NewsBRIEF. Printing company Grafotisak using Push to Stop concept from Heidelberg for book production

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1 Heidelberg Graphic Systems Southern Africa (Pty) Ltd Tel: +27 (0) February 2018 NewsBRIEF Printing company Grafotisak using Push to Stop concept from Heidelberg for book production The Speedmaster XL 162 produces up to 64 pages on both sides per sheet and is used for special book productions. Investment in complete value chain including workflow Package includes first fully automatic Suprasetter 106 worldwide with a speed of 55 plates per hour Totalizer of the new Speedmaster XL P already showing over 27 million after six months Next goal: integration with Prinect MIS system According to Wikipedia, the town of Grude in Bosnia and Herzegovina is home to four large companies: an ice cream factory, one of the biggest toilet paper factories in Europe, a brewery, and a printing company. In fact, it may come as a surprise that Grafotisak incorporates a state-of-the-art print shop and warehouses for merchandise on a total area of over 26,000 m2. Owner and Managing Director Stipan Vranješ is from Grude, and established the company in Grafotisak has gradually developed into a Group with 600 employees and a total of ten sites in Bosnia and Herzegovina, Croatia, and Serbia. Half of its sales comes from school, office and graphics supplies, while the other half comes from print production of books and the corresponding logistics distribution. 1 Books account for 90 percent of the printing company s production, and are delivered to fifteen European countries. The export share is 80 percent. Grafotisak delivered 25 million books in 2017, and expects a ten percent increase this year. To cope with this, last year the company invested in a Speedmaster XL 106 from the latest drupa generation and a Suprasetter 106 CtP platesetter, as well as in Prinect modules for the integration of postpress. Heidelberger Druckmaschinen AG (Heidelberg) supplied everything from a single source, including intensive advice in advance. Grafotisak s customers are well-known publishers like Taschen, Burda, Egmont, Disney, Harper Collins, and Gyldendal. The other ten percent of production is split between security printing of duty stamps for alcohol or cigarettes, folding cartons and lever arch file production. Quality through time we ve achieved rapid growth in the print shop with this motto, explains Marko Vranješ, son of the owner and Technical Director. We replace our machines every five years so that we re always up to date and can deliver the best to our discerning customers. The group s growth last year was 12 percent, and the goal for 2018 is up to seven percent. Productivity and integration bring economic efficiency To be able to handle all this, Grafotisak needs reliable and innovative partners. We ve trusted in Heidelberg from the beginning, and know that they will listen to us and supply us, confirms Marko Vranješ. And so it is once again with the new Speedmaster XL 106 eight-color press with perfecting and a speed of 18,000 sheets per hour. This press is fully equipped with AutoPlate XL, Wallscreen, and Prinect Inpress Control 2, and works according to the Push to Stop concept in which the operator only intervenes to change plates or stop the press. We can now have up to 30 jobs processed automatically, and in some cases are twice as fast as on the other presses, explains Marko Vranješ. Over 27 million sheets have already been printed since production started in July The pressroom now houses a total of 48 printing units from Heidelberg, including one Speedmaster XL 162 press, five Speedmaster XL 106 presses, one Speedmaster XL 75 press, and two Speedmaster SM 52 presses. The last big investment was in 2015, with a package consisting of the Speedmaster XL P and a Suprasetter 162. This enables a book with 32 or 64 pages to be produced on one sheet. New Suprasetter supplies three shifts The current investment package also includes the first Suprasetter 106 worldwide, which images 55 plates per hour (pph). Up to now, the limit was 40 pph. It is a complete

2 Suprasetter line with Auto Pallet Loader 106 K, Dual Cassette Loader with turn table, Glunz & Jensen Interplater 85 HDX, and a NELA bending line with two stacking stations and plate sorting. The Suprasetter thus fits seamlessly into the Push to Stop concept, in which the imaged plates are brought directly to the machines and each job is assigned appropriately. Around 1,200 plates in B1 format are imaged every day, which is exactly enough for three shifts. Since the software release for the capacity of 55 plates per hour and the completion of the CtP platesetter took place during Kiel Week, Heidelberg and Grafotisak came up with a novel idea: the Suprasetter 106 was painted with motifs from Kiel Week. We re more than happy with the new Suprasetter, and it s the star of our prepress setup, confirms Marko Vranješ. Integration is the beginning and the end With each investment, the workflow is also expanded and supplemented. For example, postpress was also recently integrated. It comprises four Stahlfolder TH 82-P machines. These work according to the shingled folding principle. This means that more sheets can be processed on the same line, resulting in a performance increase of up to 50 percent without raising the machine speed. High folding quality is thus guaranteed, even with delicate papers. Above all, it enables the high output of the five Speedmaster XL 106 to be processed and quickly delivered to the customers. At Grafotisak, prepress, press, and postpress are integrated via the Prinect