Strengthening the Case for 96-Page Heatset Printing: Ultra-Productive Goss Sunday 5000 Presses Play Well in the Uber-Wide Web Space, Too

Article excerpt

In our post-GRAPH EXPO coverage last October, E&P reported that man-roland believes its large, 96-page Lithoman S heatset web-offset press ultimately may challenge the gravure process in the United States. The 112-inch-wide format works especially well in Europe, where trim sizes are more fexible for high-volume retail, catalog, magazine, and insert products, said Vince Lapinski, the firm's North American CEO. (See "manroland Update" below.)

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Fellow press-maker Goss International actually was first at the proverbial table, three years ago, with the world's first single-web, 96-page press: its Sunday 5000 model. A trio of these presses in full operation in three locations, and one printer investing in a second system, prove the economic and competitive advantages of the 112-inch-wide format, according to Goss.

The Goss Sunday 5000

The first Sunday 5000 was installed by Italian magazine printer Grafiche Mazzuechelli in mid-2009. In early 2010, Impresia Iberica, part of Circle Printers, installed the 96-page Goss press model in Spain. And this January, magazine printer Stark Druck installed a second Sunday 5000 press in Germany. (Its first four-unit configuration was added in mid-2010.) Goss will supply high-speed pinless combination and former folders for the new press and an additional new former folder for the first installation. Stark Druck also operates two Goss Sunday 4000 48-page short-grain presses.

"The performance of our existing Sunday presses, including the newest 96-page system, and the advantages they allow us to provide for our customers were the key factors in our decision to invest in a second Sunday 5000," said Reiner Wormitt, managing director at Stark Druck. "Goss International shares our vision for creating new opportunities through innovative, high-pagination presses, and they have stood behind that vision with their ability to execute and support these installations."

Stark Druck has selected the Goss Autoplate fully automatic plate-changing technology and the DigiRail digital-inking system for its Sunday 5000 presses. Goss also is supplying a Contiweb FD paster, Ecoset dryer and Web Center automated workflow and control system. The new press will have a PCF-3 combination and PFF-3 former folder, both designed to run at up to 100,000 copies per hour for optimum product versatility. Stark Druck is adding a Goss PFF-3 former folder to its existing Sunday 5000 press, creating two identical 96-page systems.

Pinless former folder fosters flexibility

Teamed with the appropriate pinless folder, the Sunday 5000 press system can print as many as 104 DIN A4 (letter-size) pages in a single pass, as well as offering enormous flexibility in product format capability. The Goss PFF-3 pinless former folder produces a signature with three open sides and a full range of tabloid, square tabloid, delta fold, digest, slim jim, and magazine products at up to 3,000 feet per minute (fpm). This format versatility makes the Sunday 5000 particularly attractive to newspaper printers looking to diversify into more commercial work, and vice versa. At current sites, printers routinely use the multi-ribbon capability to produce four separate catalogs or retail flyers per impression, at up to 180,000 copies per hour.

Automated presetting, push-button changeovers and on-the-run adjustments speed up makeready and prevent unnecessary stops, and paper savings can be maximized when teamed with Goss Ecocool and Ecoset dryers. The features and ribbon Configuration of each of the PFF-3 former folders for the Sunday 5000 presses at Stark Druck will be unique in Europe, allowing the printer to offer specific products and very high copy output in low-page-count magazine format.

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Why high pagination makes sense

Goss began discussing the concept of a 96-page press with forward-thinking web printers in 2005 and became the first supplier to announce plans to develop the mammoth press two years later. …