Automated prepress technology and the latest generation of process-free plates from Kodak form the basis for Grafiche Milani's internationally recognized top-of-the-range printing
Connoisseurs and admirers of books, illustrated books, catalogs and commercial prints produced to the highest quality standards are likely to be in high spirits when they look around the exquisite production portfolio of Grafiche Milani. Carefully selected materials in sometimes unusual combinations, high-end print quality, exquisite embellishments and immaculate finishing characterize the products of the print shop based in Segrate, Milan. Among its customers are top-class publishing houses, cultural institutions, as well as fashion, interior design and luxury brands from all over Europe and the US. Founded in 1906, this family-owned business employs 58 people and has sales offices in Paris and New York.
Grafiche Milani operates three Komori B1 presses: a five-color press, an 8-color perfector, and a 5+5 color press. The company is known as a European pioneer in the use of H-UV (LE-UV) and H-UV L (LED-UV) curing technology in sheetfed offset.
Kodak prepress technology and offset plates form the foundation for Grafiche Milani’s top-quality performance in the pressroom, where production runs two shifts, six days a week. On average, 150 printing plates are required per day. A semi-automatic KODAK TRENDSETTER Q800 Platesetter has been in use in the prepress department since 2006. According to Oscar Colombo, General Manager, the platesetter’s KODAK SQUARESPOT Imaging Technology delivers “the high level of precision and repeatability we need for reliable, high-quality plate imaging.” As far as screening is concerned, Grafiche Milani uses 175 lpi or 200 lpi AM screening and stochastic 20-micron KODAK STACCATO Screening, ensuring exceptional print quality and finer detail reproduction, which ultimately enhances the visual appeal and readability of the final product for Grafiche Milani’s discerning customers.
Uncompromising CTP automation
SQUARESPOT Imaging Technology was a must when the expansion of the CTP capacity, combined with the desire for automation, became urgent for throughput and backup reasons. Grafiche Milani purchased a KODAK MAGNUS Q800 Platesetter with X-Speed and an automatic Dual Multi-Pallet Loader (MPL) that can hold two pallets with each up to 1,500 plates. In this configuration, the MAGNUS Q800, which offers a throughput of 45 plates per hour, can operate fully automatically over longer periods without operator intervention. “Thanks to this CTP productivity and process automation, our plateroom staff save a lot of work, and plate imaging can run without manual intervention for longer,” comments Oscar Colombo.
KODAK SONORA Ultra Process Free Plates excel in several ways
Environmental sustainability is a top priority at Grafiche Milani, as highlighted by the company's own “Milani green” program. It includes numerous measures and certifications to protect nature and the environment. As part of this strategy, the print shop has begun transitioning from traditional wet processed plates to process-free plates from Kodak.
“We had been toying with the idea of process-free platemaking for some time because we were fascinated by the numerous sustainability, cost and efficiency benefits. The prospect of getting rid of the plate processing equipment and the associated consumption of water, chemicals and energy and getting plates onto press faster was very tempting,” says Oscar Colombo. “When Kodak presented us with the new KODAK SONORA Ultra Process Free Plate, we were immediately willing to test it. What we particularly like about the SONORA Ultra plate is its high contrast after imaging, which is just as good as with a traditional plate. The significantly improved tolerance for handling the plates under white light also meets our operational requirements.”
During the trial productions, the Grafiche Milani team wanted to test the robustness of the SONORA Ultra plate because it is no secret that the highly reactive inks and aggressive auxiliaries that are employed for UV printing present particular challenges as regards plate life. The SONORA Ultra Plate, which offers a run length stability of up to 100,000 impressions for UV-ink applications, demonstrated convincing performance – also regarding the high demands of the company and its customers on print quality. Due to the positive results, Grafiche Milani’s management decided to completely switch to SONORA Ultra Plates by July this year.
At Grafiche Milani, another Kodak solution plays a central role – and has done so since 2007: KODAK PRINERGY Platform is the digital backbone of production, increasing productivity through automation and reducing waste by minimizing human error. Kodak's automated workflow solution ensures that the pressroom is continuously and reliably supplied with printing plates. In addition, the print shop uses the KODAK PRINERGY INSITE Prepress Portal (IPP) in its daily dealings with customers. They can upload files directly into the digital workflow environment and efficiently handle proofing, correction and approval cycles. “The INSITE web portal is an indispensable tool for us. It supports fast, smooth communication and cooperation with our clients, many of whom are based overseas,” states Oscar Colombo, who is also very pleased with Grafiche Milani's long-standing partnership with Kodak.
With the commissioning of an automated Kodak CTP solution and the transition to SONORA Ultra Process Free Plates, Grafiche Milani has opened a new chapter in its technology history – true to the company motto Grafiche Milani è la stampa di domani, da sempre (Grafiche Milani has always been the print shop of tomorrow).
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