Integration Manager. The goal for the future is complete integration with the Prinect MIS system, so that offer preparation and costing are also covered. And with this transparency and access to all data from every location. Label printers world wide use the flexibility and productivity of new Gallus Labelmaster Successful launch in China end of 2017 New standard in cost effectiveness At the beginning of December last year, Heidelberg China and Gallus Shanghai jointly organized in the Print Media Center in Shanghai a launch event for the Gallus Labelmaster in China. Around 160 guests from label print shops in China and Region Asia as well as media journalists attended the event. They were able to watch live demos of the Gallus Labelmaster in label production and experienced a new height in leading label printing. We are extremely optimistic about the future development of packaging and label printing in China, explains Benny Huang, CEO of Heidelberg China. In recent years, with an increasing middle class and accelerating urbanization processes, there are more and more specific requirements on packaging and label. It is our duty to continue providing high quality products and services for packaging and label print shops in China. Asia has become the fastest growing label market in the world. It is expected that by 2019, the Asian label market will have increased by 5.5%, in which the growth rate of self-adhesive labels will reach 6.3%. Owing to the higher cost of raw materials and labor today, print shops are paying more attention to productivity, describes Teddy Jiang, General Manager of Gallus Shanghai. At the same time, influenced by consumers and branding goods manufacturers, packaging and label printing is moving towards short run, multiple orders and product diversification. Since entering the Chinese market nearly ten years ago, Gallus has sold over 100 machines. Together with Heidelberg China Gallus will introduce their machines to more Chinese customers. The high output of the five Speedmaster XL 106 presses is processed by a whole series of Stahlfolder machines in preparation for fast delivery to customers. After the full integration of the Gallus Holding AG into Heidelberger Druckmaschinen AG (Heidelberg) in 2014, the Gallus Innovation Days were held at the Gallus headquarters in St. Gallen, Switzerland in September Customers from all over the world saw for themselves the world premiere of the Gallus Labelmaster, the latest flexographic printing press designed for the label market. A year after that, in September 2017, visitors of Labelexpo Brussels were totally convinced of the high efficiency as well as high flexibility presented by the new Gallus Labelmaster. The machine has set a new We choose Stahlfolders because they last and perform brilliantly, says Gareth Roberts, Managing Director, Bishops Printers. Click below link to read further... The family-run company Grafotisak father Stipan Vranješ (left) and his two sons Marko (center) and Nikola insist on high-quality print production and on machines from Heidelberg. overview_1/latest_news/press_release_24512.jsp 2

3 benchmark in 17 inch label printing. Already now, only three months after the market launch, there are more than 20 presses installed in foreign countries and customers feedbacks are positive. Gallus Labelmaster: Premiere in China The Gallus Labelmaster is a label printing press platform designed for the label and packaging market. It features a special platform design and can be configured by customers to meet their own specific requirements. With its open interfaces and Heidelberg platform development knowhow for offset presses of Heidelberg, this machine series represents a highly secure investment and enables users to respond flexibly to future changes in the market. The new Gallus Labelmaster for label printing thus builds on the successful, tried-and-tested design principle of Speedmaster offset printing presses from Heidelberg. Less Complexity, more Flexibility is exactly the innovation concept defined by Gallus for the Gallus Labelmaster. Modules such as flexo printing, screen printing, cold foil, die cutting etc. can be freely selected and configured, thus enabling the press to be customized to suit any specific requirement of label print shops. The unique modularity of the Labelmaster meets all popular needs on the market, from commodity labels to sophisticated, high-finish products. Therefore, the Gallus Labelmaster is able to print on a wide range of substrates, to name a few, self-adhesive label, cardboard, PE, PP, aluminum foil, tube laminate and so on. With this new press platform, Gallus has also developed a new locking system that enables quick, easy and accurate changes of printing units. The system positions them on the base unit with absolute precision and ensures 100% register accuracy. New standard in cost effectiveness The Gallus Labelmaster also sets new standards in cost effectiveness from dramatic time savings, thanks to its ease of use and high speed, to low waste and minimal material consumption. It makes label printing easier, faster and more profitable. The machine platform boasts a whole series of product highlights, such as an extremely short web path of just 1.4 m between printing units and a high maximum speed of 200 m/min, thus making the Gallus Labelmaster the fastest label printing press Gallus has ever produced. The press can be controlled centrally via a HMI touch panel, although manual intervention is also supported, with operators able to make changes with ease and, more importantly, very quickly, thereby achieving extremely short setup times. The