Printing in an African - Rotogravure
Transcript of Printing in an African - Rotogravure
Paarl Media Group
• Ten specialized printing plants
• Seamless transfer of files between plants
• Printing same product in different locations
• Extensive capacity and capability
• Reduced distribution costs and
turnaround times
Paarl Coldset
Printing
Plant
Press Capacity Mailroom Pre-press
Johannesburg Geoman
8 towers, 3 folders.
Uniset
9 towers, 2 folders.
64 B/S, 70 000 cph.
36 B/S, 75 000 cph.
100 000 tons
2 Muller Martini
Newsliners, 4 hoppers
each, 35 000 cph
4 Muller Martini
SLS3000, 3 with 4 and
1 with 8 hoppers,
32 000 cph
3 Agfa Polaris CTP
lines, 540 plates per
hour, 2 Nela plate
benders,
Arkitex / Sublima
Workflow
Cape Town Geoman
4 towers, 2 folders.
Uniset
4 towers, 2 folders.
32 B/S, 70 000 cph
16 B/S, 75 000 cph.
50 000 tons
2 Ferag MSD2 inserting
lines – 8 hoppers each
– 45 000 cph.
1 Ferag MSD2 – 7
hoppers– 37 000 cph.
1 Ferag ETR – 6
Hoppers – 32 000 cph
3 Krause LS jet CTP
lines,
720 plates per hour.
Arkitex / Sublima
Workflow
Paarl Coldset
Printing
Plant
Press Capacity Mailroom Pre-press
Durban KBA Comet
6 towers, 2 folders
15 000 tons 2 Krause CTP lines.
Port Elizabeth Uniset
3 towers, 1 folder.
Cromoman
1 towers, 1 folder.
12 B/S, 60 000
copies.
4 B/S, 45 000 copies.
15 000 tons
1 Muller Martini
SLS3000
32 000 cph
6 hoppers
2 Krause CTP lines.
240 plates per hour.
Arkitex / Sublima
Workflow
Bloemfontein Goss Urbanite
8 Units, 2 folders
16 B/S, 40 000 cph.
7 500 tons
1 Ferag Easysert
inserting.
6 hoppers.
25 000 cph
3 ECRM
CTP lines.
300 plates per hour.
Arkitex /Sublima
Workflow
Paarl Media Cape
• More than 125 000 tons annual capacity • 54 000 m2 of production facilities • High to medium volume top-end catalogues, magazines and commercial work • Publication gravure and heatset web offset plants merged in 2010
Paarl Media Cape
• Heatset web offset presses • 1 x 16 page manroland Rotoman, 578mm cut-off, with complete inline stitching, gluing
and trimming: prints up to 65 000 full colour copies per hour (2010) • 1 x 48 page manroland Lithoman: prints up to 45 000 copies per hour (2005) • 1 x 64 page manroland Lithoman: prints up to 45 000 copies per hour (2007)
Paarl Media Cape
• Three publication gravure presses, all with inline stitching, gluing and trimming. More than 12 000 format possibilities with 1 400 cylinders.
Paarl Media Cape
• Largest bindery in Africa • 2 x 18 000 and 1 x 15 000 Kolbus Publica Perfect Binders (installed between 2006 & 2011) • 2 x Muller Martini 20 000 speed Tempo Saddle Stitchers (2002) & 3 x Muller Martini Prima
Plus saddlestitchers • 2 Steinemann UV varnishing machines (2008 & 2010) • Extensive hand finishing and mailing capabilities • 2 x Muller Martini 14 000 speed Prima Plus Binders (2008)
Paarl Media Gauteng
• Established in 2005 to specifically service the Johannesburg market with an initial
investment in excess of R600m • 75 000 tons annual capacity • 30 000 m² of production facilities • High to medium volume ballots, quality commercial work and magazines • Registered security printer
Paarl Media Gauteng
• An 80-page manroland Lithoman web offset press with varying reel widths of 860mm to
2060mm (2010). Includes inline gluing, trimming, stitching and inserting functionality. Prints up to 45 000 80-page copies per hour.
