Beyond Newspapers: How Print Shops are Reinventing Themselves for a Digital Age
The story of Senner Druckhaus GmbH, a German print shop founded in 1831, isn’t just about saving a vintage press. It’s a blueprint for survival – and even thriving – in a rapidly evolving print landscape. Faced with aging equipment and dwindling newspaper revenues, Senner didn’t replace its 1996 manroland Geoman press. They radically retooled it, unlocking capabilities far beyond its original design and transforming their business in the process.
The Retrofit Revolution: Extending Lifespans and Expanding Horizons
Senner’s journey, detailed in a recent WAN-IFRA report, highlights a growing trend: print shops are increasingly opting for retrofits over complete replacements. Why? Cost is a major factor. Replacing a press can easily run into the millions, while a sophisticated retrofit, like Senner’s using DCOS technology, can extend the life of existing machinery for a fraction of the price. But the benefits extend far beyond financial savings.
The initial goal for Senner was a simple decade of extended operation. What they achieved was a complete operational overhaul. The move from a Siemens S5 control system – plagued by parts scarcity – to a modern, Beckhoff-based DCOS system wasn’t just a technical upgrade. It was a catalyst for data-driven decision-making and increased autonomy.
From Manual Adjustments to Predictive Maintenance: The Power of Data
Before the retrofit, colour registration, density control, and even cutoff adjustments were done manually. Today, Senner collects a wealth of data on every production run – speed, splices, cutoff, ink usage, and more. This data fuels a custom-built “production recorder” allowing management, staff, and even customers to analyze performance in real-time. This level of transparency is a game-changer.
“Leadership changed too,” says Markus Krichenbauer, Senner’s CEO. “Conversations moved away from blame. We stopped pointing fingers. We talk about solutions.” This shift in culture, enabled by readily available data, is perhaps the most significant outcome of the project.
Did you know? Predictive maintenance, driven by data analysis, can reduce downtime by up to 30% and extend equipment lifespan by 15-20%, according to a recent report by Pira International.
Diversification is Key: Beyond the Daily News
Senner’s story isn’t just about saving a press; it’s about adapting to market demands. While they continue to print local newspapers, they’ve successfully diversified into high-growth areas like industrial manuals and, surprisingly, flexible food packaging. This expansion required overcoming technical hurdles – achieving precise cutoff accuracy for A5 manuals and ensuring compliance with food safety regulations – but the rewards have been substantial.
This diversification strategy is becoming increasingly common. According to Smithers Pira, the global flexible packaging market is projected to reach $297.7 billion by 2028, driven by demand for sustainable and convenient packaging solutions. Print shops with the ability to adapt and offer these services are well-positioned for future growth.
The Rise of Modular Retrofits and Open Architectures
Senner’s experience also underscores the importance of choosing retrofit solutions based on open architectures. The Beckhoff hardware used in their DCOS system allows for easy component replacement and integration with other systems. This contrasts with proprietary systems that lock users into a single vendor and limit future flexibility.
We’re seeing a trend towards modular retrofits, where individual components of a press are upgraded independently. This allows print shops to target specific areas of improvement without undertaking a full-scale overhaul. Companies like DCOS and others are offering increasingly sophisticated modular solutions.
Challenges Remain: Training and Fine-Tuning
The retrofit wasn’t without its challenges. Training staff on the new DCOS system while maintaining continuous production required a phased approach and, at one point, three printers per shift. Fine-tuning the system for specific applications, like achieving the required cutoff accuracy for A5 manuals, demanded innovative solutions – in Senner’s case, developing their own ink presetting method based on DCOS data.
Pro Tip: Don’t underestimate the importance of comprehensive training when implementing a retrofit. Invest in your staff and provide them with the resources they need to succeed.
Future Trends: AI, Automation, and the Connected Press
Looking ahead, several key trends will shape the future of print shop retrofits and modernization:
- Artificial Intelligence (AI): AI-powered systems will analyze press data to optimize performance, predict maintenance needs, and even automate quality control.
- Increased Automation: Further automation of tasks like plate changing, ink management, and waste removal will reduce labor costs and improve efficiency.
- The Connected Press (IoT): Integrating presses with the Internet of Things (IoT) will enable remote monitoring, diagnostics, and software updates.
- Sustainable Printing: Retrofits will increasingly focus on reducing waste, minimizing energy consumption, and utilizing eco-friendly inks and substrates.
FAQ: Retrofitting Your Press
- Q: Is a retrofit right for my print shop? A: It depends on the age and condition of your press, your budget, and your business goals. A thorough assessment is crucial.
- Q: How long does a retrofit take? A: Retrofit timelines vary depending on the scope of the project, but typically range from several weeks to several months.
- Q: What is the cost of a retrofit? A: Costs vary widely, but generally range from 20-50% of the cost of a new press.
- Q: Will a retrofit affect my existing warranties? A: This is a critical question to address with your press manufacturer and retrofit provider.
Senner Druckhaus’s story is a powerful reminder that innovation isn’t always about buying the latest technology. Sometimes, it’s about reimagining what’s possible with what you already have. By embracing data, diversifying their services, and investing in their people, they’ve not only extended the life of their press but also secured a future for their business in a challenging industry.
What are your thoughts on the future of print? Share your insights in the comments below!
