657

4.5 Computer to Print

Introduction be given, accompanied by examples of practical print-

The following deals with those computer to press tech- ing system applications using these techniques.
nologies that do not require a master (fig. 4.5-1). So- Multicolor printing systems based on NIP technolo-
called non-impact printing technologies (NIP tech- gies (e.g., thermal sublimation and drop on demand
nologies) form the basis for printing systems of this ink jet) were also explained in section 3.2.11 (digital
kind. A brief description of computer to print systems, proof). These are also computer to print technologies
systems based on electrophotography or ink jet tech- but are not dealt with here on account of their relatively
nology, has already been given in section 4.1. low productivity.
The overview of the printing technologies is given Selected practical examples of computer to print sys-
again in figure 4.5-2. The printing technologies that op- tems in industrial use and designed for relatively high
erate without a fixed master, namely the non-impact productivity are detailed in the following section. These
printing technologies, are highlighted. This chapter will are systems for multicolor printing, single-color print-
explain the NIP technologies highlighted in color in ing, and printing with special colors.
figure 4.5-2. As highlighted in figure 4.5-2, NIP technologies can
In chapter 5 a detailed description of the physical and be used for printing with sheet-fed and web-fed systems.
technological principles of these NIP technologies will Since the NIP technology normally requires a fixing

Fig. 4.5-1
Computer to print technology compared to PostScript Page/Sheet to be printed
computer to press/direct imaging data file
image, graphics, text,
single-color or multicolor
RIP
Computer to Press

Direct imaging Computer to Print

(with master) (masterless)

Once imageable Re-imageable

master master e.g., e.g.,
Electrophotography Ink jet

Plate imaging Surface imaging Imaging Imaging directly

(per job) (per job) (print per print) with ink
(print per print)
Inking Inking
Printing Printing

Print

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
658 4 Computer to … Technologies

Printing Technology

Conventional Printing Processes Non-Impact Printing Processes

(with master) (masterless)

Screen Letterpress Electrophoto-

printing incl. flexography Lithography Gravure graphy Ionography Magnetography Ink Jet Thermography Photography

“X”-Graphy
Waterless
Continuous Drop on
Offset offset demand
Ink/Toner

Sublimation Transfer

Ink Powder Liquid Magn. Liquid Hot-melt Color donor Color sensitive
(liquid) toner toner toner ink ink (ribbon/foil) coating

Production flow Sheet or Web

(substrate)

Original Prepress Press Postpress Printed product

(analog and digital)

Digital job Computer to Print

Fig. 4.5-2 Non-impact printing technologies for use in computer to print systems

of the print image for process reasons (a separate systems, are based on diverse product information
drying operation is therefore not necessary), the press from the manufacturers and have, to some extent, been
can be directly connected to in-line finishing systems. summarized by the author.
Computer to print systems therefore enable in-line Several variants and expansion options are general-
production of complete printed products, such as wire- ly available for a base printing system. The explanations
stitched brochures or even books with perfect binding given focus on one example, with references to vari-
(see also sec. 9.2). ants.

4.5.1 Printing Systems based on DCP/32

Figure 4.5-3 shows a multicolor printing system that is
Electrophotography used to print web material with powder toners. An LED
The printing systems described below are a selection system with a resolution of 600 dpi is used for imaging,
used to explain the various technologies. The descrip- and toner is transferred directly onto the paper web.
tions, supported by outline diagrams of the printing Different charge intensities, and thereby different ton-

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
 4.5 Computer to Print 659

also be employed to influence the surface quality of the

printed image after the web has cooled down. After
printing, the web material is cut into sheets by a sheeter.
This printing system has the advantage of being able
to print both the front and reverse side of the web si-
multaneously. An extremely wide range of formats can
also be created in the direction of printing.
The printing system is available in two widths, mod-
el DCP/32D for a maximum web width of 320 mm and
DCP/50D system for a maximum web width of 500mm.
Systems are also available for printing on one side of
Discharging the web only (see table 4.5-1). The printing speed is 35
Cleaning Paper web A4 sheets per minute (equivalent to 0.13m/s) or
70 A4 page impressions per minute if printing is done
Printing unit on both sides of the web. This printing system was in-
Toner transfer
Charging

troduced to the market in 1993 and is available from sev-

Encoder (speed control) eral companies under various names and with different
Thermal
front end systems (hardware and software). The use of
fusing the printing system for label printing is explained in sec-
Inking tion 2.5.3 and in figure 2.5-30.
Imaging B Air In figure 4.5-3 a flat-bed scanner has been installed
(LED array) B cooling next to the printing system’s operator station. With this
Conditioning the M Alteration system (Pressport by Portalis) or similar equipment,
paper (temperature/ M of the analog originals can be digitized and either added to a
humidity) C surface print job already available in digital form or produced
C gloss separately.
Y
Y E-Print 1000
S The E-Print 1000 machine from Indigo was detailed in
S section 4.1.3 (see fig. 4.1-7). This computer to print
Sheeter Delivery
pile system forms the basis of a series of models for
4-color printing on sheet material (E-Print Pro) and
Paper reel Single sheet delivery six-color printing including a powerful front-end sys-
tem (TurboStream). A model with increased produc-
Fig. 4.5-3 tivity (UltraStream) has been presented in the year
Computer to print multicolor printing systems for double-sided print- 2000 with a modified printing unit design as well as a
ing on web material (electrophotography, LED imaging, powder ton- model for printing on web material (Publisher).
er) (DCP/32D, Xeikon; diagram drawn up using company literature) The TurboStream model is illustrated in figure
4.5-4, together with an outline view of the E-Print 1000
and a more detailed explanation of the components.
The system works with liquid toner. The printing
er transfer per pixel (approximately nine gray values), unit is designed as a “multipass system” and an inter-
can be generated by controlling the individual light- mediate cylinder that is fitted with a blanket is used for
emitting diodes during exposure of the photoconduc- the ink transfer onto the substrate (sheet material).
tor drum. This enables reproduction of a larger range Imaging takes place via a scanning, multi-beam laser
of color than with only two gray values per pixel. system. The printing system can also be used for du-
The printed image is fixed by heat processes (thermal plex printing. A finishing unit can be connected (see
fusing). An additional device that affects the surface of also fig. 4.1-7).
the printed image by the application of pressure and heat For four-color printing the productivity is 33 A4
transfer in a similar way to a fixing/fusing system can pages per minute (equivalent to approximately 0.15 m/s;

