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association news

Seekho aur Samjho (SaS)- Monthly Workshops for Supervisors and Staff

an initiative by the BMPA, PrintWeek India, GIPT & SIES' GST

Dear Members, Dec 31, 2014

Firstly permit us to wish each of you, your family and your businesses a wonderful brand new year.

We are excited to bring a calendar of monthly training sessions under the SaS series with the speci�c mandate of improving the skill levels of your team members: Supervisors and Press room sta�. �e SaS series will commence from Jan 2015 and shall run upto Dec 2015 based on the dates and timings as published below. �e purpose behind sharing the year-long calendar is so that you have an opportunity to do advance sch eduling and maximize the bene�t of SaS.

First workshop Jan 17th 2015 on: Correct Usage of Densitometer and Spectrophotometer

How to register for the SaS workshop?

- �e topic and schedule for the upcoming 6 months (Jan to June 2015) is as published below.- Registration is free on �rst-come basis for 50 numbers. Limited to a maximum of two delegates per member company. - Registration request received seven days prior to the event or on-spot charged @ Rs.500/- per person per session.- To register, please send the applicable fees if any along with names, email id and mobile numbers of the personnel.- Payment vide cash or cheque favouring: �e Bombay Master Printers’ Association.- �ere will be light refreshment upon the session’s ending.

Venue:

- On alternative month the SaS series is to be organized at the respective venues of GIPT (West at CST) and SIES' GST (Nerul). �ere is to be no session in the month of May.

Time:

Timings for each session – 3 pm to 6 pm – 120 min training, 30 min Q/A and 30 min tea at end of session. �e only exception is the �rst session of Jan 2015 at which the timings have been altered to 10am to 1pm.

GIPT: GIPT Auditorium, Sir JJ School of Arts Compound, CST (VT), Mumbai - 1

SIES: Auditorium, SIES Graduate School of Technology, Sri Chandrasekarendra Saraswati Vidyapuram,

Sector-V, Nerul, Navi Mumbai - 400706. Tel No: 022-61082400 or 01 or 02

SaS Workshops Jan to Jul 2015

Location Date Topic Timing

GIPT 17-Jan Correct Usage of Densitometer and Spectrophotometer 10am to 1pm

SIES 06-Feb On Press Chemistry 3pm to 6pmGIPT 07-Mar Book Binding Tips and Tricks and intro to PUR 3pm to 6pmSIES 03-Apr Paper terminology, correct usage and applications 3pm to 6pmSIES 05-Jun Tips to avoid breakdowns and information on scheduled maintenance 3pm to 6pmGIPT 04-Jul Getting acquainted with UV curable inks - Do's and Dont's 3pm to 6pm

Looking forward to your wholehearted support to the SaS series of workshops.

Team BMPALet’s do more!

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association news

Consecutive reappointments at OPA Recently on 28th of December O�set Printers’ Association (OPA), unanimously nominated Mr. PArveen Aggarwal as the President of OPA for yet another term of two years. While Mr. Kamal Chopra was nominated as the General Secretary for yet another term.

�e Annual General Body Meeting (AGM) of OPA was held at South City, Ludhiana on 28th December, 2014. Mr. Chopra elaborated the various activities undertaken by OPA and said that their Association is internationally reputed as an active printers’ association from India.

At the function OPA members also released the annual Calendar jointly at the hands of Mr. S S Dhillon, Director MSME DI Ludhiana and Mr. Parveen Aggarwal, President of OPA. Speaking on the occasion Mr. Aggarwal said it is one of the prestigious projects of OPA and this year it is expected that we will generate a pro�t of about 2 lakh from this project alone. Not only this he said, copies of this calendar are sent all over India as the calendar is quite popular with printers and often it is named as the ‘Printers’ Jantri’.

BMPA’s Exclusive Study Tour – II (Japan)�e concluding feature of our tour to Singapore and Japan in 2014 between Nov 7th to 14th. �e previous issue featured impressions from Singapore.

