2 Terminology and

Principles
Lithographic printing may be done on two types of printing press: the sheetfed
offset press and the web offset press. As the names suggest, sheetfed presses print
on precut sheets of paper while web presses print on rolls of paper. This chapter pro-
vides a foundation for understanding web offset presses by presenting basic princi-
ples and terminology associated with the printing method. In-depth information on
sheetfed presses may be found in a variety of GATFPress publications including
Sheetfed Offset Press Operating and the Lithography Primer.
Lithography is a print-
ing process that works essen- Blanket cylinder
Inked
tially on the principle that
image
water will not readily mix with areas
oil. The printing plate that
receives the ink and water is Paper
usually a thin rectangular
sheet of pliable aluminum, Impression cylinder
which can be wrapped around
Figure 2-1. Transfer of the inked image from the blanket to the
and fastened to a press cylin- printing substrate.
der. In simple terms, image
areas on the printing plate are oleophilic (meaning “oil attracting”) and readily
accept oil-based inks. The nonimage areas are hydrophilic, and so attract water. The
chemical repulsion principle keeps the oily ink film on the plate from moving into the
water-coated nonimage areas of the plate. Lithography is a planographic printing
process, meaning that the image and nonimage areas are essentially on the same level
(or plane).
Offset lithography refers to the action of transferring the inked image from
the plate cylinder to an intermediate synthetic-rubber covered blanket cylinder, thus
“offsetting” the image (figure 2-2). The inked image on this blanket cylinder then
comes into contact with the paper to transfer the image. As described in the previous
chapter, Ira Rubel discovered the offset principle around 1905. He found that offset-
ting the inked image before transferring it to the paper resulted in a cleaner, sharper
image.
Following are the basic steps involved in the most common form of offset
lithography:
18 Web Offset Press Operating

1. Plate with photochemically pro-

duced image and nonimage
areas is mounted on a cylinder.
Inking system
2. Plate is dampened with a mix-
ture of chemical concentrates in
a water-based solution, which
adheres to the nonimage areas
of the plate. Dampening
system
3. Plate surface is contacted by Plate
inked rollers, which apply ink cylinder
only to the image areas of a
properly dampened printing
plate.
Blanket
4. Right-reading inked image on cylinder Paper
the printing plate is transferred
under pressure to a rubber-like Impression
blanket, on which it becomes cylinder
reversed (wrong-reading).
5. Inked image on the blanket is
transferred under pressure to a Figure 2-2. The offset principle. The ink on the
sheet of paper or other printing printing plate is transferred first to the intermediate
substrate, producing an impres- blanket and then to the paper. Shown above is a
sion of the inked image on the typical sheetfed printing unit.
paper.
An offset press, then, is a mechanical device that dampens and inks the printing
plate and transfers the inked image to the blanket and then to the printing substrate.
A web offset press (or webfed press) prints on a continuous web, or ribbon, of paper
fed from a roll and threaded through the press at speeds four or five times greater
than that of a sheetfed press. A sheetfed offset press feeds and prints on individual
sheets of paper (or other substrate) at speeds of approximately 10,000–15,000
impressions per hour (iph). Compared to sheetfed presses, web presses have much
smaller gaps on the plate and blanket cylinders, which means that ink and water flow
much more continuously. Blanket-to-blanket web offset presses lack a hard impres-
sion cylinder, which is inherent in sheetfed press designs. This manual deals with (to
use the most accurate expression) lithographic web offset presses.
Waterless offset lithography is a variation of offset lithography that does not
require the use of a water-based dampening solution. The process uses an offset
press equipped with temperature-controlled inking systems. The process requires
special inks and special waterless plates.
Direct lithography, or direct printing, is the process of printing directly from
a printing plate to a substrate. It is accomplished in web offset by running paper
through a blanket-to-blanket unit so that the paper contacts one plate and takes ink
from it. In this case, the blanket cylinder of the couple acts as an impression cylinder.
Terminology and Principles 19

Basic Systems of Web Offset Presses

One can gain a better grasp on the web offset press by analyzing the press in terms
of its systems. We’ll use a typical four-color blanket-to-blanket heatset press as an
example. For the purposes of this book, think of the press as consisting of several
sections. The infeed of the press is where the unprinted rolls of paper are mounted.
The delivery is where the final printed material comes out. Going from the infeed
to the delivery, the elements of a heatset web offset press are, in order, infeed, print-
ing units (press), dryer, chill rolls, and delivery (either a folder, sheeter, or rewinder).
A nonheatset web press does not have a dryer or chill rolls.