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
660 4 Computer to … Technologies

Cleaning station
Laser Image memory
Ink
nozzles
Charging
System
Ink control
Deve-
collector loper PIP
1
Sheet
delivery 2
ElectroInk™

Feeder
Duplex tray
Hard
drive

Ink container Y M C K Exabyte

Separation Network
1 Blanket cylinder Recycling Imaging of recycling Data transfer
2 Impression cylinder material oil material

Fig. 4.5-4
Computer to print system for multicolor printing (electrophotography, ROS laser imaging, liquid toner, intermediate cylinder) with the op-
tion of sheet turning for double-sided (duplex) printing (E-Print 1000/TurboStream, Indigo; see also fig. 4.1-7)

the speed for a color separation is approximately The web transport must be intermittently controlled
0.6 m/s). The system’s method of operation has already because of the special ink transfer system (which the
been explained in section 4.1.3 (fig. 4.1-7). manufacturer calls “one shot technology”).
Figure 4.5-5 shows a variant derived from this print-
ing system, the Omnius model, for printing on web ma- DocuColor 40
terial. The printing method corresponds to that of Xerox’s computer to print system, illustrated in figure
sheet-fed multicolor printing and is similar to the sys- 4.5-6, is an example of another electrophotography-
tem illustrated in figures 4.1-7 and 4.5-4. The basic dif- based system for multicolor printing (see also sec.
ference is that the color separations are not collected on 1.3.3.1, fig. 1.3-28). It was first introduced to the market
the printed sheet by quadruple rotation (or six-fold ro- by Fuji Xerox around 1995. This machine’s productivi-
tation for printing with six colors) of the impression ty in tandem or unit construction is 40 A4 pages (four-
cylinder on which the sheet is held by grippers, as was color) per minute (equivalent to a printing speed of ap-
previously the case. Here, all the color separations are proximately 0.17 m/s). Imaging is done at 400 dpi by
collected on an intermediate carrier, a cylinder covered using ROS laser imaging systems. Printing is done with
with a flexible blanket, before the entire multicolor powder toner. Key features of these systems are the unit
print image is transferred to the web material in a sin- construction and the gripperless conveyance of the
gle printing contact. This enables flexible materials to printed sheets by means of electrostatic forces and a
be used since register accuracy is determined solely by conveyor belt (the Ricoh company introduced the first
the quality of the transfer to the intermediate carrier. design of this type on the Japanese market around
In this system the imaging also takes place by elec- 1990).
trophotography and laser systems with a resolution of The printing system is also designed for multicolor
800 dpi. The printing speed for four-color printing is printing on both sides (duplex printing) and productiv-
33 A4 pages per minute. ity in this mode of operation is 30 A4 pages per minute

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
 4.5 Computer to Print 661

Sorter

Imaging Scanner
Inking unit

Laser imaging Intermediate Fuser

blanket
Inking unit cylinder
Impression
Operator console cylinder
PIP
Delivery
Paper pile
Web (feeder)
guidance/
control Y M C K

b Transfer belt
Special colors

Fig. 4.5-5
Computer to print system for multicolor printing on flexible web ma-
terials by collecting color separation images on intermediate cylin-
der and the subsequent transfer onto the web in one printing con-
tact (”one shot” technology), (Omnius, Indigo)

(reduced due to the return transport of the sheet after

the initial printing on only one side). The transport
mechanism is illustrated in figure 4.5-6c.
Figure 4.5-6a shows the printing system equipped
with a sorter. Eight A3 sheets, for example, with differ-
ent page content (with two A4 pages each on the front
and on the reverse side) can be collated successively in c
the individual sorter trays for subsequent finishing op-
erations (e.g., stitching, folding). The eight A3 sheets for
Fig. 4.5-6
a thirty-two-page brochure then lie in the correct order
Printing system for four-color printing in unit construction (electro-
in the individual sorter trays, that is, if twenty sorter photography, ROS laser imaging, powder toner) with equipment for
trays were used, there are 20 copies. duplex printing (4.5-6c).
a Printing system (with sorter);
Comparison of the Printing Systems. The specifica- b Unit construction;
tions of the computer to print systems for multicolor c Paper transport and ink transfer (DocuColor 40, Xerox)

