Quickmaster 46-4 DI

The Heidelberg Quickmaster DI is a four-unit, waterless offset printing press which links directly to any PostScript prepress system through a process called Direct Imaging. Direct Imaging utilizes the digital information from PostScript systems for press set-up and on-press plate imaging. Among the major process features of direct imaging is the elimination of film, photographic plates, and all chemistry usage and disposal.>

The DI also serves to reduce labor-intensive processes normally associated with lithographic printing. This press images all plates in register, simultaneously, and presets the ink zone settings based on the page coverage requirements. Also, it prints without water, so dampening is not required. In short, page preparation and makeready times are dramatically reduced.

What is Direct Imaging?

Direct Imaging is the bridge between electronic prepress systems and true offset printing. The DI allows digital data to be sent directly to the printing press using direct-to-press, non-photographic technology. No more film or chemistry!

What are the primary benefits of the Quickmaster DI?

Since the DI eliminates a majority of the manual processes, it excels in meeting market trends in many areas. The DI is indeed a cost-effective method by which to produce fourcolor print runs of 250 to 10,000 pieces. You’ll enjoy fast turnaround time and exceptional image quality.

What is the quality of Print like?

The DI’s image quality is comparable to traditional lithographic printing. As a result of its laser diode technology, the edge sharpness and dot shape produced on the DI are the same as you would expect from a conventional image setting device.

Why are there two levels of resolution?

The DI is equipped to provide two levels of resolution; either 1270 dpi (dots per inch) or 2540 dpi. For most applications, we recommend 1270 dpi imaging. This keeps the file size small enough to accommodate up to eleven 11" x 17" makereadies on-line at once. In addition, it helps to maintain a consistent six-minute imaging time. A resolution of 1270 dpi is sufficient for work up to 150 lpi (lines per inch). For more critical applications, 2540 dpi resolution is available. It should be noted that both imaging time and file storage requirements will increase by a factor of three to four times when 2540 dpi is in use. This is much the same as you’d encounter with a film imagesetter.

Why is a waterless system preferable in short-run color printing?

Waterless printing provides for easier and quicker makeready, a sharper dot structure, and greater flexibility in ink laydown since there is no dampening system to bring into balance. In addition, waterless lithography results in less paper stretch, lower dot gain, and more consistent process control. Finally, the elimination of fountain solution in the dampening system helps reduce pressroom VOC emissions.

How does Direct Imaging work?

Direct Imaging works by a technique called "ablation technology". Wherever ink is to be laid down, a laser removes the silicone and image-forming layers from the plate, thereby exposing the base layer of polyester which accepts ink.

What’s so special about these printing plates?

These plates are non-photographic, require no chemical processing, and are insensitive to normal daylight. The plates are composed of a top layer of silicone that repels ink (which provides the waterless offset characteristics), a middle image-forming layer which initiates the imaging process, and a base layer of polyester that accepts ink and provides dimensional stability to the plate.

How long will these plates last?

These plates are good for a one-time use of 20,000 impressions. Projects are, however, stored on digital data cartridges. When a job is to be run again, the data is simply reloaded via the DI server or press computer, and then run like any other job. Jobs may also be reRIPed using the front-end system normally used in production. In either scenario, you’ll save the time and cost normally associated with registering plates and setting the ink key profiles.

Are the plates recyclable?

The plates consist of 99 percent polyester, and a very thin top layer of silicone, both of which are completely harmless to the environment. So, yes, the plates are recyclable. The plate manufacturer, accepts the used plate material, or the plates can be recycled through normal channels.

What inks can be used with these plates?

Process colors, Pantone, varnishes, and metallics are all available for use on the DI. In general, if an ink may run on a wet offset press, it may be used on a waterless offset press.

How does the Quickmaster DI benefit the environment?

The DI process eliminates the hazardous waste materials right up to the final step of printing! No film or film processing is required, the plates are non-photographic, and the disposal problems associated with the heavy metals and chemistry are eliminated, as are the costs associated with these activities. And, since the DI is a waterless offset system, fountain solution and alcohol substitutes are eliminated. The only element in production requiring proper disposal is the ink and clean-up solutions. Paper waste is also reduced significantly since the DI boasts a very quick makeready time.

How does the DI compare to "digital presses" like Indigo or Xeikon?