Roll Paper
stand

Infeed Printing section

Paper

Folder Sheeter

Dryer Chill rolls

Delivery

Figure 2-3. A four-color blanket-to-blanket heatset web offset press with optional delivery to a folder or
sheeter. The press configuration shown here is the most common, but variations are possible. For
example, with some presses having more than six units, the folder(s) is placed in the middle of the total
press configuration and the infeeds are placed at each end.

The infeed system of the press consists of the mechanisms required to guide
the web of paper into the first unit, where printing will take place. It includes all
equipment from roll stand to the first printing unit and controls the speed, tension,
and lateral positioning of the web. It keeps the web taut and flat as it enters the first
printing unit.
The printing section of the press consists of several special cylinders and ink-
ing and dampening systems. Each printing couple has the following components:
• Plate cylinder. A cylinder that carries the printing plate, which is a flexible
image carrier with ink-receptive image areas and, when moistened with a
water-based solution, ink-repellent nonimage areas.
• Blanket cylinder. A cylinder that carries the offset blanket, which is a fabric
coated with synthetic rubber that transfers the image from the printing plate
to the substrate.
20 Web Offset Press Operating

• Impression cylinder. A cylinder,

found on in-line web presses, that Inking
forces the paper against the inked system
Dampening
blanket and the paper. system Plate
• Dampening system. A series of cylinder
rollers that carry a metered film of Blanket
water mixed with other important cylinder
chemicals (together called damp- Web Impression
ening solution), “dampening” the cylinder
printing plate. The water-based
dampening solution contains addi-
tives such as acid, gum arabic, and Figure 2-4. An in-line offset lithographic press
unit that prints a single color on one side of a
isopropyl alcohol or other wetting web.
agents.
• Inking system. An ink fountain that functions as an ink reservoir and a series
(set) of rollers that transport and mill the ink, finally depositing a metered
film of ink onto the printing plate.
The dryer and chill rolls evaporate volatile solvents and cool the heat-softened
binding resins. Final solidification or setting of the ink occurs with the cooling of the
binding resins. Web offset presses may be either heatset or nonheatset. Heatset presses

Figure 2-5. Goss C700E heatset web offset press. (Courtesy Goss Graphic Systems, Inc.)
Terminology and Principles 21

Figure 2-6. Sunday 2000 web offset press. (Courtesy Heidelberger Druckmaschinen AG)

employ a hot-air dryer to evaporate solvents from inks, leaving a semidry ink film. Chill
rolls are needed in this type of system to cool the hot web after drying. Nonheatset
web presses may have no dryer at all or may employ other types of dryers, such as
ultraviolet lamps for curing UV inks.
The delivery system of the press, where the final printed material comes out,
can perform a variety of potential in-line finishing functions. Presses vary tremen-
dously in capabilities and sophistication of in-line finishing from one press to
another. However, a few in-line finishing capabilities are commonplace on web
presses. A folder delivers folded signatures ready for mailing or for binding with
other signatures to form a magazine or book. On many presses, folding is the final
press operation, whether it is a “former fold,” “jaw fold,” “chopper fold,” or “quarter
fold.” A sheeter cuts the web and delivers flat, printed sheets. A rewinder, as the
name implies, rewinds the printed web back into roll form; this is done when the
web is to be finished off line. A folder produces signatures; a rewinder produces
rolls. The bulk of web offset work involves folding and producing signatures. Presses
may also be equipped with remoistenable glue applicators, inkjet labeling devices,
plow folders, perforators, variable-cutoff units, as well as many other finishing
devices.