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
662 4 Computer to … Technologies

printing detailed above are listed in table 4.5-1. The In the system illustrated in figure 4.5-8 perfecting is car-
CLC 1000 system by Canon, discussed in section 4.1.3 ried out on web material using turning bars located be-
(see fig. 4.1-8), has also been included. Figure 9.2-7 (see tween the two printing systems.
sec. 9.2) illustrates the system link-up for the CLC 1000 In order to ensure accurate positioning of the print
printer to a finishing system for the production of image, web printing systems also process webs with
stitched booklets. tractor feed holes along the right and left sides. The webs
are perforated in an in-line process prior to printing.
DemandStream Pre-perforated web material and perforated web mate-
The DemandStream 4000 DI printing system for sheet rial fan-folded into stacks of continuous sheets are also
material and the DemandStream 8000 DI for web ma- processed (e.g., business forms printing).
terial are shown in figures 4.5-7 and 4.5-8 as examples The DemandStream 6000 DI system is shown in sec-
of relatively high productivity electrophotography- tion 9.2 (fig. 9.2-8) as an example of a “book on de-
based single-color printing (110 or 158 A4 pages/min. de- mand” production system (like the system illustrated
pending on the press width). In both of these systems in fig. 4.5-8, this system also prints on web material).
by Océ, the front and reverse side can be printed in one The printing systems listed operate with powder ton-
pass. ers and imaging is done using an LED array with a res-
The system shown in figure 4.5-7 has two printing olution of 600 dpi. The structure of the LED array is
units and can produce single-color prints on both sides shown in figure 4.5-8b. The high resolution (600 dpi)
using a duplex turner, after which the sheets are rout- and high printing speed (approximately 0.5 m/s) call
ed to the delivery. Colored overprinting can also be for a very accurate and powerful system.
done by the second printing unit. If only one side is to The printing speed of the systems for sheet-fed print-
be printed, the two printing units are used in parallel. ing (fig. 4.5-7) is approximately 0.5 m/s, which is equiv-

Model DCP/32 D TurboStream Omnius DocuColor 40 CLC 1000

(manufacturer) (Xeikon) (Indigo) (Indigo) (Xerox) (Canon)

NIP processes Electrophotography Electrophotography Electrophotography Electrophotography Electrophotography

Powder toner Liquid toner Liquid toner Powder toner Powder toner
6 colors 6 colors
Printing format, 320 mm wide, A3+ (portrait), 308 mm wide, A3+ (portrait), A3+ (portrait),
substrate web sheet 432 mm long; sheet sheet
web
Duplex printing Yes Possible No Possible Possible
Imaging method LED Array ROS System ROS System ROS System ROS System
Addressability (dpi) 600 800 800 400 400
Gray values/pixel approx. 9 2 2 approx. 9 approx. 9
Productivity:
– A4 pages/min 70 33 33 40 31
– A4 sheets/min (dupl.) 35 16.5 15 15
– printing speed (m/s) approx. 0.13 approx. 0.6 approx. 0.6 approx. 0.17 approx. 0.14
Market launch 1993 1993 (1st model: 1995 1995 1996
E-Print 1000)
Variants DCP/32 S: e-Print Pro: Omnius Card:
printing on one 4 colors; printing on sheets;
side only; UltraStream Omnius Canery:
DCP/50 D and (announced) printing on
S: 500 mm wide containers

Table 4.5-1 Computer to print systems for multicolor printing (selection, status: 1999)

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
 4.5 Computer to Print 663

Printing unit 2 Printing unit 1

Delivery Imaging (LED array) Developing station Feeder
Toner

Fixing

Photocon-
ductor drum

Finishing Duplex turner Waste tray External

operations paper feeding

Fig. 4.5-7
Printing system for double-sided single-color printing on sheet material (electrophotography with LED imaging, powder toner) with two
printing units (DemandStream 4000 DI, Océ)

alent to 110 A4 pages per minute (the format layout of fig. 1.3-29 or part 2 of fig. 4.5-17) using two independ-
the A3 sheet being “portrait,” the A4 layout is therefore ently controllable laser diodes simultaneously on a
at right angles to the direction of travel), or 158 A4 pages polygon mirror inside the raster output scanners. This
per minute with the model having a larger press width, enables a printing speed of approximately 0.8 m/s. With
using the “landscape” format layout for A3 (two A4 this printing system the imaging is done on a photocon-
pages adjacent to each other with the longitudinal sides ductor belt, as illustrated in the DocuTech 135 system in
parallel to the direction of travel). figures 4.5-10b and 9.2-9 of section 9.2.
The interlinked printing system in figure 4.5-8 pro- In a special variant of electrophotographic imaging
duces 290 (or with the format variant, 470) A4 pages (Trilevel technology by Xerox) two partial images can be
per minute when perfecting (printing on both sides). applied to the surface of a charge carrier/image carrier
(e.g., a photoconductor belt) as the charge pattern.
InfoPrint 4000 Consequently two 300 dpi print images can be created
The InfoPrint 4000 printing system (model IS2) by on the same section of the surface as a latent image in-
IBM is illustrated in figure 4.5-9. Single-sided printing stead of one 600 dpi print image. The two partial im-
is done on web material using the electrophotograph- ages can then be inked using differently configured ton-
ic method with a resolution of 300 dpi and a printing ers. This method is often applied for printing in the
speed of approximately 1.1 m/s (equivalent to approxi- highlight color process. A new hue is reproduced from
mately 470 A4 pages per minute). Printing can be car- two colors in this way, depending on the screening of
ried out on both sides by linking up two systems using the respective individual colors, although at the cost of
a perfector/turner bars as illustrated in figure 4.5-8. the reduced resolution (see also sec. 5.2.3, fig. 5.2-16/
DocuPrint 350-HC).
DocuTech 6180
The DocuTech 6180 system by Xerox is illustrated in Digimaster 9110
figure 4.5-10a. This system can produce 180 A4 This high-speed printing system by Heidelberg is
pages/min (equivalent to approximately 0.8 m/s) with shown in figure 4.5-11. Printing is done by means of
a resolution of 600 dpi. The printing format is A3+ electrophotography and imaging via an LED system
(portrait). with a resolution of 600 dpi and a printing speed of ap-
The electrophotographic imaging is carried out with proximately 0.5 m/s (110 A4 pages per minute) on sheet
a laser scanning system (ROS: raster output scanner, see material.

