As you may know, Presstek is a leading developer of digital laser imaging and chemistry-free plate technologies for the printing and graphic arts industries. The company markets to press manufacturers and directly to end users, Their patented DI, CTP and plate products eliminate darkrooms, film and toxic processing chemicals - and reduce turnaround times and lower production costs.

Financially, the company is in a good position for 2002 and plans to return to profitability. Operationally, many are familiar with the overall goals of this major industry supplier, but we wanted to know what’s really happening on the “inside” of Presstek.

Is there traction with printers and print buyers for their DI and CTP products? Will partnerships with companies like Xerox, KPG and KBA work? Is the ROI on chemical-free processing real?

For “inside” answers, we went to two industry experts that also happen to work for Presstek: Marc Johnson and Stan Najmr.

Marc Johnson (pictured below at the left) is Product Line Marketing Manager, Off-Press (CTP) Products. Marc has been with Presstek since 2000, bringing with him over 16 years of experience in marketing, sales, support, and implementation of CTF and CTP systems, workflow management systems, digital imaging, digital proofing, CEPS and DTP systems.

Stan Najmr (pictured below at the right) is Director of DI at Presstek. Stan has been with Presstek for one year, bringing with him over 15 years of experience in the graphic arts industry. Prior to joining Presstek Stan was Marketing Director for advance products at Scitex.

Q. Stan, tell us about the partnership with Xerox and the scope of your agreement with them?

Stan Najmr: The Xerox and Presstek relationship started at Drupa, with the companies entering a formal agreement in September of 2000. Under the agreement Presstek supplies Xerox with two unique DI presses and the related consumables for the North American market. The two presses are the Xerox DocuColor233 DI and Xerox DocuColor400 DI, both presses use Presstek’s ProFire imaging and PEARLdry plate technology.

Q. What are the details of the 233 and 400 DI’s and what niche do they serve?

Stan Najmr: The DocuColor 233 DI is a highly automated four-color digital offset press. Highlights of the press include a makeready time of less than eleven minutes, simultaneous imaging of all four plates at 2540 dpi in less than five minutes, small footprint, integrated console for imaging and color control, 13.39_ x 18.11_ sheet size, and 7,000 impressions per hour.

The DocuColor 400 DI is the ideal press for adding a high quality offset printing solution to a toner-based printing environment. Highlights of the 400 DI include an optional perfector, a 15_ x 20.5_ sheet size, 12,000 impressions per hour, the fastest makeready time of any press in its class, simultaneous imaging of all four plates at 2540 dpi in less than five minutes, and it is available as a four- or five- color press.

Q. The recent install of the 233 at Royal Printing received much attention from our members. Describe their situation and why this machine fit their needs.

Stan Najmr: The initial installations of the 233 DI have been very successful. Customer like Royal Printing in Guilford, CT are reporting significant improvements in turnaround time. Prior to installing their new Docucolor233 DI it was not unusual for Royal to spend three hours using their duplicators to print a 10,000 sheet four-color job (150 line screen, 4/0, 8.5_ x 11_, 2-up). Feeder and deliver set-up would take approximately 7 minutes, inking and plate change about 9 minutes, makeready for all colors was 26 minutes and run time and wash time would take 2 hours and 18 minutes. Using the DocuColor233 DI this identical job takes Royal about an hour to print. Plates are loaded simultaneously from internal spools in 30 seconds, imaging is completed in 3 minutes, and automatic plate cleaning and reaching color is accomplished in 5 minutes. The actual run time is about 50 minutes. Royal now easily completes seven jobs per shift with the 233 DI - previously they completed less than three jobs a shift.

Q. Explain the KBA and Presstek partnership.

Stan Najmr: The Presstek and KBA partnership began several years ago with the 74 Karat. Karat licensed Presstek’s technology and used PEARLdry plates. Our companies share many of the same business philosophies. The obvious ones are the need to support shorter print runs and the growing demand for short-run color. The companies believe that DI presses have reached the point of critical mass and will be further accepted by the industry. We also share the awareness that we must protect our environment; it is no longer an option or a goodwill gesture. It is a solid business proposition. I’m happy to say that the partnership now includes the 46 Karat.

Q. How does the 46 Karat use Presstek’s technology?

Stan Najmr: The 46 Karat brings Presstek’s ProFire laser imaging and spooled media technology to the Karat product family. The 46 Karat has a satellite V-shaped five cylinder system. Two Presstek ProFire imaging systems expose each color simultaneously onto our PEARLdry media. The maximum sheet size is 18.11" x 13.39". The compact press design provides for complete automation with ink profiling, plate loading, cleaning of rollers, blankets and plate cylinders all being automated. The press easily integrates into any prepress workflow.

KBA will also distribute the Dimension200 and Dimension400 outside of the United States. Dimension CTP systems use Presstek Anthem thermal plates. Anthem plates require no chemical processing; you simply image the plate, rinse it with water and put it on press. The combination of Dimension and Anthem will match well with shops using KBA’s two- and four-up presses.