Orientation to Press Direction

The two sides of the press have specific designations. One side of the press houses the drive shaft
and gears that power the press. This side of the press is called the gear side. The crew always
works on the other side, because this is where all of the press controls are located. This is called
the operator side of the press. The ends of the press are referred to as the infeed (or front) and
the delivery. The terms sheeter and folder are also commonly used to refer to the delivery end of
the press.
22 Web Offset Press Operating

Web Offset Press Configurations

Web offset presses are available in a variety of special configurations or arrangements
of printing couples within the printing units. A printing couple is an assembly that
includes an inking system, a dampening system, a plate cylinder, a blanket cylinder,
and an impression cylinder, all of which are required to apply one color of ink to one
side of a substrate. (See figure 2-4.) If another color is to be printed, the paper must
go through another printing cou-
ple. A printing unit, on the other
hand, is the housing in which a
number of printing couples may be
mounted. The exact number of
couples within the unit determines
the number of colors of ink that
may be printed as the web moves
through the unit.
Another important difference
among press configurations is the
ability or inability to print on both
sides of the web as it moves
through the press unit. Perfecting
is the term that describes printing
on two sides of the web with one
pass of the paper through the
press. The increasing need for
high-speed printing created by the
booming newspaper industry had
inspired the invention of the web
perfecting press in 1856. Some
press configurations are non-
perfecting; these designs permit Figure 2-7. The vertically arranged printing unit of a
printing on only one side of the CROMOMAN web press for four-page newspaper printing.
paper as it moves through the (Courtesy MAN Roland Druckmaschinen AG)
printing units.
There are three classifications of web offset presses in use today: (1) in-line, (2)
common-impression-cylinder (CIC), and (3) blanket-to-blanket (BTB). Each of these
types of presses varies in the impression system, more specifically in how the printing
couples are arranged within the units of the press.

In-line presses. Most products made with uncoated paper and printed on one or
perhaps both sides are printed on in-line presses. Business forms are a common
example, so much so that these presses are sometimes called business forms
presses. As the paper moves through the press, ink is printed on one side of the web
only, thus in-line presses are nonperfecting. Perfecting may be accomplished on
these presses by using a turn bar to flip the web over between units, resulting in
Terminology and Principles 23

two-sided printing. Each unit contains a single printing couple consisting of an ink-
ing system, a dampening system, a plate cylinder, a blanket cylinder, and an impres-
sion cylinder (see figures 2-4, 2-8, and 2-9). Such presses are generally smaller than
CIC and BTB presses and are also typically equipped with auxiliary devices matched
to business forms products, like imprinters, numbering devices, perforators, and
punches.

Color 1 Color 2 Color 3 File holes Line holes

Perforate

Unwind Printing units Numbering/ Processing Rewind

imprinting

Figure 2-8. An in-line press.

Web guide Offset towers UV coater

Unwind Processor Rewind

Figure 2-9. A web press system for business documents and labels. (Courtesy Brandtjen & Kluge, Inc.)

Common-impression-cylinder
presses. Each printing unit of a com-
mon-impression-cylinder (CIC) press P P
has one very large impression cylinder
B B
with the blanket cylinders of four or five
CIC
printing couples arranged around it. The B B
web of paper wraps around the surface P P
of the impression cylinder. Because of
Key:
the arrangement of the couples and the P = Plate cylinder
size of the impression cylinder, these B = Blanket cylinder
presses are also termed satellite CIC = Common impression cylinder
presses.
A CIC press can be made to per- Figure 2-10. A four-color printing unit of a common-
impression-cylinder press (CIC) with four printing
fect in two ways. The most common
couples arranged around the large common impres-
means is to turn the web over between sion cylinder. Note: For clarity, the inking and
units, in much the same manner as dampening systems are not shown.
24 Web Offset Press Operating

E
B

D A
F

Each unit (A, D) has four printing couples. The web feeds into the first unit (A), which prints four
colors on one side. It passes through a dryer (B) and over chill rolls (C), is turned over and
enters the second unit (D), which prints four colors on the other side of the web. The web then
reenters the dryer (B), is chilled (E), and finally is folded (F) and delivered.