Day 3 – Japan (Gifu) Sakurai

At Tokyo’s Narita International Airport we were met by our guide who aided the group’s swift transfer to the Tokyo Central station. Here we boarded a Shinkansen aka Bullet Train and travelled westwards to the district of Gifushi for a tour of Sakurai Graphic Systems Corp (SGS).

�e meaning of Sakurai, I was informed is ‘cherry blossoms ’. Along with their Indian Sales Associate Manager International Trade Dept. – Ajay Gandhi of Kunal Enterpises, Sakurai’s Takayuki (Tony) Nakazawa, Manager International Trade, shaped our �rst impressions about Japan. All of which are very motivating and positive. Hence I can con�dently say that Sakurai truly delivered as per the quality in its name.

�e �rst impressions are bold; Our hosts ensured that we got reliable and dependable supply of Gyaan along with great ROTI (Return on Time Invested). By the way the vegetarians amongst us did not su�er from malnourishment whatsoever through our stay in Japan. All

thanks to the wonderful arrangements made by all three viz. Sakurai, Komori and Ricoh. In fact some of the Indian restaurants in Japan rival our local favourites here.

On the day of our arrival, which was a Sunday, Tony arranged for us to visit the Gifu castle. �e next day after breakfast we were taken for a tour of SGS’ factory in the picturesque city of Mino. �e welcome was warm. �e Indian �ag at main driveway added yet another charm for all of us. In a large meeting room we were given an overview on SGS by Ayumi Yokochi, Executive Director, Production & Technology.

Once the formal presentation was complete, our group was divided into two. Each was headed by an English-speaking resource who took us through the factory. �e extensive tour showed us everything that transpires to put together a Sakurai press.

�e SGS began as a paper distribution company in 1928 and not until 1946 did they change course. SGS was the �rst manufacturer from Japan to have exhibited in Drupa (1962) with their innovation: fully auto letter press. By ’66 SGS had developed a fully automatic screen printing press and sometime in ’75 they launched their �rst sheet-fed o�set press – Oliver.

�e house unanimously elected Mr. Parveen Aggarwal as President and Mr. Kamal Chopra as General Secretary yet for another term of two years. In the picture Mr. S S Dhillon (extreme left and Mr. Romi Malhotra (third from left) garlanding Mr. Agarwal and Mr. Chopra.

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association news

SGS is a family-owned, professionally managed enterprise having extensive market share domestically and in the US too. �e factory at Mino city in Gifu generates over 320 KW solar power for its captive consumption. �is is the only company in the world that manufactures machines for two di�erent processes viz. screen and o�set. SGS also has signi�cant prowess in deployment of LED UV curing machines. �e advantages with this process of curing are: Less make-ready, no powder hence less cleaning, eco friendly (due to absence of Mercury), zero Ozone emission, requires no shutter mechanism, huge drop in power consumption and longer lamp life.

At present, Sakurai is manufacturing some proprietary technology for 3M and another development is happening in perfecting its Air Delivery Systems that make for even smaller gripper margins.

�e company deploys diamond grippers across its press range. �ese o�er life-long service. On the shop �oor we saw that every assembly within a Sakurai press features multi-coloured dots. �e shop �oor workers specialize in di�erent aspects of machine production. Each dot corresponds to a team or group. It is the responsibility of each team to expertly tend over that part of a mechanism which is encoded to their team colour and spec it to set standards. When a fault arises or is detected, it is readily tagged to the right team for appropriate solution. A highly trained and skilled team of experts undertakes QC of every press that comes o� the SGS line highly sanitised area within the factory.

�e assembly line tour culminated with a large and diverse range of job applications that were rendered over SGS’s fully automatic Cylinder Screen Printing presses. SGS has a very high stake in Industrial Screen Printing worldwide. And the company makes all endeavours to provide its customers best-in-class ecosystem comprising reliable partners.

