Full speed ahead for installation plans in Kempten

Here comes the next truck: another September day, another trip to Allgäuer Zeitungsverlag. Its cargo contains printing units and other components for the new COLORMAN e:line, having traveled the 130 kilometers from Augsburg's manroland web systems. The world's first installation and set-up of the COLORMAN e:line is running according to plan, with production set to commence at the start of 2013.

The installation team in Kempten, eleven staff from manroland web systems and the Allgäuer Zeitung, take receipt of the COLORMAN e:line components. The pace then accelerates as routine kicks in: unloading, inserting, adjusting. And everyone, as usual, in high spirits. A similar situation with Markus Brehm, Managing Director of Allgäuer Zeitungsverlag. For him, the printing press heavyweight represents entrepreneurial opportunities. Those set to benefit from the groundbreaking technology are the customers, readers and staff, and thus the entire company. Because Brehm only knows one direction and that's "up". The Allgäuer Zeitungsverlag subscribes to the same thinking, i.e. that "Quality is the future". "Quality in all aspects: the technology, the editorial office, the workplace, the staff, as well as customer and reader service," explains Brehm. And at the heart of it all? The new COLORMAN e:line.

Happy are those with automation
A look at the technology shows the large extent to which Kempten has invested in quality. With the Allgäuer Zeitung, the decision was taken to use a third plate inking roller for a better printing result. Head of Production, Bastian Korbel, has high hopes for the many automation solutions used in the measurement and control systems, as well as the plate logistics. "We can achieve greater efficiency and a better standard of quality, our work is easier and jobs are secured. Our eight local editions for the Allgäuer Zeitung will now be produced on one system instead of two separate rotary presses. We are thus able to work more flexibly until the platforms finally come to a halt at two in the morning." Korbel's enthusiasm doesn't stop there: "An important element here is the fully automatic, robot-assisted APL plate changing system, which dramatically accelerates set-up times and thus production. The plate-changing process is controlled by the operator from the central control console, where the plates are placed in transport baskets. They are then transported to the APL robot with a home-built lift, where they are then changed." The operator no longer needs to leave the ground. Overall, there is a feeling of anticipation at Kempten regarding the new technology and its promise to lighten the workload. It was precisely the ergonomic advantages of the COLORMAN e:line that played an important role from the very start of the decision-making process, confirms Korbel. "We want to create a more homogeneous working environment for our employees, coupled with a high quality of work. In addition to the plate logistics described, control systems are also very important, as is sound proofing to reduce noise. One particular feature here is the newly constructed, glazed central control console room that not only boasts the latest control technology, but also an impressive panoramic view. On one side of the colleagues is the COLORMAN e:line, on the other the mailroom lines – both impressive and inspirational. Korbel is certain of one thing here: "Of course, you need to be familiar with the technology in order to exploit its full potential. Training has already taken place in Augsburg during the preparation phase, and we'll continue to provide further training for our staff."

e:line stands for planning reliability
In Kempten, the COLORMAN e:line comes equipped with four printing towers in a blanket-to-blanket system, four reel splicers and two folders. With a web width of 1,400 mm and a cylinder circumference of 1,020 mm, the press will produce copies of the Allgäuer Zeitung newspaper in Rhinic format with up to 45,000 cylinder revolutions per hour. Advertising journals and contract printing orders are added to this during the day. It is possible to print up to 90,000 newspaper copies per hour at a printing speed of 12.75 m/s.

While it will be getting its big break in the German Allgäu region, the COLORMAN e:line has in fact been designed for those printing companies around the world looking to increase efficiency in newspaper printing and make a secure investment in a futureproof concept. Because the e:line version allows for the gradual, modular upgrade and retrofitting of the COLORMAN series 4-1, 4-2 and 6-2 newspaper printing systems, with a choice of quality, speed and commercial packages. All autoprint modules, such as those for plate logistics, job changeover or process control, can be combined or retrofitted as required. Ensuring the workflows run smoothly is the job of printnetwork, with its comprehensive selection of systems that includes prepress, printing, reporting, postprocessing and production data acquisition systems.

Investment represents an opportunity
For Markus Brehm, there is no getting around regular new investments and he has been involved in such projects five times already. "Business risks need to be taken. I want to discover new things in order to drive the company forward. I embark on these projects wholeheartedly, I want to set an example for fellow colleagues." If the prospects are good, Brehm wastes no time in leading the way as the world's first purchaser of a printing press generation. The COLORMAN e:line also meets Brehm's requirements when it comes to providing both an internal and external message: "The press has to catch the customer's attention. There is no need for me to explain that this is the best, the latest and the fastest technology. That's obvious." Brehm is certainly expecting to garner plenty of attention from other publishing houses and readers with the COLORMAN e:line: "The Allgäuer Zeitungsverlag is an open-minded company – and that's not only reflected in its glass front facade. More than 200 groups with altogether around 5,000 visitors pay a visit each year. We place particular importance on promoting young talent; students and even kindergarten children have visited the premises. This is something that we, as initiators, and our 1,000 employees are very proud of."