lightweight aluminium printing cylinders that were specially developed for this machine type can be changed in just a few quick steps, thus ensuring that job changes can be completed with unparalleled speed. Heidelberg NewsBRIEF February 2018 Security Printing Day. Wiesloch-Walldorf, April 10, Security printing in the age of global mobility. Discover counterfeit-proof travel documents at the Info Day Security Printing 2018! The global world depends on unlimited mobility. Counterfeit-proof ID documents and therefore the possibility to provide unequivocal proof of identity anytime and anywhere are an essential part of this worldwide mobility. A necessary consequence is international, sophisticated standards. Learn about the new challenges and opportunities, current trends and innovations. Together with competent partners, we have established an entire marketplace for you around the topic of security printing of ID and travel documents. Find out more: Talks, workshops, and presentations around the topic of ID and travel documents Perspectives, experiences, and solutions from partners from the software, materials, and consultancy fields Hands-on on Speedmaster XL 75-6 specially designed for complex applications in high-security printing In focus: rainbow effects, waterless UV printing, and the Cristala TASTE effect We invite you to an extraordinary event for an exclusive circle of customers. At the Heidelberg Info Day Security Printing 2018, on April 10. Register now. We look forward to hearing from you! Benny Huang (right), CEO of Heidelberg China and Teddy Jiang, General Manager of Gallus Shanghai, started the Gallus Labelmaster together at the launching ceremony end of 2017 in the Print Media Center in Shanghai. 3

4 Uniqueness catches on Kunst- und Werbedruck is reinventing itself as a full-service provider, focusing on quality and tight delivery schedules Investment package of over 9 million in Heidelberg machines Successful field test with Speedmaster XL 106 Push to Stop, the first press in the world to be partially equipped with Hycolor Multidrive It is worth it for companies to question their business model, to start over, and then start again. That s was happened at Kunst- und Werbedruck (K + W) in Bad Oeynhausen. In late 2013, K + W said goodbye to web offset printing and a hodgepodge of different presses. Since then, it has embraced sheetfed offset printing in 3B format and a high level of vertical integration. As a partner it chose Heidelberger Druckmaschinen AG (Heidelberg), which had already installed the first Speedmaster XL 105 in 2012 and then in 2014 installed a second Speedmaster XL 106, this time as a perfecting press, as well as several finishing presses. We offer everything from a single source and does not work does not exist solutions, says Stefan Belte in describing the new approach. Together with Frank Pieper, he has been working as a Managing Director at K + W since The recipe for success? We take on any challenge, whether technical, economical, organizational or logistical, and always deliver something special. Otherness as a brand More than 100 employees produce mostly complex and sophisticated printed matter such as brochures, catalogs, books, calendars, and leaflets for mainly national customers. The company often supplies the market leaders from industry, trade, banks, the automotive industry, the pharmaceuticals industry, and publishing, all of whom are looking for something special which they find at K + W. The printed objects are becoming more and more complex, and customers want visual and tactile stimuli. For example, we are seeing a renaissance in traditional catalogs; the runs are shorter, but demand for language versions and embellishments is up. The delivery dates are getting ever tighter, confirms Frank Pieper. Belte and Pieper went on the offensive once more to be able to implement all this even better and more economically, and this year invested in a full package from Heidelberg worth more than 9 million. The package consists of a new Suprasetter 106 CtP platesetter with fully automatic 106 G pallet loader, two Speedmaster XL 106 presses, and the Prinect Business Manager for networking the existing Prinect workflow components with an MIS system. K + W uses printing plates and coatings from the Saphira range and also trusts service offerings like Service 36plus with remote service and e-call for high press availability. Having a partner that covers as many of our requirements as possible is important to us. With Heidelberg, we negotiate on an equal footing and deal with plain-spoken and fair partners, explains Stefan Belte. World s first for exceptional printed products The first of the two new printing presses, a ten-color Speedmaster XL 106 with perfecting and a speed of up to 18,000 sheets per hour, was installed in February It is the first press in the world to be partially equipped with the innovative Hycolor Multidrive inking unit drive in the 1st, 5th, 6th, and 10th printing units. Normally, the system is used in all printing units in presses for packaging printers. K + W had already put itself forward for the field test as a 4 commercial printer because the order spectrum matched exactly. Hycolor Multidrive constitutes a major customer benefit here, since the inking unit can now be operated independently of other activities and makeready processes on the press. With Hycolor Multidrive, the inking units can be washed while the printing plates are changed in parallel with AutoPlate XL 2 via the main drive and rubber blankets and impression cylinders are washed at the same time as the makeready process. This is particularly