At this display arena we got to see a technology that is equivalent of CtP, the Digital Light Engraver (DLE). It is a computer to screen architecture developed by CST Germany. �e DLE uses micro-mirrors and can adjust their angle and expose UV light onto the screen mesh for screen making. �e revolutionary technology will have great impact on the process.

Now here’s some serious food for thought and ideas for growth for O�set players who are unexposed to the nuance and reach of Screen printing process.

Screen printing facilitates the printing of messages on virtually all materials except for water and air. Screen printing is widely applied in commercial printing that adds value to products such as packaging for cosmetics as well as in industrial printing for products including:

• DiffusionFilmPrinting(forLCDmanufacture)

• SecurityPrintingforCreditCard,ICCardand Passport

• FPCB(FlexiblePrintedCircuitBoard)Printing

• AutomobileOverlayPrinting

• ApplianceOverlayPrinting

• TransferPrinting(Tag-lessLabel)

• DecalandLabelPrint

• Specializedcoatingandsurfacetreatment(Currency anti-counterfeit)

• TransferPrintingforChinaware

• CoatingandpackagingPrinting

Soon after the factory tour we departed for a traditional Japanese lunch. It was exquisite and delicate. Post lunch we visited two of Sakurai’s customers: Druck Japan and Packman.

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association news

Day 4 – Japan (Gifu and Nagoya) Sakurai and Toyota

�e next day, Tuesday, we checked out from our hotel and were chaperoned by Tony Nakazawa and Ajay Gandhi to Toyota’s Motamochi car factory located in Toyota city. Our appointment, which stressed highly on punctuality amongst other protocols, was met when we arrived at their gates by 1.20pm. Our guide for the tour was Yuri Ooba. Yuri spoke �uently in English and showed us around the multi-product assembly line. With Toyota it is a common practice to show its assembly lines to visiting groups including its competitors from the auto segment. Hence the routine is thoroughly rehearsed. A suspended track that snakes above the entire assembly line gave us a bird’s eye view. We got to see Kaizen in practice. One of Kaizen’s main principles ‘of sharing openly’, was responsible for getting us this opportunity to visit Toyota. �e tour ended over a photo-op and visit to the Toyota Museum.

�e next stop in our journey was Tokyo for the Komori lag. After the Toyota visit, we boarded yet another Shinkansen from Nagoya and reached Shinagawa. Shinagawa’s relation to Tokyo is that of Churchgate to Andheri in terms of distance.

Day 5 – Japan (Tokyo) Komori

On Wednesday, the twelfth of November, we made a visit to Komori customer – Kinyosha Printing Co. Ltd. �e journey to Kinyosha was via the busiest expressway of Tokyo – Osaka. It was picturesque as well. �e famous Mt. Fujiyama makes for an idyllic backdrop view from Kinyosha’s meeting room that doubles-up as cafeteria for its sta� too.

A warm welcome was accorded to us by Kaneaki Hayashi and his team. Kinyosha was established way back in 1926 and has always been known as a manufacturer of high-quality printed products. �e company is singularly focused

– it only manufactures Digi-packs under all formats conceivable. It can easily be called a live showroom for Komori presses, having seven Komori presses under its roof at this location. In addition, they also have an HP-Indigo press. Kinyosha has state-of-the-art technology across the spectrum of processes. It follows the Kaizen process to the core and has very high environmental standards.

If I had to pick a novelty at Kinyosha then this is it: Within the press there is a warehouse with an inventory of 420 pallets - of di�erent paper grades. �e stocking and delivery process of the pallets is fully automated. �ey are piled over one another and the piles run upto seven decks high to reach the ceiling of the press room. �is inventory of pallets approximately su�ces Kinyosha for a week’s production (�ve-days). At another location Kinyosha also has water-based Flexo printing setup. �e company has a super-specialized QC department that checks every product and every sheet that leaves the press. �is department is wholly sta�ed with women for in Japan they regard the fairer gender to be more productive and accurate than their male counterpart.