• Three 16 manroland Rotomans, with 578mm and 620mm cut-off (2005, 2007, 2009). Offer quick make-ready and printing speeds up to 65 000 full colour copies per hour.
Paarl Media Gauteng
Expanded bindery facilities : • 2 x 15 000 speed Kolbus Publica PUR binders (2008 & 2010), is backed up by a Muller
Martini Normbinder. • One Muller Martini C140 Primera saddle stitcher (2011) • Three Muller Martini Prima Plus gangstitchers (2 X 2005, 1 X 2007) • 1 x Steinemann Colibri UV varnishing machine (2008)
Paarl Media Paarl
• High volume books, ballots, specialised magazines and covers, promotional and direct
marketing material, as well as financial reports • Sheetfed, specialised book and web offset printing • Awarded Sappi African Printer of the Year 2010
Paarl Media Paarl
• Komori Lithrone S1040P ten colour long perfector • Komori Lithrone S840P eight colour long perfector • Komori Lithrone S640C six colour with anilox coater • Specialised web offset press, manroland Octoman, for promotional and direct marketing
material: 50 000 impressions per hour • Unique book press, manroland 901/1 backprinter (2010) for single colour book printing
Paarl Media KZN
• New plant established in Durban with an initial investment of R200 million.
• High to medium volume quality commercial work, ballots and magazines.
• Two 16-page manroland Rotoman presses with 578mm cut off: prints up to 50 000
full colour copies per hour. Includes high gloss coating and inline gluing and
trimming.
• Binding and finishing services with saddle stitching and perfect binding.
New publication gravure press
• Cerutti Rotogravure Publication Aurora Press
• 2nd of its kind to be installed (first at Abril, Sao Paulo)
• Purchased September 2011, to be in production August 2012
Why a New publication gravure press ?
• An enormously vibrant retail market in South Africa
• A retail market in Sub-Saharan Africa which is set for exponential growth
• A great desire for super calendared paper in both the retail markets and mass
magazine market
• A complete range of tabloid sizes are still in vogue with commercial clients and
evidence of this is increasing.
• A catalogue market which shows signs of stability and sustainability
• A constant need for shorter lead times.
Cerutti Publication Gravure Aurora Press
Net production speed
+ 21%
Job changeover time 1 hour
Waste at start-up - 33%
Energy consumption - 12%
Manning required on the press - 25%
Total Publication Gravure Capacity
• 54 000 tonnes of publication gravure capacity
spread over four presses:
• 3 Cerutti
• 1 KBA
Population of South Africa
'000s
2002 2010 2011*
Black 36.0 39.6 40.2
Coloured 4.0 4.5 4.5
Indian 1.1 1.3 1.3
White 4.3 4.4 4.6
Total 45.5 49.9 50.6
Source: General Household Survey, Stats SA
*Mid-year Population Estimates 2011
• Still experiencing population growth • Middle class growing at a rate exceeding that of the population growth
Proportion of Population by Age Group & Race, 2011
Black Coloured Indian White Total
Age % of Total
0-14 33.4 27.6 22.4 18.1 31.3
15-29 30.5 25.8 26.5 20.2 29.0
30-59 29.9 39.3 40.0 41.1 32.0
60-80+ 6.2 7.3 11.1 20.6 7.7
Total 100 100 100 100 100
Source: Stats SA, Mid-Year Population Estimates 2011
• Extremely young population by comparison to Europe • Emphasis is on literacy up to tertiary education level
Average Annual Growth Rate in GDP (%) by Sector
1981-1993 1993-2001 2001-2009
Agriculture * 0.6 1.2 2.0
Mining * -0.2 -0.6 -0.9
Manufacturing * -0.4 3.1 1.8
