People & Print

KBA Trendsetter in Printing Technology

Roland Gebauer, KBA - Sales Manager for UK/ Ireland / South Africa / KBA NOTASYS-Security Printing

KBA: the worlds first press manufacturer

1807-1812: Friedrich Koenig built the first cylinder
printing press in London

In 1814 The Times in London became the first

newspaper in history to be printed by machine
Koenigs double-cylinder press

In 1817 Koenig & Bauer started up the worlds first

First cylinder press, 1812

printing press factory in Oberzell, near Wrzburg

200 years after the mechanical printing press was

invented the group is moving into the high-growth
digital print market with the KBA RotaJET 76

First inkjet web press, Drupa 2012

KBA

KBA: technological leader with strong market position

Second-biggest manufacturer of printing presses

worldwide with sales of some 1.3bn and around
6,000 employees
Extensive, highly advanced product portfolio for
volume and niche markets
Top innovator and technological trailblazer in
many areas
No. 1 in web offset (newspapers, commercials)
No. 1 in large-format sheet-fed offset
(no. 2 overall)
No. 1 in packaging offset, security printing and
metal decorating
Mover and shaker in green printing

KBA - Print Promotion - 2014

People & Print

The todays market situation

Global press market by segments

Market volume in 2013
approx. 5.3bn

Web offset
(newspaper and

Sheetfed offset

commercial)

approx. 2.7bn

Flexo, gravure,
screen
approx. 700m

Digital**

(presses only)
approx. 1.3bn

approx. 630m

Market volume in 2015

approx. 5.5bn

Web offset

Sheetfed offset

approx. 400m

approx. 2.5bn

Flexo, gravure,
screen
approx. 750m

Digital**

(presses only)
approx. 1.8bn

- The enhanced productivity of modern, automated presses reduces additional market volume/growth
- The digital printing business mainly comprises of over 50% consumables and service contracts - not included here
**estimated number of toner and inkjet presses for industrial printing plants (excluding copiers, consumables and service)
KBA - Print Promotion - 2014

07/2013

Strong growth in packaging sector in the near future

Internet is reducing print and advertising market volumes in the newspaper, magazine and
catalogue sectors

The trend to eReader like iPad, Kindle or others is responsible for the decline in book printing
Packaging, label, film printing are classic growth markets and are scarcely affected by the
internet and digital printing (apart from labels)
40%

Global print market * by product 2008-2014

36.7% 36.3%
34%

35%
29%

30%
25%

2008

20%

2014
15%
10% 9.5%

10%
5%

5.5% 4.8%

7.4%

6.4%

6.2%

4.6%

5% 4.6%

0%
Books
KBA - Print Promotion - 2014

Catalogues

Magazines

Newspapers

Advertising

Packaging

Other

* Source: PRIMIR/NPES, World Wide Market for PRINT 2008 - 2014 Update

Strategic Core Areas

1. Strategic Focus on Packaging
2. Reorganisation Newspaper & Commercial
3. Entering Digital Printing
4. Strong Base Security Printing
5. Focus on Emerging Markets
6. Becoming a Full Service Provider
7. KBA: The Easiest Company to Deal with

KBA - Print Promotion - 2014

Does KBA come to mind when looking at these products?

Examples from KBA customers

KBA - Print Promotion - 2014

Portfolio includes high-tech printing / systems solutions

Special solutions for the packaging sector
Web printing

Bank notes /
Security

Machinery
business

Construction /
Project
business

Construction /
Systems

Web offset

Special

Marking and
Coding

Flexible
Packaging

Metal /
Coated steel

Systems
business

Machinery
business

Construction /
Project
business

Glass

Type

Products

Sheetfed
Offset for
Packaging

Targeted markets

Small-,
medium- and
large-format
presses for
packaging,
book, poster,
display and
commercial
printers

Small and
medium-sized
print runs in
premium
quality

presses for
newspapers,
inserts,
magazines,
catalogues,
flyers, books,
brochures in
higher print
runs

Inkjet digital

Substrates
from lightweight paper
to corrugated
board plus
plastics
KBA - Print Promotion - 2014

web press for

books, direct
mail,
advertising,
newspapers
from one copy
to mediumsized editions

printing
presses with
varied printing
processes
such as
intaglio for
printing bank
notes