�e journey to Kinyosha from Tokyo was quite long; we set o� a bit early since we had a special opportunity – dinner meeting with Yoshiharu Komori the Chairman & CEO of Komori Corp. �e dinner meeting was located in downtown Tokyo close to two famous landmarks – the Tokyo Sky Tree and Asahi (Beer) HQ. When we reached the restaurant at the 20 something �oor we were surprised to �nd that Mr. Komori was awaiting us. At 75 Yoshiharu Komori came out as a man who has seen and more importantly done much. His calm demeanour and simplicity established more than what can be described in words. For sure, he had the entire group feeling easy. He welcomed the BMPA delegation and raised a toast to us. He referred to the Tsukuba plant, which we were to visit the next day, as a ful�lment of a big dream. �e President, BMPA,

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Faheem Agboatwala, made a thank you speech at this gathering and invited Mr. Komori to deliver a talk at Print Summit 2015. After some consultations – he did agree to be with us all in Mumbai on Jan 16th 2015 over Print Summit.

Day 6 – Japan (Tsukuba) Komori

Located about 90 minutes from Tokyo the group arrived at Komori’s latest manufacturing plant located in the town of Tsukuba. Komori’s vision of setting up the most advanced printing press production facility has been realized via the Tsukuba facility. At this plant, the web o�set press and banknote/security press and production functions from Komori’s Sekiyado unit have come to get integrated in a novel way. In addition, they have setup a Komori Graphic Technology Centre (KGC) that imparts continuous training, real time press demonstration and resolves technical dilemmas. KGC also features a versatile display and library of printed products – that demonstrate the superior quality of production and design that is achieved via Komori technology. �e production facilities at Tsukuba use Kaizen and are environment friendly.

�e plant is spread over 1.85 lakh sqm having a constructed �oor space of 63,344 sqm. �e architectural design is simple and sharp. It houses R&D on the second level while the �rst and ground level are used for plant sta� and production and KGC respectively.

�e production area is divided into two zones. All the materials distribution, assembly line, sub-assembly line, machining facilities are located in one zone while the other zone is dedicated predominantly for press testing and KGC functions.

Komori’s Tsukuba plant operates by reduction in CO2 emission by relying on alternate forms: solar and wind and has a gas-powered air-con system. Zero emissions are better achieved via a waste handling area with more than 20 recycling categories.

Naomasa Hashimoto, the BMPA’s got-to-man for everything related to Komori Corp, took us on the assembly line that has a speed of 7cms per minute and is some 160-metre long. �e mandate of this production setup is to manufacture seven presses a day with an annual target of 2,500 presses. We were informed that Komori manufactures its own electronics (read PCBs). �e gears are machined in-house and needle bearings with triple races are deployed on Komori presses. Mr. Hashimoto compared the Komori bearings to be of equivalent grade as the Shinkansen. Like in Sakruai presses, Komori too uses pre-greased diamond grippers that are maintenance-free for the life of the press. �e assembly line is a multi-product type. �e same line manufactures the Lithrone SX 40, G series, Banknote/Security presses and the S series.

Incidentally no other Japanese manufacturer besides Komori makes currency printing presses.

Komori operates its plants under a Meister (read Master) programme. �e Tsukuba plant currently has three Meisters who mentor and train the group of engineers and technicians that work on the assembly line. It is quite a tradition that successive generations from the respective families get into employment with Komori. �is way technical knowledge is very e�ciently handed down from one generation to another.

It was evident that Komori’s order book was pretty healthy as we saw many presses being assembled, quite a few on testing and many more ready for shipping. In progress were also two Banknote/Security presses. So all in all the entire production �oor was abuzz and lively.

Besides Tsukuba, Komori manufactures in Yamagata the small-format sheetfed, digital press and printing machine for printed electronics. Komori –Chambon in France manufactures o�set and gravure web presses along with in-line die cutting equipment for package printing.