interesting when using several spot colors or a print varnish. Parallel washing and makeready operations are possible while the next job is being prepared, which leads to extremely short makeready times and guarantees short delivery times for customers. At K + W, color changes already account for 30 to 40 percent of the time expenditure, and the time saved is correspondingly high. Intensive or deep cleaning of the inking unit can also be performed here in parallel, which leads to shorter makeready times and better washing results. Another benefit is the intelligent shutdown of printing units when they are not in use. This simplifies the work tremendously and offers a high level of operating comfort. The absence of a color assignment in a printing unit means that the printing unit that is not needed is automatically shut down without user intervention, protecting the rollers, reports Artur Benz, Technical Manager at K + W. Hycolor Multidrive is integrated in the Prinect Press Center XL 2 machine control station and is controlled there by the Intellistart 2 software. Intellistart 2 always calculates the fastest and best possible use of Hycolor Multidrive for the makeready processes. The Wallscreen XL displays all makeready processes at a glance, thereby supporting the operator. Timed processes The field test for the new Speedmaster XL P, which is equipped with the automatic AutoPlate XL 2 plate changer and the Inpress Control 2 color and control system, also tested and implemented the Push to Stop concept insofar as possible with the current MIS software. This involves production processes that control themselves and run automatically, and operators who only have to intervene when necessary or not at all. The aim is to increase net productivity to a previously unknown level. With Push to Stop and networking via the Prinect module from prepress, press, and postpress, we can fully exploit the potential of the press, even if the new MIS, the Business Manager, is fully installed, says Artur Benz in summing up his experiences. Both short and long runs can now be processed quickly and productively. The press has fully met our expectations. In particular I d like to emphasize the high level of user-friendliness with Hycolor Multidrive and the short makeready times. With one simple mold change within a print job, all eight plates are changed within 80 seconds without the need to wash any blankets. Recently, a job with a run of 750 sheets in two languages and 16 signature sections with 256 plates was printed in three hours. The totalizer was already showing 48

5 million printed sheets in November. The second new press an eight-color Speedmaster XL 106 with coating will be installed in early Together with the existing five-color Speedmaster XL 105 with coating, K + W believes it is well positioned for the future. We can calmly handle our utilization peaks in production volumes when printing sometimes involves web offset jobs, confirms Frank Pieper. Quality and speed are the number 1 priority for us, and we also have the customers in our company for over a week when it comes time to approve the job. All the better, therefore, that the processes are transparent and timed. The new production sequences means that pallets now move in one direction only in our company. This makes us much more efficient and powerful than before, explains Stefan Belte. The complete Workflow connection with the Prinect Business Manager is set to be implemented in 2018, in order to further expand the business orientation with key figures and controlling. A corresponding software field test with Heidelberg has just been signed for this. Discussions are also in progress about a new five-color Speedmaster XL 106 with coating as well as a new Stahlfolder TH 82 P folding machine, which can process the high output from the new printing presses thanks to its high level of automation. We will stand for something special, something sophisticated in the future also, and produce high-quality and complex print media with a pronounced depth of vertical integration for medium and long runs, says Stefan Belte in outlining the company strategy. We want to increase customer loyalty and adapt our services even more to the market, for example with extended logistics and by positioning ourselves as a general contractor overall. Heidelberg NewsBRIEF February 2018 Company Kunst- und Werbedruck this year invested in a full package from Heidelberg worth more than 9 million, and positions itself for its customers as a full-service provider. Managing Directors Stefan Belte (left) and Frank Pieper (right), together with Technical Manager Artur Benz, are more than happy with their decision. The new Speedmaster XL 106 ten-color with perfecting is the first press in the world to be partially equipped with the innovative Hycolor Multidrive inking unit drive. Always want to be one step ahead? Click on the link below to find out more... Visit the Heidelberg eshop. shop.heidelberg.com Order today and receive your delivery quickly. The Heidelberg eshop takes you straight to whatever you are looking for. Everything Heidelberg. Heidelberg eshop. The online portal that enables customers to shop safely and securely 24/7. With clear page structure, navigation and customised shopping lists, customers will find a wide selection of thoroughly tested Saphira consumables perfectly attuned to their production systems quickly and efficiently. Some of the benefits include: Push to Stop - Autonomous Printing. Intellistart 2 makes it possible - Commercial. One-stop shop Order 24/7 Reliable delivery Complete product portfolio Transparency & cost control 5