Electricity * 3.5 1.8 3.2
Construction -2.8 1.8 9.5
Trade Sectors 0.7 3.9 3.3
Transport & Comms 0.8 6.7 5.2
Financial Services 2.0 4.7 6.3
Personal Services 2.6 1.1 3.3
General Government 2.6 0.1 3.1
TOTAL 0.6 2.9 3.7
* Export oriented sectors
-10
-5
0
5
10
15
20
04 05 06 07 08 09 10 11
Gro
wth
(%
)
Growth in Retail Sales
Source: Statistics South Africa
Retail Sales According Type of Dealer at Constant 2008 Prices (%)
Weight
2010 1st Qtr 11 Apr 11 May 11 Jun 11
y-o-y % y-o-y % y-o-y % y-o-y % y-o-y %
General Dealers 38.1 4.5 5.1 7.9 5.5 3.4
Food, Beverages & Tobacco 9.3 1.4 -4.0 6.6 -9.0 -4.1
Pharmaceutical, Medical Goods, Cosmetics & Toiletries 6.5 11.1 11.0 12.3 3.2 9.2
Textiles, Clothing, Footwear & Leather Goods 21.0 8.1 5.2 16.2 -2.5 2.9
Household Furniture, Appliances & Equipment 6.3 15.2 10.4 12.7 3.5 6.2
Hardware, Paint & Glass 6.3 -3.3 13.3 9.2 -9.0 -3.0
All Other Trade 12.6 2.4 6.7 6.2 -2.4 -0.7
Total 100.0 5.2 5.7 10.0 0.2 2.2
Source: Stats SA
• Furniture and appliances are a serious growth industry and more than 50 % of publication gravure printing stems from this.
Medium 1975 1990 2000 2010
TV Stations nil 7 56 100
Radio Stations (separate buys) 7 34 105 138
Daily Newspapers 22 22 17 21
Major Weeklies 19 25 21 26
Consumer Magazines 180 250 480 655
Business to Business 219 300 580 700
Community Newspapers uncounted uncounted 260 470
Web Pages N/A N/A 1.4 bn trillions
Growth of media in SA…
Positives for South African Outlook
• Although growth weaker than other emerging markets, it is likely to outperform
developed economies
• Low government debt levels compared with developed economies
• Sound fiscal & monetary policy being sustained
• Beneficiary of commodity price cycle & African recovery
• Fully fledged democracy, coupled with media freedom & independent judiciary &
sanctity of contracts prevent socio-political turmoil
Positives for South African Outlook
• Magnificent work being done by NGO’s
• Private sector still functioning relatively efficiently
• SA invited to join BRICS
• Strong retail growth
• Positive growth in print media advertising
• Stronger household consumption
• Many global companies have underestimated the impact of Africa’s size
• The following countries could fit within Africa
Topography
China 3,705,390 sq.mi
United States 3,618,770 sq.mi
India 1,266,595 sq.mi
Europe 1,905,000 sq.mi
Argentina 1,065,189 sq.mi
British Isles 94600 sq.mi
Total 11,655,544 sq.mi
Africa’s area 11,707,000 sq.mi
Source: Maps of the World
IMF Forecasts for Growth of Sub-Saharan Countries
2012-2016
Zambia 7.7
Mozambique 7.7
Tanzania 7.2
Angola 7.1
Uganda 6.9
Kenya 6.7
Democratic Republic of Congo 6.4
Nigeria 6.2
Ghana 6.1
Côte d'Ivoire 6.0
Botswana 5.5
Malawi 5.3
Senegal 5.2
Zimbabwe 5.1
Lesotho 4.7
Namibia 4.4
Mauritius 4.4
South Africa 4.4
Swaziland 2.3
Source: IMF WEO, Apr & Jun 11
Internet Usage
June 2010 Internet Users User Growth (2000-2010)
Penetration
(% of Popu)
Tunisia 3 600 000 3500.0 34.0
Morocco 10 442 500 10342.5 33.0
Nigeria 43 982 200 21891.1 28.9
World 1 966 514 816 444.6 28.7
Egypt 17 060 000 3691.1 21.2
Algeria 4 700 000 9300.0 13.6
Zimbabwe 1 422 000 2744.0 12.2
Africa 110 931 700 2357.3 10.9
South Africa 5 300 000 120.8 10.8
Kenya 3 995 500 1897.8 10.0
Uganda 3 200 000 7900.0 9.6
Zambia 816 700 3983.5 6.8
Namibia 127 500 325.0 6.0
Botswana 120 000 700.0 5.9
Libya 353 900 3439.0 5.5
Ghana 1 297 000 4223.3 5.3
Angola 607 400 1924.7 4.6
Lesotho 76 800 1820.0 4.0
