Systems For Commercial Printing

Programme
SYSTEMS FOR
COMMERCIAL PRINTING.
A world full of solutions.
Delivery: fixed deadline.
Inside Augsburg.
Stephan Rumpf, freelance photograph in Munich, documents the
production of a commercial web
offset system.
150 years of experience.
Competence and variety.
Leadership world-wide: MAN Roland.
MAN Roland, the world market leader for
PECOM process electronic system opens up
commercial web offset printing systems, offers
trend-setting dimensions for the control of the
more in all respects. Thus, a practice-oriented
printing process and the entire printing
and differentiated series programme is available
management.
for the wide range of commercial web offset,
allowing printhouses of any size to match
Equal importance is attached to our service
their production technology individually to
which is available to you everywhere and at any
the job structure and the strategic objectives
time. As a global player, MAN Roland is com-
of the company. The offer ranges from the
mitted to the principle of a direct response to
16-page POLYMAN and ROTOMAN series, the
the market and its customers: 140 sales offices
ROTOMAN S with 24 pages to the world-wide
as well as associated partner companies in
technology leader in high-volume offset, the
224 countries know the markets, respond to
LITHOMAN series with 32, 48 and 64 pages.
trends and focus on significant lines for
In addition, digital printing systems for the
consultation, service and support. Thus, the
production of fully coloured low circulations
product range from MAN Roland is unique as
are offered.
compared with our international competitors.
For more profitability by design.
Our objective is to provide our customers with
an excellent quality at the highest degree of
economy. Emphasizing the technology of the
printing systems, presses from MAN Roland
set standards for system flexibility, for a fast
change of jobs and in the variety of opportunities
for the production run. And the high-capacity
Sheet-fed
systems
Digital printing
systems
Newspaper web
offset printing systems
POLYMAN, ROTOMAN,
ROTOMAN S, LITHOMAN
The MAN Roland series for commercial printing.
3
Success is programme.
Commercial offset
is a growing
market offering
great chances.
MAN Roland can
help to use them
successfully.
Various trends, higher
requirements.
Commercial offset, one of the
most competitive market segments of the graphic arts industry,
features more and more new
tendencies: New formats are
pushed on the market in the
journal and magazine segments.
Numerous launches and relaunches extend the offer, and
lead to a still greater variety.
Lavish covers and a high-quality
appearance are designed to
make a difference at the kiosk.
The integration of special pages
or CD-ROMs increase the benefit
for the reader. And a stronger
orientation on target groups is
designed to improve the bonds of
the reader or to find a new public.
In the case of catalogues, an obvious trend towards assortment
and partial assortment catalogues
can be seen, connected with a
more frequent publication at
significantly lower page counts.
In addition, the integration of
editorial pages, a higher individualization as well as a more
extensive orientation on dialogues
by including response media are
features of the developments.
Commercials and brochures are
increasingly launched under the
aspect of a more exact orientation on target groups at lower
distribution losses.
Tip-on cards or tear-off coupons
increase the advertising efficiency.
Ready-made items, demanding
in-line enhancements, the integration of samples and interactive
elements as well as unusual
formats and folding types are
other challenges which can only
be met if the production solution
provides a maximum of flexibility,
variety and productivity, and is
fully integrated into the digital
workflow.
1,350° C.
4
More up to date,
more flexible, more efficient.
The developments on the market for heatset products can be
summarized to form a requirement profile which explains the
central challenges, but also the
chances associated with them:
the prime requirement for more
topicality in publishing printing
means a reduction of printing
and delivery times for the printing companies.
Therefore, printing systems providing the highest productivity
and reliability of production are
in demand. The production of
off-prints, split to accommodate
target groups, regions and interests more exactly, frequently
requires job changes at variable
circulations and page counts.
The system approach must satisfy these requirements by a
higher flexibility, shorter makeready times and lower waste
values. Within the ranking of requirements, one aspect is of
major importance: More than
ever, the efficiency of production
is the crucial factor for the competitiveness and future viability
of the printing companies in illustration offset.
Trends and challenges.
MAN Roland solutions.
Printed commercial products are
a market of the future. For the
years to come, a continued dynamic growth of this market segment which allows printhouses to
extend their position is emerging.
Provided, they work with production systems which have the
flexibility to print the wide range
of products efficiently and simultaneously at a high quality.
The complete MAN Roland series program of innovative offset
and digital printing systems satisfies the requirements for economical success in illustration
offset printing, centering around
a high printing quality, short
makeready times, low waste and
highest operator convenience.