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
664 4 Computer to … Technologies

Fig. 4.5-9
Printing system for single-color printing (one-sided, electrophoto-
a graphy, LED imaging, powder toner) on web material (InfoPrint 4000,
IBM)

Photo-
conductor
drum 4.5.2 Printing Systems based on Iono-
Selfoc graphy, Magnetography, and Ink Jet
optics
ImageFast 180 (Ionography)
IC chip While with electrophotography the latent image is
created on the charge carrier by imaging via light/
Conductor photons, in ionography imaging is done by transferring
rail the charge using a controlled ion source (see sec. 5.3 for
LED chip details of this).
Copper support/heat sink A printing system from Delphax (now Xerox) is
shown in figure 4.5-12. The ion source is designed for a
b Heat exchanger resolution of 240 dpi and the system operates with pow-
der toner. The printing speed is approximately 0.55 m/s,
which is equivalent to 90 A4 sheets per minute (further
Fig. 4.5-8
Printing system for double-sided printing on web material. developments by Delphax/Xerox have been announced
a Twin installation of two systems for perfecting via turning bars; with systems having 600 dpi and printing speeds of up
b Underlying principle of LED array for imaging (600 dpi), to approximately 1 m/s). In the configuration of the
(DemandStream 8000 DI, Océ) printing system illustrated in figure 4.5-12, 90 sheets are
printed on both sides per minute, yielding a produc-
tivity of 180 A4 pages per minute with this tandem con-
In figure 4.5-11b the underlying principle of the elec- figuration of two systems with perfector.
trophotographic printing unit is explained. The latent Figure 5.3-6 shows another printing system based on
charged image is transferred via the LED array to a flex- the NIP technology of ionography (instead of the drum
ible belt coated with photoconductive material. as shown in fig. 4.5-12c, a dielectric belt is imaged with
Further details on the Digimaster printing system are ions).
given in sections 1.3.3.3 (fig. 1.3-34) and 9.2 (fig. 9.2-10).
In figure 1.3-34 system components for the transfer and VaryPress T700 (Magnetography)
digitization of analog originals and a finishing unit for Figure 4.5-13 shows a printing system based on the NIP
booklet production have been added to the system con- technology of magnetography from Nipson/ Xeikon. In
figuration shown in figure 4.5-11. this system, as shown in figure 4.5-13b, the print image is

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
 4.5 Computer to Print 665

Fig. 4.5-10
Printing system (electrophotography, ROS
laser system, powder toner) for the produc-
tion of single-color printed media using
digital printing methods.
a Printing system (DocuTech 6180;
180 A4/min);
b System design (DocuTech 135;
135 A4/min, Xerox)

created as a latent magnetic field pattern on a mag- of two adjacent A4 sheets (no overprinting). With a
netizable cylinder using an imaging system consisting of web width equivalent to A4 width, two colors can first
individually controllable miniature magnets (fig. 4.5-13c be printed on one side of the web and, after the side
and for details see sec. 5.4). The magnetic powder toner printed first has dried and the web has been turned,
is transferred in accordance with the magnetization pat- two-color printing can also be done on the reverse side
tern. Fixing is done by heat transfer, and in special de- of the web using two other ink jet imaging systems. If
signs by a “flash-fusing system” in which pulsed, non- the web is only diverted and not turned, a third and
contact heat is transferred to melt the toner. The print- fourth color could be overprinted on the A4 page after
ing system shown produces around 700 A4 pages a the first and second colors have been printed. Other ink
minute (two adjacent A4 pages; A3, landscape) at a res- jet systems for printing on web material are shown in
olution of 480 dpi and a printing speed of 1.75 m/s. figures 1.3-32, 5.5-7, and are announced for multicolor
printing.
VersaMark MPS4 (Ink Jet) The specifications of the computer to print systems
Figure 4.5-14 shows a computer to print system that us- for single-color or special color (spot color) printing
es ink jet non-impact printing technology. The four im- described are summarized in table 4.5-2.
aging systems work on the continuous ink jet principle
(see fig. 1.3-30 and sec. 5.5). The system produces at a 4.5.3 Design Principles of Computer to
resolution of 300 dpi and a printing speed of up to 2.5
m/s, equivalent to 1000 A4 pages per minute for a web
Print Systems
width corresponding to A3 (landscape: two A4 pages The examples of printing systems dealt with above
configured vertically alongside each other). clearly show that various components are used for im-
The system is fitted with four 9" (229 mm) wide ink aging, for example, LED systems or laser scanning
jet imaging modules, which enables two-color printing (ROS) systems. They also, however, clearly show that