Figure 2-11. A two-unit common-impression-cylinder (CIC) press.

in-line presses. The second method involves printing half-webs of paper, where the
width of the web is only half the width of the plate cylinder. The web is threaded so
that it runs along one side of the printing unit, resulting in the top of the half-web
being printed. The web then moves through a turning bay where it is flipped over,
and returned to the printing unit, where it runs on the other side of the cylinder. On
its second pass through the printing unit, the other side of the web is printed. During
operation, paper runs continuously on both sides of the press. This method of per-
fecting on CIC web presses is called double-ending.
The large size and longer makereadies are disadvantages inherent in the design
of CIC presses, but their speed is higher than that of blanket-to-blanket presses.

Blanket-to-blanket presses. The most common commercial web offset press in the
United States is the blanket-to-blanket (BTB) press, which is a perfecting press. Each
printing unit on a blanket-to-blanket press has two blanket cylinders simultaneously
printing both sides of the web, with each blanket cylinder serving as the other’s
impression cylinder. Each blanket cylinder is part of a printing couple that comprises
a dampening system, inking system, and plate cylinder. Each unit of the web press
contains two printing couples, typically with one on the top and one on the bottom.
These presses have no impression cylinders; the blanket cylinder of the top couple
Terminology and Principles 25

acts as the impression cylinder for

the bottom couple, and vice versa.
Inking
Perfecting capability is inherent in system
the BTB design
Dampening Plate
Blanket-to-blanket press units system cyl.
come in two basic configurations.
The most common arrangement is
Blanket
horizontal, where the web runs cyl.
through the printing units in a hori- Web
zontal plane; the printing couples
are therefore stacked vertically, one Blanket
cyl.
on top of the other. Vertical blanket-
to-blanket presses, common in
Dampening Plate
newspaper printing, have the web
system cyl.
running vertically between blan-
kets, with the couples organized Inking
horizontally and with the folder system
located in the center of the press.
One advantage of this arrangement
is easier access to the printing cou- Figure 2-12. A typical blanket-to-blanket printing unit
(horizontal). Each blanket cylinder acts as an impression
ples. With a vertical web press, the
cylinder for the other couple in the printing unit. Blanket-
rolls are usually located on a level to-blanket units have two couples, arranged to simul-
below the pressroom. taneously print both sides of the web.

Figure 2-13. CROMOMAN web press for four-page newspaper printing. (Courtesy MAN Roland Druck-
maschinen AG)
26 Web Offset Press Operating

D C E D C C
B

Rolls (A) are located on a level below the pressroom (B), a common arrangement in newspaper
plants. Three units on this press are blanket-to-blanket units (C). Two of the units are semi-
drum units (D), each with three couples. The folder (E) is located in the center of the press.

Figure 2-14. A vertical web offset press.

Two-level, seven-web coldset press configuration with splicer located in the basement

Two-level, twelve-web coldset/heatset press configuration

that can be operated as two independent presses

Figure 2-15. Two possible configurations of the CROMOMAN web press. (Courtesy MAN Roland Druck-
maschinen AG)
Terminology and Principles 27

One web, four units—

One 16-page signature, four colors

Two webs, four units—

One 32-page signature, two colors

Three webs, four units—

One 32-page signature, one color; one 16-page, 2 colors

Four webs, four units—

One 64-page signature, one color

Figure 2-16. Four possible products achievable from a four-color blanket-to-blanket press.
28 Web Offset Press Operating

The popularity of the blanket-to-blanket press is due to several factors:

• It is capable of producing a high-quality product.
• Makereadies are efficient.
• Paper passes through a dryer and cooling system once.
The BTB press is also flexible in terms of web configurations and the number
of colors run in one pass. Many of these presses have the capability of feeding one or
multiple webs simultaneously. In this way, many different variations of product may
be achieved. For example, with a four-
unit press, one web can be run straight
through, with four colors printed on each
P
side. Alternately, the press might be set Second-down
up so that four webs are fed into the “offset” color
press, each through one unit resulting in
B
only one color printed per side, but four
Web
times the output as a single web. Many
variations in between are possible. This B Blanket acts
as common
flexibility combined with high speed impression
accounts for web offset’s popularity. Fig- First-down cylinder
ure 12-16 shows four possible products P
“direct” color
produced from a four-unit blanket-to-
blanket press.
In rare cases, BTB web printers
may employ an “s-wrap” to print by direct
lithography, rather than offset. In this Figure 2-17. A blanket-to-blanket offset press unit
that has been so threaded that the web comes in
way, the inked image is transferred
direct contact with one plate and takes ink from it.
directly from the plate to the paper. This Two colors are printed on the same side of the
enables the press operator to lay an addi- web, one by offset lithography and one by direct
tional color of ink on one side of the web. lithography.