This is provided by systems
and equipment such as the automated Power Plate Loading (PPL)
system, automatic washing
systems, responsive inking and
damping units as well as a high
capacity and modularly expandable folders.
In particular, the leading PECOM
process electronic system contributes to a flexible and efficient
change of production which
occurs more and more frequently.
PECOM not only allows the
presetting of all functions on the
central control console, but also
the job preparation and an evaluation of process data. The
MAINSYS planning and maintenance software as well as the
AUROSYS material logistic system
set standards for an efficient
production. The programme is
completed by the approach of the
open system architecture and
the extensive world-wide service
provided by MAN Roland. Thus,
whoever builds on profitability
by design, may count on MAN
Roland: the competent system
partner for future-oriented
solutions in commercial offset
printing.
V2A steel.
Tolerances up to ±0.5 µ.
As a global
system partner,
MAN Roland can
offer trend-setting
technologies and
concepts.
4 m2 details.
Tool kit.
Printing systems.
For all-round printing.
Inserts, catalogues, brochures
and magazines at low and
medium circulations and page
counts characterize the field of
all-round printing where the
POLYMAN and ROTOMAN can
prove their strength. This includes
the short makeready times for
fast changes of jobs and the excellent price-performance ratio.
POLYMAN: the clever press.
Advanced technology from the
automatic reel splicer to the flexible folder, this is the POLYMAN
design: the 16-page production
approach in the long grain format
combines a low investment
volume with the performance of
40,000 cylinder revolutions or
640,000 DIN A 4 pages per hour
at the highest printing quality.
In addition, this series proves itself
by requirement-based automations and high operator convenience in the PECOM system.
All this makes the POLYMAN an
ideal printing system for all-round
printing. For companies, wishing
to gain a new foothold in commercial web offset printing, as well
as a supplementary machine for
large printhouses the POLYMAN
is a prime selection.
ROTOMAN: performance.
With its capacity of 55,000 copies
or 880,000 DIN A 4 pages per
hour, the ROTOMAN is the highperformance system in all-round
printing. The high degree of automation for quick changes of jobs
at shortest makeready times is
a feature of excellent economy.
Keywords: shaftless single drive,
automated PPL change of plates,
inking unit temperature control,
web scanning and register control via the PECOM video-system.
In the 16-page
commercial web
offset segment,
MAN Roland can
offer highly efficient and flexible
printing systems,
each of them a
In addition, modularly expandable
folder super-structures and folders with various in-line finishing
components allowing an optimum
adaptation to the job structure are
available. Thus, the ROTOMAN
can produce the entire traditional
repertoire in commercial offset
printing most efficiently and at
high-end quality.
class of its own.
The POLYMAN.
7
For classic commercial printing.
Wherever heatset
products are
mainly printed,
the ROTOMAN in
the 65,000 class
can prove its high
The market for classic commercial
printing requires highly flexible
printing systems which can be
used universally to produce a
wide range of circulations efficiently
and at the best printing quality.
Thus, the ROTOMAN technology
has consistently been designed
for these requirements with its
convincing performance and
productivity.
ROTOMAN:
the power system.
A system approach which meets
the trend towards smaller offprints at a higher topicality and
is economic and efficient up to
the highest circulations at the
same time: this is the ROTOMAN,
market leader in the 16-page
format. With its perfect synthesis
of highest performance and prime
quality at excellent efficiency.
productivity.
With its 1.04 millions of DIN A 4
pages per hour, the ROTOMAN
sets an outstanding standard in
the production capacity. The
automatic PPL change of plates,
the automatic paper web infeed
and the automatic washing
systems can reduce the makeready times and the waste rates.
Simply exemplary: the high
printing quality by the bearer ring
technology and the low-vibration
cylinder run, the constant web
tension and a responsive inking
and damping unit.
The ROTOMAN.
8
The high-capacity folders allow
an almost limitless variety of production. Advanced technology,
a high level of automation and the
presetting optimization as well
as the workflow networking within
the PECOM systems are the prerequisites for productivity and
quality for a wide range of jobs.
For the market of classic commercial printing, the ROTOMAN
is an excellent printing system
with future-oriented protection
of investments.
Printing systems.
For high-volume offset printing.