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
666 4 Computer to … Technologies

the superimposed printing of screened color separations

for multicolor images can be carried out using differ-
ent methods, such as collecting the color separations
on an intermediate carrier or directly on the paper.
The examples of systems were also used to explain
that with systems based on NIP technologies it is rela-
tively easy to design complete systems for single-color
and multicolor printing that link together prepress,
press, and postpress production stages in-line (also on
account of the generally low production speeds com-
pared to those technologies requiring a master and
equivalent systems).
a Prepress functions are integrated into the printing
system via the digitally defined print job and, for ex-
Print sheets ample, using an integrated flat-bed scanner. Since the
Pressure
Vacuum roller
running towards print image is usually dry immediately after printing,
transport system the delivery/ as NIP technologies require fusing, finishing can be
finishing
done in-line. The postpress (finishing) process can
Toner transfer onto Heating therefore also be integrated into the system.
the print sheet
Toner fusing There are numerous finishing options. The systems
are usually modular in structure so that production
Paper feed
systems for different end products can be set up. The
Image (toner)
Cleaning unit system can usually be converted by the operator for dif-
(electrically and
Register roller mechanically)
ferent types of products.
Removal In-line production is illustrated in the form of a block
of residual LED array
carrier (for improving diagram in figure 4.5-15.“Data in”-“Product out”is an apt
Photoconductor
particles the image quality) belt description of this digital print media production system.
Densitometer
It is essentially the design of the multicolor printing
(quality inspection) process and the imaging system specifications that de-
Drive termine the productivity and quality of the printing
Charge system.
transfer
Inking unit
(toner supply) Multicolor Printing Systems. Several options for collect-
Electrometer ing color separations for multicolor printing are shown
(monitoring LED Array for in figure 4.5-16. Distinction is made between collecting
Two-component toner the charge) imaging (600 dpi)
(carrier: approx. 30 1m ∆, on the paper, collecting on an intermediate carrier
toner: approx. 10 1m ∆) (drum or belt), and collecting directly on the imaging
b surface.
The image can be transferred to the paper with or
Fig. 4.5-11
without an intermediate image carrier system.
Computer to print system for single-color printing and in-line pro- Systems in which color separations are collected on an
duction of print media (electrophotography, LED imaging on photo- intermediate carrier and transferred to the paper in one
conductor belt, 110 A4 pages per minute). printing contact (as shown in fig. 4.5-5) can also be de-
a Example of system configuration (add-on see figs.1.3-34 and scribed as “singlepass”systems,such as those used for mul-
9.2-10); ticolor printing systems in unit design (e.g., fig. 4.5-6)
b Basic principle of the electrophotographic printing unit where the multicolor print is produced by sheet transfer
(Digimaster 9110, Heidelberg) in one pass through the press. In “multipass” systems the
multicolor print is transferred to the substrate in several
print contacts with the intermediate image carrier or the
imaging system in one printing unit (e.g., fig. 4.5-4).

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
 4.5 Computer to Print 667

Fig. 4.5-12
Digital printing system for single-sided and
double-sided printing on sheet material
(ionography, 240 dpi, 90 A4 pages per
minute, single side).
a Printing system;
b Paper guidance and system components
for double-sided printing;
c Ion source for imaging (component of the
page-wide imaging system)
(ImageFast 180, Delphax/Xerox)

Printing unit Sheet reversal unit

Feeder
for
simplex
printing

Printing unit
Sample tray Fusing units
Delivery

Feeder for
duplex printing
b

Electrode
Insulator
Imaging signal
Ion source

Imaging electrode
Approx. 150 1m
(240 to 300 dpi)
Dielectric coating

c Imaging cylinder

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
668 4 Computer to … Technologies

Line
c
Magnetic Discharging the
a magnetic load
imaging system
Cleaning
Paper web

Fusing station
Toner supply Imaging
(magnetic powder toner) cylinder
Suction
b (image enhancement)

Fig. 4.5-13 Digital printing system (magnetography) for printing on web material.
a Printing system;
b NIP printing unit (magnetography);
c Miniaturized magnets for imaging (detail of array for 480 dpi, six-line structure with 80 dpi per line) (VaryPress T700, NIPSON)

Fig. 4.5-14
Ink jet printing installation with four print-
ing systems and drying equipment for print-
ing on web material.
a Computer to print system;
b Diagram (two printing units each having
two printing systems, drying unit);
c Ink jet module in printing unit
(VersaMark MPS4, Scitex Digital Printing)

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
 4.5 Computer to Print 669

Model DemandStream DocuTech 6180 Digimaster 9110 ImageFast 180 Varypress VersaMark
(manufacturer) 4000 DI (Océ) (Xerox) (Heidelberg) (Delphax) T 700 (Nipson) MPS 4 (Scitex)

NIP processes Electrophotography Electrophotography Electrophotography Ionography Magnetography Ink Jet (cont.)
Printing format, A3+ (portrait), A3+ (portrait), A3+ (portrait), A3+ (portrait), approx. 457 mm e.g., A3+ (land-
substrate Sheet Sheet Sheet Sheet wide, web scape), web