Special
security
technology
and systems
for pre-press,
quality control,
post-press

Bank note
design service

Inkjet, laser,
hot stamping
and thermal
transfer
solutions for
marking
and coding

Marking and
coding on
very varied
substrates
such as
synthetics,
plastic film,
glass,
ceramic,
board

Packaging
presses for
flexible, nonabsorbent
materials
such as foil
Varius 80 web
offset press
for shorter
runs
Flexo presses
offered by
Flexotecnica
for higher
print runs

Solutions
supplier for
printing,
coating,
drying and
metal sheet
logistics

Systems for
air purification

Machinery
business

Presses for
decorating
hollow
containers
made from
premiumquality glass,
plastic and
metal

Application in Directly
decorated
packaging
segments:
food,
cosmetics,
tobacco

glass
containers are
mainly used
for cosmetics,
perfume and
spirituous
beverages in
the top price
class
13

Contribution of market segments to KBA sales

Sheetfed offset
presses for
packaging, book,
commercial
and poster
printing

Web offset
presses for
newspaper,
magazine,
catalogue and
commercial
printing

15%

Metal-decorating
solutions for
packaging
(coating,
printing etc.) made
of aluminum and
coated steel

40%

~ 5%

Special
solutions for
bank note
design and
production,
security
printing

20%

Estimated sales for individual sectors

KBA - Print Promotion - 2014

Industrial
marking
and coding
systems
on synthetics,
film, glass,
ceramics,
cartons
~ 5%

Services,
spare parts,
retrofits,
upgrades

15%

14

Sheet-fed presses from small to super large format

Sheetfed
KBA Genius 52UV
KBA Rapida 75
KBA Rapida 76
KBA Rapida 105
KBA Rapida 106
KBA Rapida 145
KBA Rapida 164
KBA Rapida 185
KBA Rapida 205

Wide range of sheet-fed offset machines: small (360 x 520 mm) to super
large format (1510 x 2050 mm) for commercials, books, posters and
packaging. KBA Radebeul is the world market leader in large format!

KBA - Print Promotion - 2014

Innovations for print

KBA Rapida 106: worlds fastest press and makeready champion in B1 format

Medium-format press with the maximum level of automation to support simultaneous

makeready processes

Flying job changes and pre- and post-perfect coating in four-over-four production

Coater with simultaneous forme change and anilox roller loader

Maximum rated speed 20,000sph in straight mode, 18,000sph in perfecting mode

KBA - Print Promotion - 2014

KBA speciality: long presses for packaging

The commercial market is suffering in many countries, the packaging market is still growing

Historically KBA is very strong in packaging with its medium- and large-format presses

In 2013 more than 60% of all Rapidas went to packaging printers around the world

Long presses for UV or Hybrid printing with inline-coating and cold-foil module
like this 14-unit Rapida for Bulgaria are becoming more popular in Europe

In the meantime KBA installed presses with energy-saving HR- and LED-UV dryers,
e.g. at commercial printers in France and Benelux

Presses like this RA 106 SIS-10+L+T+T+L ALV2 450 mm raised for Bulgaria, with inline-coating and cold-foil equipment, becoming more popular in Europe

KBA - Print Promotion - 2014

Innovations for print

KBA Rapida 145: fastest large-format press with the shortest makeready times on the market

Maximum rated speed of 17,000sph straight and 15,000sph in perfecting mode

Automation modules originally engineered for the world makeready champion Rapida 106,
now in large format

The Rapida 145 and 164 reaffirm KBAs pole position in large format and packaging printing

KBA - Print Promotion - 2014

Innovations for print

Enhanced efficiency and flexibility thanks to automation
Automatic nonstop systems at the feeder and delivery of the KBA Rapida sheetfed
presses, integration in an automated pile-logistics system

Networking of press control, nonstop pile changing systems and pallet supply for efficient print
production

Proven logistics modules, elaboration of customer-specific solutions with RFID-controlled

logistics and warehousing

Automating pile logistics for bulky substrates (cardboard, corrugated) can deliver substantial
productivity gains in high-volume production