High-volume offset can guarantee
large runs with high and low page
numbers as well as low runs at
high page counts. For example,
this includes catalogues and
partial catalogues, special interest
titles and widely distributed direct
mails. In this market segment
with its dynamic growth, the
high-capacity ROTOMAN S and
LITHOMAN series occupy a
leading position.
ROTOMAN S: the sprinter.
Whenever high productivity
and efficiency are demanded, the
ROTOMAN S is unrivalled. A
feature of this 24-page machine
for long grain format is the sleeve
technology: the gapless blanket
cylinder and the plate cylinder with
their extremely narrow clamping
gap provide a very small imagefree area as well as an excellent
printing quality even at the highest
production speed.
Using a maximum of 80,000
cylinder revolutions per hour, the
ROTOMAN S can implement an
enormous performance potential
with only two pages in its cylinder
circumference. Ideally, if highest
capacity is required and mainly
12- and 24-page products must
be printed.
The convincing approach of the
highly automated ROTOMAN S
additionally includes the single
motor drive, the responsive inking
and damping unit as well as the
folders designed for a wide variety
of production. Equipped in such
a way, the ROTOMAN S can
produce demanding heatset products such as magazines, brochures, newspaper inserts and
advertising journals not only efficiently and at a high quality, but
also with a page count that
meets the market requirements.
The 24-page
ROTOMAN S
combines a high
capacity with a
high flexibility
for an efficient
production.
Depending on the folder used,
various products from 6 to 24
pages can be produced. And in
connection with the double former folder, even the two-page
skip is possible at an optimum
utilization of the stock.
The ROTOMAN S.
9
The world-wide
market and
technology leader
in high-volume
offset: the highcapacity
LITHOMAN series
from MAN Roland.
LITHOMAN: the champion.
In the market segment of highvolume offset, the LITHOMAN sets
unrivalled standards regarding
productivity, printing quality and
efficiency: the double cylinder
circumference with its four pages
in the circumference and the
maximum web speed of up to
15 meters per second are general
features of the series in the short
and long grain format. Their high
performance potential and web
widths of up to 1,980 mm increasingly develop job potentials
formerly reserved for gravure
printing.
The outstanding LITHOMAN
technologies include the automatic web infeed at 50 meters
per minute, the TECOSYS web
tension control, the automatic
PPL change of plates, the finely
metered inking and damping units
as well as the high-end folders
for a wide variety of products to
yield excellent printing results in
industrial commercial web offset
at lowest waste and shortest
makeready times. In addition, high
efficiency can be achieved by
the technical production planning,
the automatic machine presetting as well as the control of the
printing production within the
highly intelligent PECOM system.
The LITHOMAN.
10
For all production requirements
in industrial high-volume offset,
the LITHOMAN approach allows
the implementation of a tailormade solution: the printing
systems are available in long grain
with 32, 48 and 64 pages, in
short grain with 32 and 48 pages.
Various configuration capabilities
and the high-quality print at
superior efficiency over wide run
ranges emphasize the world
class of the LITHOMAN.
Printing systems.
LITHOMAN IV, long grain.
For printhouses with a high share
of magazines and catalogues in
standard formats, the LITHOMAN
IV with its long grain format is the
prime selection, as a 32-, 48- or
64-page system. This format
offers advantages in particular for
DIN A 4 products with a subsequent adhesive binding.
The 16-page stepping of the
press series is matched to meet
the different capacity requirements
in a practice-oriented manner.
The 64-page LITHOMAN with
its output of 2.5 millions DIN A 4
pages gains gravure ground if it
is for productivity and efficiency.
Long grain
LITHOMAN III, short grain.
The LITHOMAN III with 32 or 48
pages in the short grain format
offers convincing advantages for
an in-line production of jobs with
different product volumes: The
product volume can be varied
over the web width at an optimum utilization of the paper. In
addition, DIN A 4 products can
be produced especially simply
and reliably since the fold spine
is formed by the 1st cross fold.
Be it short or
Furthermore, the number of
pages for the products within the
DIN A4 range can be flexibly designed in four-step paces. High
productivity and page flexibility
are the strong features of the
32-page LITHOMAN III which
can produce up to 55,000 copies
per hour. And the 48-page
LITHOMAN III S with its sleeve
technology can use the benefits
of the short grain format for web
widths of up to 1,905 millimetres.
all job profiles.