Duplex printing possible possible possible possible possible possible

Imaging method LED array ROS system LED array Ion sources Magnetic head Nozzle array
array array
Addressability
(dpi) 600 600 600 240 (300) 480 300
Gray values/ 2 2 2 2 2 2
pixel
Productivity:
– A4 pages/min 110 180 110 180 700 1000
(90 sheets
duplex)
– printing speed approx. 0.5 approx. 0.8 approx. 0.5 approx. 0.54 approx. 1.75 approx. 2.5
(m/s)
Market launch 1997 1997 1999 1996 1998 1999
(DocuTech 135 (previous
since 1990) models with
240 dpi)

Table 4.5-2 Computer to print systems for single-color and special color printing (selection, status: 1999)

Fig. 4.5-15 “Data in” “Product out”

Digital system for the production of print
media with integration of prepress, press
Digital system for print media production
and postpress

Digitally
defined Color
print job monitor

Raster Multi-
Data file
Finishing

Image System control Printing system color

(e.g.,
Processor Bit- console (NIP technology) print
PostScript)
(RIP) map products

Scanner Prepress Press Postpress

Postpress

In part 1 of figure 4.5-16 the color separations are col- four-color print takes place on a common impression
lected directly on the paper using a system in unit de- cylinder.
sign (cf. the system shown in fig. 4.5-6). This could al- In the year 2000 Heidelberg and Kodak (joint venture:
so be achieved with the printing system illustrated in NexPress Solutions) launched the new multicolor print-
part 2, which is based on a satellite design. Here the ing system (NexPress 2100) for sheet-fed printing. With

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
670 4 Computer to … Technologies

Collecting on paper

1 Direct, without intermediate carrier (unit design) 2 Via intermediate carrier (satellite design)

Imaging Cleaning
M C
Cleaning Imaging
Inking B
Printed Inking Y
sheet Y M C B Paper
Intermediate
carrier
(“blanket”)
Belt (paper fixed by electrostatic forces) Printed sheet Paper feed

Drum (“Impression
cylinder”with grippers)

3 Collecting on intermediate carrier 4 Collecting on image carrier

Conditioning
Image carrier Imaging
(cylinder) Inking Imaging C
Intermediate Inking
carrier (belt M
or drum) Cleaning
B C M Y Image carrier B
(drum or belt) Y
Cleaning Cleaning
Multicolor print Paper feed Multicolor print Paper feed

Fig. 4.5-16 Designs for collecting color separations in multicolor printing with computer to print systems (singlepass systems)

this production system the multicolor print is based on part 3 of figure 4.5-16 (production speed: 60 A4 pages
the method shown in part 1 of figure 4.5-16. However, to per minute, addressability: 600 dpi).
obtain better printing quality each printing unit is With the printing system from Indigo already de-
equipped with an additional intermediate cylinder that scribed (see fig. 4.5-5), color separations are collected
is covered with a rubber-like material (fig. 4.4-2 on the on an intermediate cylinder with a flexible, rubber-like
right). The printing system produces 2100 A3 pages surface. With the system shown in figure 4.5-4, on the
(four-color) per hour (this corresponds to 70 A4 pages other hand, they are collected on the paper by switch-
per minute) and is equipped for simplex printing as well ing the toner supply four times while the sheet is held
as for duplex printing (perfecting). The NIP technique on the impression cylinder in a single printing unit
used is electrophotography; imaging takes place via an (single unit design, multipass system).
LED array with 600 dpi and numerous gray levels per In the concept shown in part 4 of figure 4.5-16 the
pixel (see fig. 9.2-11). color separations are collected directly on the imaging
Part 3 of figure 4.5-16 shows a variant in which the cylinder (or belt), that is, imaging and inking take place
multicolor image is collected on an intermediate carri- in the same system. The “Trilevel” method for highlight
er in the form of an endless belt. The image is then color printing described previously is an example of this
transferred in a single contact with the paper. At the be- option.
ginning of the year 2000 Xerox introduced a new print- In the middle of the year 2000 Xeikon (in coopera-
ing system (DocuColor 2060). This system has a simi- tion with Agfa) has launched a multicolor system for
larly structured multicolor printing unit as shown in printing on sheet material. In this system based on the

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
 4.5 Computer to Print 671

1 Multibeam system (scanning) 4 1 Laser diode & Light valve

Imaging head (multibeam, scanning)

Light source
Image signal Beam forming optics
Image Image
Laser diode signal Light valve
carrier Example: spacing 15 mm
Imaging optics
2 Rotating mirror system (ROS: Raster Output Example:
Rotating mirror Scanner, stationary) 480 channels
Image signal spacing: 15 1m
Laser

Laser diode 5 Light source & Digital Micromirror Device (DMD)

array (multibeam, stationary)
Example: Light source
800 dpi
Beam
3 LED array (stationary, page-wide) Image signal forming
optics
Mirror
device
DMD: e.g., chip with 7056 micromirrors Image signal
aligned in one line (Mirror spacing: 17 1m)
Example: 600 dpi Photoconductor drum and 64 lines

Fig. 4.5-17 Variants for the configuration of multibeam systems in optical imaging of computer to ... systems