Actually, the two technologies complement one another. Electrophotographic printers, such as Indigo or Xeikon products, provide good quality, imaging up to 500 impressions, with both of these technologies, whether you’re printing one or 500 pieces, the cost is constant. It makes true production-oriented printing beyond 500 copies uneconomical, however, when compared to the DI. From a technology standpoint, all are PostScript printing devices. That’s where the similarities end, however. The Indigo and Xeikon are electronic printers, or xerographic devices. An electronic charge is applied to a sheet of paper and either dry or liquid toner particles are polarized (oppositely charged) so the toner adheres to the sheet. The DI takes advantage of an entirely different technology known as dry lithography, or waterless printing. From a marketing standpoint, the DI and electronic printers, even color copiers, address the quick turnaround, short-run, four-color process printing market. When you’re looking at a run of from 500 to 10,000, however, the DI offers the highest-quality, most COST-EFFECTIVE solution on the market today.

What paper can run on the DI?

The DI can print on any substrate from an onion skin of .0024 in. to board in thicknesses up to .012 in. Choices include all substrates that can run on a conventional offset press, including coated, uncoated, recycled, mylar, and self-adhesive papers. Sheet sizes range from 3.5" x 5.5" to 13.4" x 18.1". (For your information, a final size of 11" x 17" allows for the most efficient use of paper.)

1. Page Layout Data

The maximum imaging format for DI is 12.5"x17.75", with a maximum sheet size of 12.5”x18.125". Define the page size for the document, or set the original size of your document. Please check whether the trimming is set to 3 mm. Make sure that you trap your objects with 0.144 points, if necessary. Please note that each trapping you create will be printed in the same way as we receive it from you. If your product is to be folded, please specify the correct position and folding style using proper crop marks in your file.

2. Images

Convert all image data from RGB to CMYK. If you separate the RGB images in Adobe Photo shop, use the GCR medium. For best results we recommend an area coverage of 95% for black and a total area coverage of 340%. Save the images as TIFF or EPS. Do not use DCS, Sitex CT, JPEG formats or LZW compression. Don't use TIFF files with alpha channels or bitmap mode. Avoid the placement of half-tone images in EPS or TIFF files. If QuarkXpress or PageMaker pages are saved as EPS data and placed in another document, please send the QuarkXPress pages and all the data which are required for this page. Enclose the original Illustrator or FreeHand document if you have imported graphics from FreeHand. Scan line images with 1240 dpi or higher. This will ensure optimal quality. Set a scan resolution of 300 dpi for color images at 100% size. Use an EPS file format when a clipping path is necessary and set path flatness to 5. Only import your scans into a layout program in 100% or lower zoom values. Enlargements may impair quality. Turn, scale and trim all images before you import them into your document. Set the image frame background color, if possible, to white with 0% black in QuarkXPress. Convert the curves in Photoshop and use the qauss soft symbol to prevent steps. Do not save any screen information and separation curves in your Photoshop document.

3. Fonts and lines

Use Type1 fonts (fonts with both screen and printer icons). It is important to tell us all the font names. Take a little time to check all your illustrations to find the fonts used in them. Supply us with all fonts used on documents. Select a font from the font menu. Do not use any style options from menu or keyboard if possible, Define the lines using precise dimension systems. If you wish to use a hairline, define it as a 0.25 point line. Define all color names uniformly and use CMYK both in your graphics and in your page layout program. Do not mix Type1 & True Type fonts in the same document.

4. Colors

Spot colors must be converted to CMYK. For solid black areas use rich black. Create a rich black color using 60% cyan, 60% magenta, 60% yellow and 100% black. This helps to make the black areas more glossy in your final product. Use photoshop blends for best produced blends. Add noise (7 point, gaussian) to produce the best results. Illustrator, Freehand or QuarkXPress blends have a greater tendency to produce banding. Lighther blends print better than dark blends. Try not to run your gradient color to zero. Avoid solid colors. Rather than using a solid color, use a texture pattern or add noise to solid.

5. Data Directories

Supply us either with a color proof. Regardless of what you decide to supply, please supply us with a hard copy in a size of 100%. Please let us know the data directories under which you have saved your jobs.