LITHOMAN is
more than only a
format class:
most different
approaches for
Short grain
64 pages
(2 webs
32 pages)
48 pages
64 pages
32 pages
LITHOMAN III
III S
32 pages
LITHOMAN IV
long grain - the
48 pages
64 pages
(2 webs
32 pages)
96 pages
(2 webs
48 pages)
Formats for all requirements: long grain
or short grain, for 32 to 96 pages.
11
For full-colour digital printing.
No films, no plates,
no mechanical
conversions –
these are the
features of the
digital DICO prin-
The trend to a specialisation
and individualisation of products
in illustration printing leads to
increasingly lower print runs.
To account for the special economy of this trend, MAN Roland
offers digital printing systems
for quick and profitable jobs in
fully coloured low circulations.
Market surveys show a disproportional growth in short run
colour products.
ting systems from
MAN Roland.
DICOweb:
Forget your plates.
DICOweb from MAN Roland
provides the first genuine computer-to-press offset printing
system world-wide for illustrating, erasing and re-illustrating
the print forme directly in the
machine. Fully automatically, at
a high printing quality, without
any film, make-up and, above all,
without any change of plates –
thus, DICOweb opens up unparalleled potentials in multicolour printing of short circulations. Technical magazines, CD
booklets or books can thus be
produced at low circulations.
Providing a printing speed of
3.5 m/s and a production output
of 20,000 prints per hour (at a
cut-off length of 630 mm), it is
an ideal system for an economical production of low circulations
with 1,000 to 20,000 copies.
Further advantages include the
high format variability by exchangeable sleeves of different
thicknesses, and an exchange
of basic cylinders is possible for
larger format skips. A modular
platform approach provides
a special system advantage:
The system can be configured
individually from the reel splicer,
the printing units to the dryer
system, cross cutter and folder,
and can be supplemented by
different additional and print
converting units.
DICOpress: Individual low
circulations.
Producing individually designed
products at a high quality economically by using variable data,
this is what DICOpress has
been designed for. Regarding
up-to-dateness and flexibility
in particular, this press is hardly
unrivalled: modifications to the
printing data can be performed
at the last minute, and a change
from one print job to the next
one can be made non-stop.
The individual dialog with the
customer in 1:1 communication
is as uncomplicated as the flexible production of a pre-launch
issue for the magazine market.
DICOpress operates at a printing
speed of 3,900 DIN A 4 pages
per hour, offering high format
DICOweb.
12
flexibility, a wide range of material
variety and a top quality with its
perfecting register for 4/4-colour
printing. A direct link to the
pre-press stages, smooth oneman operation and a complete
process control by an integrated
data management are other
benefits of DICOpress which is
available in two web widths of
320 mm and 500 mm.
DICOpress.
System control.
For a variety of colours.
Intermediate check.
Networking on an open platform.
The PECOM
digital process
electronic system
can combine the
job preparation
with the printing
process and the
management
functions.
The PECOM system.
The PECOM central control console can control the entire system,
monitor the printing process
and optimize the printing quality.
A touch of a finger will suffice to
initiate whole standard jobs from
the flat keyboard of the central
control console: printing and
movement commands as well as
the control of the folder superstructure and folder, infeed unit,
dryer and chill rolls. From the
colour desk, settings for the ink
zones, colour registers, ink and
damping duct rollers as well as
the ink zones can be changed.
An interface for data communication even allows on-line
diagnostics by the MAN Roland
specialists. In addition, the On-line
Video Service (OVS) is available,
allowing dynamic processes to
be transmitted as a video conference directly to the technical
departments with MAN Roland.
The PECOM central control console for
controlling the entire production process.
14
Production planning online.
The PECOM ProductionManagerTM
is the tool for optimum planning,
presettings and evaluation of the
print job, preparing the production
data centrally for one or more
systems. To this effect, the colour
measuring values from the
scanner or the colour data from
the pre-press stages can automatically be prepared online via
the PrePressLink, and the determined presetting values can be
transferred online to the central
control console. Even the machine assignment plan as well as
other production-dependent
setting data can be programmed.
In addition, MAINSYS can be
used to integrate the automatic
material handling and maintenance schedule system.
Video sees more.
In connection with the ColorLoop
system, the PECOM video-system
is a module for further automation
and for highest printing quality.
The colour register with its automatic mark search according to
the mark position specification,
for instance, allows a change of
marks at any time, the compensation of errors as well as a continuous adaptation of the contrast.
The web scanning system is integrated into the colour register
control system. In addition, the inline colour measurement ensures
a meticulous quality control and
an extensive quality report.
Line control, service.
