DVD & CDs are a feast for the eyes!
Why Offset Printing?
© KBA-Metronic AG ! Veitshöchheim, Germany
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
... the leading manufacturer of printing, coding and marking systems
CD & DVD’s: Are a feast for the Eyes!
Because of:
Quality
New Customers
© KBA-Metronic AG ! Veitshöchheim, Germany
Response
Happiness
Money
... the leading manufacturer of printing, coding and marking systems
Printing onto Optical Discs
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Printing Systems for CD/DVD
• Pad Printing
• Flexo
• Silk Screen
• Offset
• KBA-Metronic Offset
• Digital
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Pad Printing
© KBA-Metronic AG ! Veitshöchheim, Germany
"
Solvent inks
"
Intermediate working process
"
Expensive print-plates
"
Slow process
... the leading manufacturer of printing, coding and marking systems
Flexo Printing
© KBA-Metronic AG ! Veitshöchheim, Germany
"
Rotative process
"
UV-curing inks
"
Limited quality
"
High dot gain
... the leading manufacturer of printing, coding and marking systems
Silk screen
For the longest time, silkscreen printing used to be the dominating
technology when it came to optical disc decoration. This has changed
dramatically since DVDs are on the move. More and more the complete
industry is changing into order and print on demand. The capability to
reach a higher quality with offset printing is the reason why offset printing
is well established into the traditional silk screen market.
squeeze
Ink
Screen
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Silk-Screen Printing
© KBA-Metronic AG ! Veitshöchheim, Germany
"
Ideal for full surface printing
"
Bright colors
"
High print costs
... the leading manufacturer of printing, coding and marking systems
What is Offset Printing?
Offset Printing is the most common commercial printing technology in use today.
Offset printing applies layers of ink on the page. For each layer, a reverse image
of the page is placed on a roller in the printing press. Ink is applied to the nonimage areas on the roller, so that as the roller presses against substrate moving
through the press, the proper image is left on it.
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Offset Printing
© KBA-Metronic AG ! Veitshöchheim, Germany
"
Rotative principle
"
Excellent resolution
"
Complicated machines
"
Skilled operators necessary
... the leading manufacturer of printing, coding and marking systems
KBA-Metronic Offset Printing
© KBA-Metronic AG ! Veitshöchheim, Germany
"
Simple operation
"
Easy reproducibility
"
High through-put
"
Perfect quality
... the leading manufacturer of printing, coding and marking systems
Forecast Optical Disc Output 2004-09
Worldwide
Million Discs
40000
30000
20000
10000
0
2004
2005
2006
2007
2008
2009
CD-R
10000
10000
10000
10000
10000
9500
DVD
5500
7000
7500
8000
9000
10000
CD
14000
13500
12500
11000
9000
8000
DVD-R/+R
3000
4000
5500
6500
7500
8500
Total
32500
34500
35500
35500
35500
36000
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Projected DVD Supply
Europe
3500
Million Discs
3000
2500
2000
1500
1000
500
0
Audio DVD**
DVD-ROM
DVD Video
© KBA-Metronic AG ! Veitshöchheim, Germany
2003 2004 2005 2006 2007 2008 2009
5
5
6
15
37
69
102
196
247
306
429
575
691
660
1021 1611 2008 2140 2205 2230 2240
... the leading manufacturer of printing, coding and marking systems
Projected DVD Supply
Worldwide
Million Discs
10000
8000
6000
4000
2000
0
2003 2004 2005 2006 2007 2008 2009
Audio DVD**
16
23
33
DVD-ROM
544
711
840
DVD Video
© KBA-Metronic AG ! Veitshöchheim, Germany
94
170
257
343
1070 1358 1599 1651
3490 5091 5898 6423 6864 7260 7615
... the leading manufacturer of printing, coding and marking systems
Projected HD DVD & Blu-ray Production
Million Discs
Europe
500
450
400
350
300
250
200
150
100
50
0
2006
2007
2008
2009
2010
HD DVD Production
1
2
5
9
8
Blu-ray based PS3 Production
0
31
89
128
155
Blu-ray Video Production
4
30
82
190
326
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Projected HD DVD & Blu-ray Production
North America
Million Discs
1500
1200
900
600
300
0
2006
2007
2008
2009
2010
HD DVD Production
4
24
65
90
78
Blu-ray based PS3 Production
3
65
122
164
182
16
96
260
570
1012
Blu-ray Video Production
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
That’s why we need Offset-printing
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Reasons
Quality!
• Needs to be Photorealistic
• More Details
• More Colors
• Easier Operation
• Match to Proof
• Special requests from your customers
• Digital printing is not (yet) accepted
• DVD is the driving force for offset demand
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Reasons
The Optical Disc market is still growing!
• New formats HD DVD / Blu-Ray
• The global forecast shows growth
• Reduced delivery time (stock reduction)
• Printing on Demand
• Tendency to smaller job sizes (1800 pcs. in average)
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Reasons
Profit
• Investment in new expensive Silk Screen Printing Presses
• Cost of Silk Screen Consumables
• Cost of Skilled Operators
• Cost of Material Waste
• Job Changing & Setup Time
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Offset printing onto Optical Discs
Currently there are two options to be able to offset print onto optical discs. The
difference between these two technologies is, that the wet on wet printing only
has UV dryers after the printing unit and wet on dry requires a UV dryer after
each printing unit. We KBA-Metronic AG offer both wet on wet printing as well
as wet on dry printing.There are also two different inking units out on the
market. The traditional offset inking unit with approx. 16, 18 or even more
rollers and the patented short inking unit from KBA-Metronic AG.
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Conventional Inking Unit
ink chamber & ink zone keys
plate cylinder
transfer cylinders
printing cylinder
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Ink Unit from KBA-Metronic AG
ink chamber
anilox roller
only one transfer
cylinder
plate cylinder
printing cylinder
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Offset printing costs for CD & DVD
Assumed printing area:
diameter 120 mm = 11.309 mm²
Print:
1 colour, diameter 120 mm
Inking:
UV-colour
Printing material:
CDs, DVDs etc.
Price per 1 kg ink:
approx. 35,00 USD
Transfer of ink:
ca. 2 g / m²
Typical area coverage:
approx. 20 %
All-over print:
approx. 500 m² / 1 kg
20 % area coverage:
approx. 2.500 m² / 1 kg
Printing costs:
printing area 11.309 mm² = 0,011309 m²
20 % area coverage:
2.500 m² x 0,011309 m²
equals 221.063 prints
Price per print:
35,00 USD : 221.063 prints
equals USD 0,0001583
Price per 1.000 Prints:
1-Colour 0,15 USD
4-Colour 1,63 USD
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Cost Consideration (silk screen – offset)
• The running costs on offset printing presses are only 25% compared
to silk screen printers
• Thickness of ink in offset is approx. 1,5 microns, 1 kg of Ink is approx.
good for more than 200 000 discs
• Waterless printing plates are approx. 3 USD each compared to
approx. 10 USD per each silk screen frame
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
Summery
• Offset Print quality is much higher
• Offset Printing Presses are easier to operate
• Offset Printing is less expensive
• Offset Printing is faster
• Offset Printing is well established
• Offset Printing Presses are easier to match with the Proofing device
• Digital Printing has not yet the printing quality
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems
KBA-Metronic AG
Thank you very much for your attention!
Please feel free to ask any questions!
KBA-Metronic AG Booth # 0603
© KBA-Metronic AG ! Veitshöchheim, Germany
... the leading manufacturer of printing, coding and marking systems