Fast production and a host of finishing options
Heidelberger Druckmaschinen AG (Heidelberg) offers a technology for the Speedmaster XL 75 and XL 105 that enables coating before and after sheet reversal in a single pass. About 150 participants followed Heidelberg's invitation to experience the hands-on demonstrations and to exchange experiences with initial users on new opportunities provided by double-sided coating in a single pass. Print shops can use this technology to significantly boost their productivity by fitting processes that previously required two passes into just a single pass. This minimizes production times while also increasing the variety of surface finishing options available.

A systematic step towards greater cost-efficiency
Print jobs now only have to pass through the press once. In addition to cutting production times, double-sided coating enables print products to proceed immediately to postpress. This eliminates unproductive waiting and drying times as well as the associated intermediate storage of semi-finished products.

Heidelberg has achieved this by customizing all its dryer systems to the relevant press in order to optimize dryer efficiency and print quality, even with high machine speeds, high ink coverage, and exacting coatings. Drying is so effective that the printed sheets can go virtually straight to postpress. The environment benefits, too, because optimized drying is achieved with minimized energy consumption and lower operating costs.

Saphira consumables from Heidelberg are perfectly coordinated with the press and print application and are a further key part of this complex process. The inks and coatings have been specifically developed for double-sided coating in a single pass and ensure the best possible print results while minimizing production times.

In addition to the advantages for production processes at the print shop, this new XL technology also benefits print shop customers. For example, if a customer is approving prints at the print shop, the finished products coated on both sides are now ready for final inspection in no time at all.

Winning new customers with special effects
Soon after the first Speedmaster XL 105 in LPL configuration started production in the U.S., the Daneels Graphic Group in Belgium was the first European supplier to use an XL 105 with LPL technology.

Coating units before and after sheet reversal not only make for more effective results in standard production, they also offer many more surface finishing options than standard machine configurations. That was one of the main reasons K&D Graphics in Orange County, California, opted for this particular configuration. The company commissioned the Speedmaster XL 105-6+LYY-P-6+L (UV) with CutStar sheeter in December 2008 to deliver a more efficient service to both the premium and high-volume commercial and packaging markets. K&D Graphics is known for its high-quality print products such as brochures, posters, postcards, and packaging. The UV version of this Speedmaster XL 105 makes it possible to create a wide range of special effects to satisfy the demand from print shop customers for unique print products. For example, the press can print four colors plus two spot colors in a single pass and also apply a spot, scented or gloss coating. It can also create special effects with Iriodin or metallic colors plus a protective coating. Duo applications are possible, too, for example applying opaque white to aluminized paper in the coating unit and then overprinting and coating. "The new press has enabled us to expand our premium packaging printing capacities over the past year and win numerous new customers," sums up Don Chew, President of K&D Graphics.

The delivery time makes all the difference
The strategy of the Daneels Graphic Group based in the Belgian town of Beerse is to ensure short delivery times even for long runs. The company's production facility near Antwerp is a constant hive of activity. "Delivery times have become a crucial part of being competitive. We can only maintain our productive edge with state-of-the-art technology such as the Speedmaster XL 105-6+LYY-P-6+L," reports Managing Director Kris Daneels. The company already uses several XL 105 presses plus a Speedmaster SM 102 twelve-color press with perfecting device and Perfecting Coating Solution (PCS). Over half the print shop's products are coated on both sides. In addition to improving quality, it also speeds up postpress operations and delivery. This is key to business success. Around a third of products - commercial products such as brochures, flyers, and leaflets for well-known customers from the automotive, cosmetics, consumer electronics, and food industries - are exported to neighboring countries. With these jobs, the time pressure is particularly high.

"Our new Speedmaster XL 105-LPL allows us to process jobs even faster," states Daneels. What's more, the press is equipped with Prinect Inpress Control. This system automatically measures the color and the register during printing and immediately forwards any corrections required to the Prinect Press Center. End-to-end automation and the JDF workflow also help to get the most out of the XL 105. "We can print the front and reverse sides of a sheet with up to six colors and apply a dispersion coating - all in a single pass. This extra flexibility and cost-effectiveness enables us to deliver high quality on time and at a fair price," stresses Daneels. He is even looking to go one step further in future by using his new Speedmaster XL 105 to apply a double-sided spot coating in a single pass.