We know how.
MAN Roland is
the competent
partner for
consultation and
service, worldConsultation first.
For restructuring, expansion and
new installation projects, we can
provide support with consultation
services for a high degree of
safety in the future. The strategic
investment planning is based on
the analysis approach from MAN
Roland: starting out from the
product mix, the production and
capacity requirements as well as
the cost structure of the company,
system, technology and production approaches can be worked
out and evaluated according to
efficiency aspects.
The MAN Roland approach of the
open system architecture does
not commit printhouses to types
or manufacturers, but only to the
adherence of certain interfaces
to ensure that components of a
printing system can be included
in accordance with individual
customer requirements: always
the best only.
At high speed from the
beginning.
New production plants and technologies are changing the business structure. The MAN Roland
project team can take care of a
smooth integration into the production process and coordinate
procedures so that the management and staff can cope with
the change quickly and efficiently.
This ensures that the delivery,
installation and commissioning
of the plant is performed exactly
in time.
During the start-up phase,
MAN Roland can accompany you
in the selected optimization of
processes based on the data
from the machine control system
and the log or the production
report. The training centres of
MAN Roland in Augsburg and
MAN Plamag in Plauen can provide technical knowledge in the
field of printing and process engineering, electrical engineering,
electronics and mechanical engineering. Experienced experts
will provide training for the printing
staff, from mechanical engineering
to the detection of errors, repair
and maintenance.
Wherever we are needed.
The Tele Support Centre (TSC)
can be called around the clock
as your central contact for a
qualified support in all questions
and problems, combining advanced communication and information technologies with the
use of multi-media tools to provide our services quickly and
cost-efficiently. For example, the
range of the world-wide available
support from the Tele Support
Centre includes selective remote
diagnostics, an evaluation of
production data, the optimization
of processes as well as the transmission of software updates.
wide available to
you at any time.
Tailor-made maintenance contracts as well as an efficient spare
part service will complete the
after-sales programme. The central store in Augsburg is the
largest of its type world-wide.
15
Night shift.
Made in Germany.
Profitability by design.
DIN A 4 pages
Cut-off length (mm)
Web width (mm)
Capacity max. (Cp./h)
Page layout
POLYMAN
ROTOMAN
ROTOMAN S
LITHOMAN III
16
16
16, 24
32
546, 578, 630
533, 546, 553, 565
578, 598, 620, 630
520–630
820–904***
965
965
965–1,460
1,260
40,000
55,000*
65,000
80,000
55,000
Long grain
Long grain
Long grain
Short grain
X
Sleeve technology
X
Automated PPL
change of plates
Change of plates
without tools
X
X
X
X
Multiple motor drive
X
X
X
X
X
X
X****
X
X
Folding system.
1:2:3:2
2:3:3
2 : 3 : 3 gripper fold
2:5:5
Double former folder
18
X
X
X**
X**
X
X
X
Production programme.
LITHOMAN III S
LITHOMAN IV
48
32, 48, 64
820–904***
1,105–1,260***
up to 1,905
up to 1,980
55,000
42,500
Short grain
Long grain
X
DICOweb
DICOpress
Printing process
Offset
LED-based
electrical photography with dry toner
Output cp/h
or sheets/h
(DIN A4 4/4) max.
20,000 at a cut-off
length of
630 mm
3,900
Web width and/or
printing width
min./max. (mm)
300–520
307.6 ; 473
variable
unlimited
CMYK
CMYK
open (depending on
the print conversion
and dryer)
Paper, plastics,
labels
80–250 g/m2
3.200
600x600
8 (formatdependent)
non-stop
PECOM,
integrated
link to the
pre-press stages
DICOstream
Cut-off length and/
or printing length
X
X
X
X
X
Inks
Stocks
dpi resolution
Change of formes
(min).
X**
X
X
X
Control
software
The commercial printing system is subject to continuous enhancement and altered according to the results of
research and development gained from practical experience. Therefore, we reserve the right to modify design
features and technical data. Only the confirmation of order will be binding.
* Including one quarter fold.
** Up to 70,000 rpm.
*** Other cut-off lengths
on request.
**** Up to 50,000 rpm/h.
19
www.man-roland.com
MR A19.1.0601, printed in Germany, englisch, Illustrationsdruck
MAN Roland
Druckmaschinen AG
Postfach 10 00 96
D-86135 Augsburg
Phone +49 821-424-0
Fax +49 821-424-3303