Q. Presstek has said that DI presses produce a more stable print run with more accurate registration. What is this compared to?

Stan Najmr: Presstek’s DI technology delivers higher quality output than traditional printing methods. The DI production process reduces manual intervention and the number of iterations between the original and finished plate. Gone are the instabilities associated with traditional chemical-based systems such as emulsion variances, processor condition, and age of chemistry plus there are no more remakes due to processor or vacuum frame deficiencies. In addition, Presstek enabled DI presses are waterless presses temperature is controlled by factory installed chilling systems so the need to balance ink and water on press is eliminated. Registration is more accurate because all four plates are imaged simultaneously on-press using state-of-the-art lasers and software to control accuracy. In certain press designs, like the Ryobi 3404 DI, 46 Karat and DocuColor 233 DI, the sheet remains in a single set of grippers without transfers furthering the accuracy of registration in four-color printing.

Q. Tell us about the DIdirectory.com resource? Is this about influencing the end users to print on presses with DI inside?

Stan Najmr: DIdirectory.com is a comprehensive online resource for DI information for print buyers and graphic designers. Features of the site include information on the latest DI technologies, a worldwide DI printer directory, a DI library, and a "Featured DI Printer" section that offers profiles of companies that have successfully utilized DI technology. Visitors to the site are also invited to post their DI projects. The site is becoming a central resource to find information and ideas quickly and easily about DI printing. We're working hard to provide content that delivers real value and will continually update the site to best meet the interests of the graphics arts community.

Q. Marc, what benefits are there by using Dimension CTP?

Marc Johnson: Our customers have told us that making the move to Presstek CTP – the Dimension platesetter and Anthem wet-offset plates – has made a tremendous difference in their printing operations in three main areas: time, money, and waste.

Moving to CTP brings a suite of benefits – first generation quality, better registration, decreased make-ready, and the ability to run with more ink.

Q. Versus the competition, how does Presstek CTP go further?

Marc Johnson: First, completely chemistry-free plate making. Presstek Anthem plates require no chemical processing. A simple wash with water and the plates are ready to mount on press. The complete process takes just about 8 minutes. Secondly, Anthem plates are rated for 100,000 impressions – without any pre- or post-bake ovens needed.

Additionally, the Presstek Dimension images Anthem plates using a high-powered, 830nm thermal imaging laser diode, ablating (removing) the non-ink receptive portions of the Anthem plate. Because there is no reliance on photochemical processing, Anthem plates have an unlimited shelf life, and require absolutely no gumming after cleaning. And finally, a lower cost of ownership. Presstek CTP saves time, materials, and labor resulting in an overall lower plate production cost.

Q. Explain the real savings for printers by having no chemical processing?

Marc Johnson: Chemical processing adds much more to the cost of printing than just the cost of the chemistry. There’s shipping (both bringing it in and disposing of it), storage, handling, and clean up. There’s also something we call the cost of error – which is the simple fact that as the number of steps increase in the production of a product, the more chances there are for human or mechanical errors to occur. Also, the later an error happens in the production cycle, the more steps will have to be done to recover.

With Presstek’s Anthem thermal plate, film and film processing are eliminated, and there is no chemical processing- normally the last step in the pre-press production cycle.

An added bonus to going chemically-free is that in certain markets there are government incentives such as tax breaks and subsidized financing given to companies investing in products that reduce toxic wastes.

Q. Tell us about the recent agreement with KPG?

Marc Johnson: Presstek and Kodak Polychrome Graphics - Japan have announced an exciting partnership to bring the advantages of chemically-free CTP to the Japanese printing market – the third largest in the world in terms of net shipments. Under this license, KPG-Japan will have the exclusive rights to sell products containing Presstek’s chemically-free plate technologies through its own dealer network and under its own brand name. Our mutual goal is to optimize the distribution of products that we believe have a great fit for the Japanese market- especially in terms of footprint, environmental friendliness, and price.

Q. Presstek is the leading supplier of DI technology, are you being accepted as a supplier of CTP technology as well?

Marc Johnson: Our market share is growing every quarter– both in plates sold and platesetters installed. The timing of the Dimension and Anthem launch was right when smaller printers started to adopt CTP. We had- and continue to have – the right product, at the right price, at the right time. Presstek’s CTP products have been validated by industry leading companies including Kodak Polychrome Graphics, and KBA agreeing to distribute our Dimension CTP systems and Anthem thermal plates.

Also in July, GATF awarded the Dimension platesetter, Anthem plates, and ProFire imaging technology with a 2001 GATF InterTech Technology Award. I believe that this clearly demonstrates that a company that develops the laser, imaging, and plate technologies together can provide a complete solution with advantages in speed, quality, and cost-savings required in a CTP system today.