NIP technology of electrophotography, the color aging, the design of computer to plate or computer to
separations are transferred successively onto a photo- film systems and also in the examples in this chapter on
conductor belt via only one imaging system and inked electrophotography-based computer to print systems.
one after the other in accordance with the separation. The system in part 1 of figure 4.5-17 is used in princi-
Overprinting takes place on the paper at four contact ple in the Quickmaster DI computer to press/direct im-
points with the imaged and inked belt. (In principle aging printing system (figs. 4.4-6 to 4.4-9). The concept
this concept is similar to the one shown in part 1 of fig. shown in part 2 is, for example, used in electrophoto-
4.5-16. The only difference is that the individual imag- graphy-based printing systems (figs. 4.5-4 or 4.5-10).
ing cylinders were replaced by a photoconductor belt The multibeam imaging system illustrated in part 3
with just one imaging system.) Duplex printing on this is used in the printing systems shown in figures 4.5-3,
system (CSP 320D/Xeikon and Chromapress Csi/Agfa) 4.5-8, and 4.5-11.
is achieved through two multicolor systems that are The multibeam imaging system as shown in part 4 is
arranged in a line (productivity: 32 A4 pages per installed in computer to ... systems illustrated in figures
minute, addressability: 600 dpi). 4.1-4, 4.3-3, 4.3-33, and 4.4-11 but could also be em-
ployed as a module for page-wide imaging in elec-
Imaging Systems. Different variants for the design of trophotographic systems.
multibeam optical imaging systems (which can also be The system in part 5 represents a special concept.Here,
used for electrophotography) are illustrated in figure the multibeam system can be set up for page-wide im-
4.5-17. Most of these systems have already been present- aging using electrophotography via individually con-
ed in previous sections on computer to press/direct im- trollable micro-mirrors. In a mirror array provided by

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
672 4 Computer to … Technologies

Conventional Printing Processes

(“mechanical” printing)
with master/
permanent image
e.g., Offset
Convent. Printing
RIP C to Film plate-
Digital full page or print sheet press
(image, graphics, text, multicolor) making
e.g., Offset, Gravure
C to Plate Printing Printed sheet
Digital RIP (full page)
Pre- printing (C to Cylinder) press
Data
press file (processes, e.g., Offset
systems) C to Press/ Finishing Printed
RIP (Postpress) product
Digitally defined Direct Imaging
print job
RIP C to Press/
Direct imaging
Electronic Printing Processes with re-imageable
(NIP Technologies) master

without permanent master,

i.e., no fixed image e.g.,
Electrophotography

Imaging Inking Printing

Imaging & Printing

RIP C to Print inking
e.g., Direct
Imaging
Printing Ink directly
on paper

e.g., Ink Jet

Fig. 4.5-18 Digital printing technologies, components, and systems

Texas Instruments the individual, micro-mechanically put devices (computer to film, computer to plate, com-
manufactured mirrors are only 17 µm apart and the line puter to press/direct imaging or computer to print sys-
length is approximately 120 mm. Magnification by a fac- tems) are controlled via raster image processors (RIP).
tor of 2.5 produces an imaging width of approximately The levels of digitization in the production systems
300 mm with a resolution of 600 dpi. Practical applica- and solutions available for printed media production
tions for printing have not yet been implemented (for can vary greatly.
computer to plate there are some announcements). Figure 4.5-18 explains how digital printing based on
a digitally specified print job can be interpreted/un-
derstood. The basic starting point when using digital
4.5.4 Digital Printing printing options is the single- or multicolor digitally
described full page or print sheet with the entire image,
The computer to... technologies dealt with in chapter 4 text, and graphics information. As illustrated, different
are all based on a digitally defined print job.Various out- printing technologies can now be used. On the one

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
 4.5 Computer to Print 673

Computer to Press Printing Technology

Computer to Print
Direct Imaging
Conventional printing Non-Impact printing
(with master) (masterless)

Screen Letterpress incl. Litho- Electro- Magneto-

printing flexography graphy Gravure photography Ionography graphy Ink Jet Thermography Photography

“X”-Graphy
Waterless
Offset
Offset

Sublimation Transfer

Computer to Film Sheet or Web

Computer to Plate (substrate) Production system

Originals
Prepress Press Postpress Printed product
& Data

Digital with Computer to print (NIP technologies)

Proof

Fig. 4.5-19 Printing processes, computer to ... technologies, and workflow for the production of print media

hand, the conventional printing processes that operate ried out. With this digital printing variant, the multicol-
with a permanent master (“mechanical” printing) can or printed product is produced in the press (without a
be used and on the other hand there are the “electronic” permanent master) directly on the paper via the control
printing processes that do not require a fixed master of the imaging system solely by the transfer of ink via an
(NIP technologies). intermediate carrier or, with the ink jet process, directly
When conventional printing technologies such as off- from the nozzle array.
set printing are used, the lowest level of digitization for In the case of computer to press/direct imaging tech-
digital printing within the entire process chain is com- nologies that use re-imageable masters, digital printing
puter to film. A relatively high level of digital printing occupies a position between “mechanical” printing
is the more direct linkage of prepress to press via com- with a fixed, permanent master and “electronic” print-
puter to plate. When computer to press/direct imaging ing without a fixed print image. It represents the high-
presses are used, the master is produced directly in the est level of digitization of printing processes using a
press from a digitally defined print job; since the film permanent master since with this process (computer to
and mounting of the imaged plate have been dispensed press/direct imaging with re-imageable master) the
with this version of digital printing represents a high stored image can, in principle, be deleted and a new im-
level of digitization with a fixed master. age built up on the plate or cylinder surface after each
The introduction of electronic printing processes such as printing rotation (although this is not the aim and the
electrophotography or ink jet represents the highest lev- strength of these kinds of processes).
el of the expansion of digitization within the entire pro- It must be emphasized that this description and the
duction process, especially if in-line finishing is also car- illustration in diagram 4.5-18 show that digital print-