Cameroon 750 000 3650.0 3.9
Tanzania 676 000 487.8 1.6
Congo, Dem. Rep. 365 000 72900.0 0.5
Source: Internet World Stats
Internet usage South Africa
YEAR Users Population % Pen. Usage Source
2000 2,400,000 43,690,000 5.5 % ITU
2001 2,750,000 44,409,700 6.2 % IWS
2002 3,100,000 45,129,400 6.8 % ITU
2003 3,283,000 45,919,200 7.1 % Wide World Worx
2004 3,523,000 47,556,900 7.4 % Wide World Worx
2005 3,600,000 48,861,805 7.4 % Wide World Worx
2008 4,590,000 43,786,115 10.5 % W.W.W
2009 5,300,000 49,052,489 10.8 % W.W.W
Increasing aid for education
Country Total
population
GDP Growth School
population
Aid received spend on
education USD
Nigeria 155,215,573 6.4 % 64,545,000 102,000,000
Ethiopia 90,873,739 8.1 % 35,402,000 234,000,000
DRC 71,712,867 6.5 % 30,172,000 86,000,000
Tanzania 42,746,620 7.1 % 18,974,000 110,000,000
Kenya 41,070,934 6.5 % 16,576,000 111,000,000
Uganda 34,612,250 6.7 % 15,512,000 125,000,000
Angola 13,338,541 7.5 % 8,161,000 60,000,000
Zimbabwe 12,084,304 5.6 % 5,015,000 25,000,000
Rwanda 11,370,425 6.7 % 4,102,000 91,000,000
TOTAL 473,025,253 198,459,000 944,000,000
Note: These figures exclude any spend by government on Education.
Sources: EFA Global Monitoring Report 2011, RMB FICC Research: August 2011
What does this mean for publication gravure
printing in South Africa?
• South Africa has a vibrant publication gravure market with eight publication gravure presses
• GDP growth, retail growth and literacy will keep the written media popular culture • Advertising growth continues to increase all media possibilities • A growing population and the advent of the middle class leads to an increase in
aspiration and associated advertising • Growth in literature programmes means additional printing opportunities
Publication Gravure: Catalogue & Retail
Work – Paarl Media Group
Total value in excess of R 352 million Tonnage in excess of 22 000 tons Grades of paper used: SCB 49gsm SCA 52gsm LWC 60 - 80gsm
• Products vary between A4 – tabloid – broadsheets • Pages 4 / 6 / 8 / 12 / 16 / 20 / 24 / 32 • Tonnage 1 900 tons per month • The market takes full advantage of the cut off flexibility offered by the
gravure process • Print runs vary between 2 million – 10 million copies per product • Covering between 20 – 50 individual products per month
DBE Workbook Project
• South African Department of Basic Education (DBE) launches workbook project
in 2010 to assist literacy and numeracy skills development in schools
• First phase:
• 24 million books, 105 titles, distributed to 18 475 schools throughout South
Africa
• Next phase:
• 46 680 762, 306 titles, distributed to 24 989 schools
What does this mean for Printing in Africa?
• Two cornerstones: Democracy & Literacy
• These will lead to investment, retail, economic growth
• These will require infrastructure, distribution, printing
• The Paarl Media Group is already represented in Nigeria, DRC, Angola,
Zimbabwe and Mozambique
Examples of work in Africa
• Paarl Media African printing experience
• Paarl Media has experienced increasing success in securing print work for elections and education.
• Elections
• DRC in 2006.
• Nigerian elections printed in 2007 and 2011.
Examples of work in Africa
• Paarl Media African printing experience • Paarl Media has experienced increasing success in securing
print work for elections and education. • Education • Angola • Zimbabwe • Mozambique • Botswana, Zambia and Namibia – turnover secured from
Via Afrika. • DRC • Malawi