KBA - Print Promotion - 2014

People & Print

Strategic Focus on Packaging

Strategic Focus on Packaging

KBA enters the growing flexible packaging market
The new Varius 80 variable-format web offset press
built by KBA-Meprint targets packaging printers with
non-absorbent flexible materials

Acquisition of Flexotecnica, a popular Italian

manufacturer of central-cylinder flexo presses for
printing on various flexible packaging materials

KBA - Print Promotion - 2014

Strategic Focus on Packaging

Acquisition of Kamman, a German packaging
specialist offering screen presses for decorating
hollow containers made from premium-quality
glass, plastic and metal

Set up of a cross-process engineering

and workflow competence in the
packaging production

Investigation of further printing-related

market segments for packaging

KBA - Print Promotion - 2014

Strategic Focus on Packaging

KBA-MetalPrint has a strong position in metal

decorating and is market and technology leader in
premium printing and coating systems

Applications primarily for packaging: food,

cosmetics (Nivea tins), cigars etc.

Portfolio: printing, coating, drying and logistics

systems for metal sheets, air purification systems

Activities will be expanded with newly developed

products and solutions

KBA - Print Promotion - 2014

Strategic Focus on Packaging

KBA-Metronic has a strong technology position in

digital and analogue marking and coding systems

Growth potential by increased internationalization

and new products

Extension of the product portfolio for packaging

systems (Coding, Branding, Marking)

KBA - Print Promotion - 2014

Strategic Focus on Packaging (Sheetfed offset presses)

KBA is the technological and market leader in packaging printing on sheetfed offset presses
60 % of our customers are packaging printers
Our target is to expand our leading market position
Our philosophy: Customized solutions for packaging printers

A straight-on press with 19 printing and finishing units including cold foil and a
total length of 35 meters at Amcor Tobacco Packaging in Rickenbach, Switzerland

KBA - Print Promotion - 2014

Special press configurations / Rapida 106 with 19 units

1. Coating unit (Aqueous / UV) with DriveTronic SFC and Anilox-Loader
2. Dryer units / VariDry hot air / UV
3. ColdFoil Infigo SF110
4. 10 printing units with DriveTronic SPC / PlateIdent / CleanTronic Synchro
5. Coating unit (Aqueous / UV) with DriveTronic SFC and Anilox-Loader
6. Dryer units / VariDry hot air / UV
7. Coating unit (Aqueous / UV) with DriveTronic SFC and Anilox-Loader
8. UV Inert final dryer with KBA AirTronic drum
9. Quality control / QualiTronic Professional
10. KBA VariDry-Technology / - VariDry Blue hot air, UV final dryer + Infra red

10

5
4

KBA - Print Promotion - 2014

Strategic Focus on Packaging (Sheetfed offset presses)

KBA is the technological and market leader in packaging printing on sheetfed offset presses
drupa 2000: long perfecting press in South Africa; installed in 2001
First RA 145-6+L in South Africa; installed in 2013

KBA - Print Promotion - 2014

Automation concept for make ready savings

Cutting edge technology and constant innovation for

top performance, flexibility and economic efficiency

State-of-the-art automation modules for saving

makeready times, less waste and best quality in print

DriveTronic
DriveTronic
DriveTronic
DriveTronic
DriveTronic
PlateIdent
DriveTronic

Feeder
SIS
SPC

SFC

KBA - Print Promotion - 2014

CleanTronic
CleanTronic
CleanTronic
CleanTronic
CleanTronic

Synchro
Multi
UV
Re Ink

Quality
Management
ErgoTronic
QualiTronic

VariDry
VariDry IR/ TL
VariDry Blu
VariDry UV
VariDry HR-UV
VariDry LED-UV
VariDry Inert UV

DriveTronic SIS / Sensoric Infeed System

USP

DriveTronic SIS = Sensoric Infeed System

No setting errors, as no settings to make

Longer period of rest for sheet alignment
Reduced make ready time
Marking-free

Cost advantages through

Fewer production stoppages and higher productivity

KBA - Print Promotion - 2014

DriveTronic SPC / simultaneous plate change system

All units in ca. 50 seconds

Plate changing parallel to other make ready processes possible:

-

washing of printing and coating unit

format settings

all preadjustments

KBA - Print Promotion - 2014

Overview of KBA washing device

CleanTronic

CleanTronic Synchro

Designation

No. of washing bars

Process

System

CleanTronic

1 mobile washing bar

blanket & impression

Serial

blanket & rollers

synchronous

2 washing bars

blanket & impression

synchronous

1 x blanket

Blanket & rollers

synchronous

1 x impression

blanket, impression, rollers

synchronous

CleanTronic Synchro

KBA - Print Promotion - 2014

CleanTronic ReInk

USP

Roller washing is now absolute independent

High speed roller washing with auxiliary drive
Duration between 1 - 1,5 minutes*
Option: operation during production
Roller washing possible during
Blanket washing
Impression cylinder washing
Coating form change
Production

KBA - Print Promotion - 2014

KBA VariDry dryer technology - overview

IR/ Hot Air- Dryer for conventional inks
and water-based varnish
UV-dryer for UV inks and UV varnish
(UV, GA-UV, OzonFree-UV)
Combination dryer for hybrid presses
(IR/TL/UV)
Special UV-dryer for high reactive inks
(HR-UV, LED-UV, UV-Inert)

KBA - Print Promotion - 2014

People & Print

Rapida 106 Concept for energy saving

KBA VariDryBlue

Rapida 106 / KBA VariDryblue

USP

KBA VariDryblue: Lowest energy consumption in its class

Still unsaturated hot air from Modules 1 and 2 returned to Module 3

Reduction of power consumption and waste air volume by approx. 50%

Heat register integrated in the extension (short distance to the hot air knifes)

KBA - Print Promotion - 2014

Comparison of dryer efficiency

Production forme

Pantone 4975 + Pantone 1665 + CMY + conventional coating

Ink coverage: 53.65%

Production speed: 13,000 sheets / h

Anilox roller 100 L/cm; Volume 12.0 cm/m

Dryer: 30C temperature in pile

Substrate: GD2 300 g/m

Rapida 106-9+L SW4

KBA - Print Promotion - 2014

Example calculation without obligation

Comparison dryer efficiency

KBA VariDry Blue

Standard dryer

251

251

7,4

7,4

5.015

5.015

KBA VariDry Blue

Standard dryer

33

70

165.495

351.050

Energy costs in pro kWh

0,10

0,10

Energy costs per Jahr in

16.550

35.105

102,10

216,6

Planned capacities
Working days per year
Shifts a day
Working hours per shift
Production hours per year
Measurement results
Measured energy consumption (kWh)
Energy consumption kWh/ year

CO2-emission (t/Jahr)
Possible savings
Energy saving (kWh/ year)
Energy saving (%)
Cost saving (/year)
CO2-reduction (t / year)
KBA - Print Promotion - 2014

KBA VariDry Blue

188.555

53

18.555

114,5

Example calculation without obligation

People & Print

Quality Management

Innovations for print

Enhanced efficiency thanks to inline quality control
Cutting-edge inline quality measuring technology closed loop system QualiTronic Professional
inspects the sheets and tags faulty images

Online - ErgoTronic

Register Control

ErgoTronic ACR
ErgoTronic ICR

Color Control

Inspection
KBA - Print Promotion - 2014

Inline - QualiTronic

QualiTronic ICR

ErgoTronic ColorDrive
ErgoTronic ColorControl

QualiTronic ColorControl

DensiTronic PDF

QualiTronic Professional

People & Print

KBA Services Complete workflow solutions

Process Automation JDF/JMF Networking

KBA Services: Complete production workflow

"A special printhouse workflow cannot be bought it needs to be developed!"

MIS

KBA - Print Promotion - 2014

Complete workflow solutions Summary

Job data passed through from the branch software
to the press console

Single point of data acquisition and input, no errors

due to multiple points of input

Full control and analysis of the production process

in real time

Increased productivity through faster makeready

Exact consumption records enable optimized
materials management

Precise statistical cost accounting and effective

controlling

Optimum integration of KBA presses into a

continuous JDF workflow

Profitable production through efficient processes!

KBA - Print Promotion - 2014

KBA: The Easiest Company to Deal with!

KBA - Print Promotion - 2014

People & Print

Thank you! Any interest? Please contact us!

Koenig & Bauer AG
www.kba.com