Heidelberg QM 46-4 DI serial numbers

Difference between PRO and Plus

Printing stock thickness extended to max. 0.45 mm With the new stream feeder on the Quickmaster DI 46-4 Pro, changes have been made to sheet feed and sheet travel. The maximum printing stock thickness is now 0.45 mm - an increase of 0.15 mm on the previous QM DI 46-4 Plus model. The advantage for customers lies in the extended range of printing stock which will give them greater flexibility in their service portfolios. Existing product portfolios can be expanded to include new jobs in the packaging printing or calendar printing sectors. QM DI 46-4 Pro presses supplied previously can be upgraded by adjusting the mechanical double-sheet detector to enable them to process printing stock thicknesses of up to 0.45 mm. Optimized, cost-effective plate consumption The printing units of the Quickmaster DI 46-4 Pro are equipped with plate cylinders, each with an integrated printing plate roll. Up till now, the supply of plate material these contained was enough for 36 consecutive print jobs. The new V 3.0 press software allows format-dependent plate feed. The plate feed mechanism adjusts itself according to the size of the document to be imaged, eliminating the need to feed a complete plate in full format for every job. This is particularly useful for small-format jobs such as envelopes and letterheads or for imprinting onto pre-printed documents. Depending on the structure of the job, plate material costs can be significantly reduced, thus enhancing the cost-effectiveness of the Quickmaster DI Pro still further. Difference between CLASSIC and PLUS The Classic machine has 8 ink keys instead of the 12 that the Plus model has. This is not a huge difference, but in some instances it proves to make some jobs easier. The ink fountain in the Classic has ink liners which can be removed an thrown out for a fast clean up. The Plus machine does not have these and takes a little longer to clean. It is hard to say which one is an advantage, some say not having to buy ink liners is cheaper, my personal feeling is most people do not clean the Plus/Pro version ink fountain properly or quickly which ends up costing the same price as liners in chemicals and time. Imaging time is 9 minutes on the Classic and 6 minutes on the Plus machine. This proves to be the biggest difference in terms of production. Depending how efficient your pressman is, this difference could affect your recievables. There also is a difference in the feeder, on the Plus machine it disengages duriing imaging due to the high imaging speeds thus reducing wear to parts. The Classic machine does not have this feature because the imaging speeds are lower. The Vacuum extraction units for plate silicone are much easier to service on the Plus version and have a tendency to keep hickeys out of the ink rollers.

Quickmaster DI Pro Advantages

• Cost-effectiveness and profitability
• Seamless linkup of all workflow components to form a complete integrated concept
• Direct transfer of digital data into the printing press
• Elimination of expensive and time-consuming inter- mediate stages
• Flexibility in the production of high-quality printed matter
• Fast processing of demanding print jobs
• Minimum makeready times (< 10 min)
• Clear cost savings through reduced startup waste
• Fast job changes
• High production run speed (up to 10,000 sheets per hour)
• High degree of automation, e.g. automatic color presetting
• Fast job throughput times and high process reliability
• Easy to use GUI
• Convenient job management
• Versatility and flexibility
• Wide range of printing stock including India paper, foils, envelopes and Chromolux
• Material thicknesses between 0.0016” and 0.012”
• All formats from postcards to B3+ posters
• Flexible data handling means customers can make changes right up to the last minute
• Printing with process colors and special colors
• Quality
• The Quickmaster DI Pro combines the high quality of offset printing with the speed of the digital workflow
• High registration accuracy
• True-to-register imprinting, for example with a fifth or sixth color
• Waterless offset printing with optimum color con- sistency
• High reproducibility and accuracy in the production run
• Fast finishing: Highly rub-resistant results mean that folding, cutting and binding can be performed almost immediately
• Workflow
• Uses a powerful IBM Intel workstation, optimized for Delta™Technology
• Automatic quality control thanks to preflight testing and security functions
• High print quality with optimized screens and Color
• Operating concept
• Simple operation using the CP2000 Center™
• Direct control of the entire printing process via touch- screen
• Easy-overview ink zone display
• Fully-automatic job preparation while press is running
• Convenient job management: Standard or repeat jobs can be stored and retrieved
• Viewer provides detailed view (softproof)

1. Imaging unit with 16 laser diodes
2. Remotely controlled CP knife-type ink fountain with 12 ink zones
3. Blanket cylinder
4. Quadruple-diameter central impression cylinder
5. Dryer (optional)
6. Delivery
7. Temperature-controlled inking system for waterless offset with 12 rollers, including 3 form rollers with different diameters
8. Plate cylinder for fully automated plate changes for 35 masters per reel
9. Plate cylinder cleaning system
10. Blanket washup system
11. Stream feeder

Return to knowledge base from Quickmaster Review.