Shaftless Presses
Web offset presses have traditionally been constructed with a mechanical line shaft
running the length of the press. Each unit is driven off this single shaft, which is pow-
ered by a main drive motor. Gears and timing belts make up the gear train, which
provides synchronous motion of all driven rollers and cylinders, from the reel stand,
through the printing units and folder.
Shaftless presses are becoming more popular with press manufacturers in
recent times, and some experts predict that all new presses will be shaftless in years
to come. With shaftless presses, manufacturers are attaching individual, independent
AC servo motors to each driven element in the press, including printing couples, reel
stand, chill rolls, and folder. Each electric motor is controlled via a fiber optic link to
a central controller. As such, all units are electronically synchronized and independ-
ently controlled for speed, position, and torque. Following are several advantages to
shaftless presses:
Terminology and Principles 29

Figure 2-18. ROTOMAN shaftless web offset press. (Courtesy MAN Roland Druckmaschinen AG)

Reduction of mechanical errors. As already stated, all components of a mechani-

cal line shaft press are synchronized via a line shaft, gears, chains, clutches, belts, and
pulleys. Because all of these elements are connected end-to-end, any slight gear
backlash (caused by any slight play in the gears) in one unit is passed down the line to
the units that follow. The mechanical error introduced, resulting in a slight accelera-
tion or deceleration, is cumulative and can worsen as it moves through the press if
more error is introduced. These accumulated errors can cause problems with color
register, web tension control, and print faults such as slur.
By contrast, each independent motor on a shaftless press is synchronized elec-
tronically, rather than mechanically, capable of maintaining synchronization with
other motors to within an arc minute (or 0.008°). Errors are not passed down the
line, and a tighter machine stiffness is achieved.

Dynamic synchronization. Each press unit can also be adjusted independently of

its companions. Because of this, plates can be changed and blankets washed on one
unit without driving or affecting any other unit. This is also possible on mechanical
line presses, but it requires clutches and other mechanical parts that make the manu-
facture of the units much more complicated.

Figure 2-19. LITHOMAN shaftless web offset press. (Courtesy MAN Roland Druckmaschinen AG)
30 Web Offset Press Operating

Figure 2-20. The KBA COMPACTA 215, a shaftless 16-page commercial web offset press. (Courtesy
KBA North America, Web Press Division)
With a five-unit press, the press can be running at full production speed
through four of the units while plate changes are made on the fifth unit. When the
plate change is complete, the fifth unit can be brought up to press speed, synchro-
nized with the other units, and the impression can be turned on. This capability is
known as dynamic synchronization, which is only possible on shaftless presses.

Velocity variations. The speed of each unit is controlled independently, allowing for
precise web tension between units. Variations in velocity allow the motor driving a
unit to run at a fixed speed percentage above or below press speed. This allows a pos-
itive or negative draw of almost any amount to be established between any two units
in the press. The draw can be dynamically controlled based on feedback from a ten-
sion load cell. This allows for much higher level of tension control on the running
web. With mechanical line shafts, any draw must be built into the gear system, with
little capacity for variation.

Simplified cylinder timing. Each print couple’s circumferential register adjust-

ments can be made directly at the servo motor. Unit-to-unit timing (synchronization)
is simple because each unit can advance or retard with respect to the main press
synchronization.

Ease of press modification. Because electronically timed presses are designed and
built in sections, presses can be modified more easily to meet new production require-
Terminology and Principles 31

ments. When adding a new component, there is no drive train to tie into and no gears
to align. A new section can be tested and installed and then electronically synchro-
nized to all other press sections.