In a presentation made by Toshiyasu Kubotera, General Manager Export, we got to learn of an interesting marketing concept: Komori On Demand. �rough this Komori has leveraged its rich 90-year heritage to provide a hi-tech solution that facilitates short runs and quick turnarounds by shortening makeready time, cutting paper waste and providing a reliable solution which reduces the printing process to an absolute minimum. �e core of the H-UV process that o�ers “O�set on Demand” is a fusion of the KHS-AI integrated control systems and Komori’s award-winning H-UV curing system. �e H-UV is an innovative powderless UV drying system that enables instant drying using a UV lamp developed by Komori with proprietary know-how. �e H-UV enables immediate drying with just one lamp for each printed side of the sheet. It also o�ers ecological and economic bene�ts and remains reliable producing high quality prints.

In his presentation, Kubotera told us that the KGC also extends itself as a Printing College and a Technical Training Centre. Technologists, shop �oor and press room resource along with press owners and their wards can take advantage of the training programmes, which come for a nominal fee and also include residential space within Tsukuba plant’s beautiful complex.

Some pointed takeaways form the Komori presentation to the BMPA group:

• Komoriofferstotalprintingsolutionsfor– Digital, O�set, Nano printing, Currency printing, Printed electronics, Gravure or Intaglio printing

association news

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association news

• WatchoutforKomori’sImpremiaIS29-UV Inkjet Ink with LED-UV Curing with 1200 x 1200 dpi

• LandaNanogrphywillbearealitysoonerthan expected. Watch out for Nanography S10FC

• TheLithrone‘G’seriesiscurrentlythecenterpiece in Komori’s o�set sheetfed portfolio

• Packagingwillmakeup43%oftotalglobalprint product sales in 2017 followed by Publishing, Commercial printing, Business forms and POP in decreasing orders.

• ThevalueoftotalPackageprintingsalesby 2018 is likely to be US$ 974.5 of which Asia’ssharewouldbeapproximately41%

• TrendsorpressureonPackageprinting:Stringent quality and cost requirements, shortening of product cycle, product di�erentiation through package (design sophistication along with brand enhancement and protection) and strict process requirements in terms of safety and security

• KomoriofferscuringunderClassic–UV,LED –UV (not suitable for Packaging) and H-UV

• TheKomoriH-UVadvantages:nosmell,straight press, long perfector, in-line coating. Disadvantages: works only with H-UV inks

• InAugust2014thereare470H-UVpressesoperating worldwide. 283 in Japan, 40 in US, 103 in Europe, 10 in India and 38 in rest of the world

• Komoriclaimstoprovidethesharpestdotand the smallest dot gain

• WiththeKHS-AIitclaimstooffershortestmakeready with minimum waste

• Widerangeofperfectingoptionsincluding

one-pass double side printing with elimination of gripper on tail edge

• Komoriclaimtheirpressestobemostoperator friendly, hands-on-press having most e�ective cost of ownership

• Asof2012,44%ofKomoripressproduction was consumed domestically, followedby20%inAsia,then19%inEurope,TheAmericasat9%andOtherregions8%

Day 7 – Japan (Tokyo) Ricoh Corp

With Friday, November 14th, our itinerary was drawing to a close but not before getting a sneak-peek at the Ricoh HQ and the Ricoh Innovation Centre. �e welcome was swift yet very fascinating. An eye catching circular structure greeted us : Swagatam BMPA India.

From the start, it was very clear that something formidable and closely guarded transpires in this super-building. Our access within the premises was monitored and restricted. �e Ricoh team engaged our group over a presentation that was followed by a product tour with job samples. We were informed about the latest o�erings available from Ricoh diverse product portfolio and more importantly about Ricoh’s recent foray into the go-to-market within the digital stream aka Ink-jet.

Ricoh had organised a guided tour for our delegation. Our guide took us around few landmarks and arranged for some shopping time in Ginza. Very soon, we saw ourselves getting back to the airport – tracing our route back to Mumbai. We were returning enriched

– making new friends, with better information and deeper understanding and some new strategy. All in all the BMPA’s Study Tour is best de�ned by the Japanese Kando: Beyond Expectations!