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )
674 4 Computer to … Technologies

ing is not merely the production of printed products Cost, F.: Pocket Guide to Digital Printing. Delmar
using non-impact printing technologies/systems, but Publishers, Albany (NY) 1997.
De Schamphelaere, L. et al.: Digital Color Presses,
that digital printing is realized by operating pro- Applications and Technologies. Tenth International
duction equipment in the digital workflow that is Congress on Advances in Non-Impact Printing
controlled via the digitally defined print jobs using the Technologies (Proceedings). The Society for Imaging
various computer to ... technologies. The prerequisite Science and Technology (IS&T), Springfield (VA) 1994,
is therefore digital prepress and an interface to the pp. 517–526.
computer to ... system via a raster image processor De Schamphelaere, L. et al.: Short Run Digital Color
(RIP). Digital printing is therefore practiced in Printing, Eleventh International Congress on Advances
companies with extremely diverse installations that in Non-Impact Printing Technologies (Keynote paper).
The Society for Imaging Science and Technology (IS&T),
are adapted to meet the requirements of the specific Springfield (VA) 1995, p. 11.
clientele and print orders. Fenton, H. M.; Romano, F. J.: On-Demand Printing: The
Finally, figure 4.5-19 demonstrates once again the Revolution in Digital and Customized Printing.
role that the various computer to ... technologies, pro- 2nd ed. GATF, Pittsburgh (PA) 1997.
duction systems, and technologies play by way of a Kipphan, H.: Computer to ... -Technologies; New
comprehensive overview of printing technologies and Developments in the Graphic Arts Industry for
of the production flow of printed media production. Producing Multicolor Printed products. Tenth
International Congress on Advances in Non-Impact
Printing Technologies (Proceedings). The Society for
Further Reading for 4.5 Imaging Science and Technology (IS&T),
Ninth International Congress on Advances in Non-Impact Springfield (VA) 1994, pp. 301–306.
Printing Technologies/Japan Hardcopy ’93 Kipphan, H.: Direct Imaging in Theory and Practice –
(Proceedings). The Society for Imaging Science and Computer to Press vs. Computer to Print. TAGA-
Technology (IS&T), The Society of Electrophotography Proceedings, Rochester (NY) 1996, pp. 589–612.
of Japan (SEPJ), Springfield (VA) 1993. Kipphan, H.: Status and Trends in Digital Multicolor
Tenth International Congress on Advances in Non-Impact Printing, Technologies, Materials, Processes,
Printing Technologies (Proceedings). The Society for Architecture, Equipment and Market. NIP 13:
Imaging Science and Technology (IS&T), International Conference on Digital Printing
Springfield (VA) 1994. Technologies (Proceedings). The Society for Imaging
Eleventh International Congress on Advances in Non- Science and Technology (IS&T), Springfield (VA) 1997,
Impact Printing Technologies (Proceedings). The Society pp. 11–19.
for Imaging Science and Technology (IS&T), Kipphan, H.: Future Challenges for Digital Offset Printing.
Springfield (VA) 1995. Advances in Printing Science and Technology (vol. 25);
NIP 12: International Conference on Digital Printing Advances in Offset Printing (ed. J. Anthony Bristow,
Technologies (Proceedings). The Society for Imaging IARIGAI). Pira International, Leatherhead 1999,
Science and Technology (IS&T), Springfield (VA) 1996. pp. 127–132.
NIP 13: International Conference on Digital Printing Landa, B.: Digital Offset Color – Today and Tomorrow.
Technologies (Proceedings). The Society for Imaging SPIE Proceedings, vol. 2171, Color Hardcopy and Graphic
Science and Technology (IS&T), Springfield (VA) 1997. Arts III. Bellingham (WA) 1994, pp. 2–7.
NIP 14: International Conference on Digital Printing Niv, Y.: The Technology behind Indigo’s E-Print 1000,
Technologies (Proceedings). The Society for Imaging IS&T/SPIE Invited Paper, 1994 (not published). Tenth
Science and Technology (IS&T), Springfield (VA) 1998. International Congress on Advances in Non-Impact
NIP 15: International Conference on Digital Printing Printing Technologies (Proceedings).
Technologies (Proceedings). The Society for Imaging Springfield (VA) 1994, p. 196.
Science and Technology (IS&T), Springfield (VA) 1999. Océ (Ed.): The World of Printers. Edition 3a. Océ Printing
NIP 16: International Conference on Digital Printing Systems, Poing 1998.
Technologies (Proceedings). The Society for Imaging Océ (Ed.): Das Druckerbuch, Technik und Technologien
Science and Technology (IS&T), Springfield (VA) 2000. der OPS-Hochleistungsdrucker, Drucktechnologien.
Broudy, D.; Romano, F.: Personalized & Database Printing, Ausg. 4b. Océ Printing Systems, Poing 1999.
GAMA, Micro Publishing Press, Salem (NH) 1999.

© H a n d b o o k o f P r i n t M e d i a, H . K i p p h a n ( I S B N 3 - 5 4 0 - 6 7 3 2 6 - 1 )