Factors Affecting the Productivity of Web Offset Presses

Web offset presses are highly productive machines, though they vary widely in cost
and capability. There are several key measurements that can be analyzed to deter-
mine a press’s productivity, including press size, press rate, makeready requirements,
and in-line finishing capabilities.

Press size. To analyze press size, both the width of the press and cutoff must be
specified. As the paper is printed, the image on the plate cylinder is repeated over
and over again along the length of the web. The length of the repeated image is
called the repeat length. The gaps between the repeated image will be cut into
sheets at the delivery end of the press, thus the term cutoff. The circumference of
the plate cylinder determines cutoff. A larger-diameter plate cylinder will produce a
longer repeat length.
Besides web cutoff length, web presses sizes are also determined by the across-
the-cylinder direction, which is usually the maximum roll width that can be handled.
A wider press is capable of printing a wider web of paper, resulting in more image
area per cutoff. It is important to note that a wider press could also print narrower
webs, providing the printer with more possible product variations.
The size classifications of web offset presses are typically measured by the size
of the signature that can be printed, which are traditionally stratified into 32-page,
24-page, 16-page, 8-page, and narrow web. Signatures are large sheets of paper with
multiple pages printed on them. A 32-page signature would contain 32 sequential
pages when folded down to the size of a single page. (See figure 2-21.) These terms
are based around the number of 8.5⫻11-in. (216⫻279-mm) pages or, in metric, A4
pages that can be arranged on a single cutoff.
The larger web offset presses can print a 32-page signature, with sixteen
8.5⫻11-in. pages on one side and sixteen identical-sized pages on the back. These
presses might be about 60 in. (1,524 mm) in width with cutoffs of about 35 in. (889
mm). Presses categorized as full-sized presses can produce either 24-page signa-
tures (12 equal sized pages on each side) or in some cases 16-page signatures, with
eight equal sized pages printed on each side of the signature. These presses tend to
be about 40 in. (1016 mm) to 60 in. in width with cutoffs of about 23 in. (584 mm).
Half-sized presses print 8-page signatures, with four equal-sized pages on each side.
These presses are commonly about 25 in. (635 mm) in width with cutoffs of about 17
in. (432 mm). Quarter-sized presses and narrow webs vary in size considerably,
but typically will print webs from about 20 in. (508 mm) wide and narrower, with cut-
offs of about 18 in. (457 mm) and less. This size allows for the printing of a four-page
8.5⫻11-in. signature or smaller 8.5⫻11-in. forms.
32 Web Offset Press Operating

9 24 17 16 15 18 23 10

8 25 32 1 2 31 26 7

5 28 29 4 3 30 27 6

12 21 20 13 14 19 22 11

Top side of form Bottom side of form

Figure 2-21. An imposition for a 32-page signature.

Many web presses being manufactured today are variable-cutoff presses. This
means that the press design allows for a plate and blanket cylinder assembly of one
cutoff to be removed from the press and replaced with a plate and blanket cylinder
assembly of a longer or shorter cutoff. This capability allows the printer to match the
product with the most efficient cutoff, providing greater flexibility and minimizing
paper waste.

Press speed. The rate or speed of a web offset press is typically measured in feet
per minute (fpm) or, in metric, meters per second (mps). This measurement refers to
the length of the web that is removed from the roll in one minute or one second.
Typical web offset press speeds range from 8 mps to about 15 mps in very fast presses.
Sheetfed press rates are always measured in impressions per hour (iph), which
is the number of sheets that can be delivered in one hour. Web press rates can be
measured in much the same manner. However, on web presses the rate is defined as
cutoffs per hour (cph). This rate measurement refers to the number of cutoff signa-
tures that are produced each hour. It is important to note that a variable-cutoff press
moving at 10 mps will have various cph ratings, depending upon the cutoff length.
Conversions between mps to cph can be calculated as follows:
• Number of millimeters per cutoff ÷ 1000 = meters per cutoff
• Speed in mps ÷ meters per cutoff = cutoffs per second
• Cutoffs per second ⫻ 3600 = cph

