adding, “Others such as QuadTek and QI were also interested in the competitive estimate and time frame that we received from the Swiss team, which were a fraction of the cost and the whole process took just 45 days. The actual machine was down for a few hours only on two days for the retrofit work. After shifting to the Grapho Metronic system, it took us another few days to create the new curves. We are even looking at a similar solution for our Goss heatset press, which is a year younger than the Komori 38S.”
The Grapho Metronic inline density control (IDC) measuring system features quick measuring and response cycles with high resolving capacity cameras, LED flash illumination and a design that is claimed to have no moving parts, and thus no wear. With the parallel arrangement of the cameras, the measuring strip can be covered across the full width of the paper in one measuring. The high measuring frequency means that with the dynamic fast-reaction controls, process fluctuations can often be compensated for even before the tolerance limits are exceeded. The control process includes the zonal shift elements and also the ink fountain roller thus covering the entire ink flow effectively, using the linked fountain-key opening actuators and fountain-roller speed.u
This article has inputs from manroland web systems.

2023 promises an interesting ride for print in India

Indian Printer and Publisher founded in 1979 is the oldest B2B trade publication in the multi-platform and multi-channel IPPGroup. While the print and packaging industries have been resilient in the past 33 months since the pandemic lockdown of 25 March 2020, the commercial printing and newspaper industries have yet to recover their pre-Covid trajectory.

The fragmented commercial printing industry faces substantial challenges as does the newspaper industry. While digital short-run printing and the signage industry seem to be recovering a bit faster, ultimately their growth will also be moderated by the progress of the overall economy. On the other hand book printing exports are doing well but they too face several supply-chain and logistics challenges.

The price of publication papers including newsprint has been high in the past year while availability is diminished by several mills shutting down their publication paper and newsprint machines in the past four years. Indian paper mills are also exporting many types of paper and have raised prices for Indian printers. To some extent, this has helped in the recovery of the digital printing industry with its on-demand short-run and low-wastage paradigm.

Ultimately digital print and other digital channels will help print grow in a country where we are still far behind in our paper and print consumption and where digital is a leapfrog technology that will only increase the demand for print in the foreseeable future. For instance, there is no alternative to a rise in textbook consumption but this segment will only reach normality in the next financial year beginning on 1 April 2023.

Thus while the new normal is a moving target and many commercial printers look to diversification, we believe that our target audiences may shift and change. Like them, we will also have to adapt with agility to keep up with their business and technical information needs.

Our 2023 media kit is ready, and it is the right time to take stock and reconnect with your potential markets and customers. Print is the glue for the growth of liberal education, new industry, and an emerging economy. We seek your participation in what promises to be an interesting ride.

– Naresh Khanna

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