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
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