Makeready requirements. Makeready is defined as all of the preparations per-

formed on the press in order to produce the first salable sheet or signature coming
off the delivery. This may include changing blankets, inking the press, mounting a roll
and webbing the press, hanging plates, cleaning impression cylinders, running pre-
Terminology and Principles 33

Figure 2-22. The DICOweb press, a computer-to-press offset printing system. This system is based on
DCO (digital changeover) technology that allows printers to image, erase, and reimage printing forms
directly on the press. (Courtesy MAN Roland Druckmaschinen AG)

liminary impressions, checking ink film thickness and color, checking and correcting
registration problems, and setting up in-line finishing devices. These functions can
require a considerable amount of time—time that will increase the cost of the job.
Web presses vary greatly in the amount of automation equipment incorporated into
the design. Newer presses tend to incorporate a great deal of efficient automation
features, including automatic plate hanging devices, automatic registration, and auto-
matic blanket and impression cylinder washers. These devices cut down considerably
on the time required for makeready. However, presses with these features also tend
to cost more.

Auxiliary Equipment
Auxiliary equipment for a web press is composed of those devices that perform spe-
cialized operational functions. These devices can significantly improve print quality
and increase productivity. The following auxiliary equipment may be found on a web
offset press:
• Remote control console, a free-standing computerized device that enables
the press operator to control numerous press functions without leaving the
inspection table. A computerized (remote) console allows the operator to
adjust inking, dampening, and circumferential register; control ink density
and ink trapping; and monitor dot gain.
• Plate scanner, a device that measures the image area percentages at selected
increments across the printing plate prior to mounting the plate on press.
• Scanning densitometer, a computerized quality control table that measures
and analyzes printed color bars using a densitometer.
• Web preconditioners, located in the infeed before the infeed metering
roller. They moisture-condition the web and burn off paper lint and slitter
dust. They also help to reduce paper stretch and blistering problems.
34 Web Offset Press Operating

• Sheet cleaners, mounted on the press in front of or in place of precondition-

ers. They remove loose paper, lint, and dust from the surfaces and edges of
the web before it reaches the first printing unit.
• Ink agitators, which keep ink in the fountain in constant motion, lowering
its viscosity and allowing it to flow to the forward part of the fountain and
transfer to the fountain roller.
• Water-cooled ink oscillators, which maintain the temperature of the ink
oscillator at a level that will not set the ink.
• Fountain solution recirculation systems, which pump fountain solution
into each fountain pan from one or more central tanks.
• Fountain solution refrigeration unit systems, which keep the solution at
constant, low temperature to avoid problems due to fluctuating dampening
solution temperature; e.g., changes in viscosity. Chemical changes occur more
slowly at lower temperatures.
• Fountain solution mixers, usually incorporated into recirculation systems.
These units mix in small quantities, constantly adding fresh fountain solution
and maintaining greater uniformity.
• Automatic blanket washers, which consist of a row of nozzles, mounted
over the blanket, from which solvent is sprayed onto the rubber surface. Sol-
vent and loosened material are carried off by the web. Some automatic blan-
ket washers also utilize a cloth and brush system.
• Automatic plate changers, devices that automatically mount a new printing
plate on the plate cylinder.
• Side-lay sensors, which detect minute lateral web movement and signal
steering devices to adjust the paper’s position.
• Web break detectors, devices that mechanically, electronically, or pneumati-
cally detect a break in a web of paper, subsequently stopping the press.
• Remoisturizers, devices that apply moisture to the surface of the web after
it is chilled in order to replace lost moisture during the drying process and to
minimize dimensional change after binding and trimming.
• Antistatic devices, which turn the air immediately adjacent to the web into a
conductor by ionizing the air. Antistatic devices employ electricity, ultraviolet
light, and even a weak radioactive field to neutralize static charges.
• Imprinters, usually a flexographic unit with a rubber letterpress plate, an
impression cylinder, and a simple inking system. Used to print a small amount
of copy such as names and addresses for varying pressruns.
These auxiliary devices are discussed in detail later in this book.