Digital Printing Services             ( digital printing information | good things to know )

What is a Quickmaster DI?

The Heidelberg Quickmaster Direct Imaging press (or 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 four-color 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 imagesetting 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.

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 copier quality, imaging up to 500 impressions, at a cost of $.70 to $1.70 per sheet. With both of these technologies, whether you’re printing one or 500 pieces, the cost is constant. It makes true production-oriented printing beyond 200-300 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 250 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.)

How are files RIPed on the DI?

The DI utilizes a “Software RIP”. This type of RIP is generally preferred because it’s easily upgraded and can execute on many standard computer platforms. The computer Heidelberg chose was the DEC (Digital Equipment Corporation) AlphaStation 200 with a Microsoft Windows NT operating system. This is one of the fastest combinations of hardware/ software available on the market today. Under most circumstances, we will RIP and separate customer files in times ranging from four to eight minutes. Since the system is multi-tasking, files may be received over the network, and the press will continue printing while other files are being RIPed.

Can I proof my files before going to press?

Digital color proofing is now widely accepted in the industry. At HEX Graphics, Inc. we use the Epson 5000 with the Fiery RIP. In addition to digital proofing, the Heidelberg RIP of the press computer allows for “softproofing” of the finished pages prior to printing. With this quality control feature, we can preview the finished pages on screen to assure that the correct fonts are being used, trapping has been properly set, and the page position is correct.

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.

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?

What inks can be used with these plates?

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.