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September 2010

Quad/Graphics Bets On the Power of Print

Innovator, Now Public, Acquires Worldcolor; Five Plants to Close Debut of Packaging Conference Photos of Winning Entries in 2010 Golden Cylinder Awards Cylinder Society Inducts Seven


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Table of Contents

September 2010

Features

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Cover Feature

Quad/Graphics Acquires Worldcolor

The largest acquisition involving two printing companies promises to offer more print and related multichannel solutions on a global scale.

14 Requiem for an Expert: Bruce G. Beyer, 1955-2010 16 Leaders Attend Summit By Roger Ynostroza

At GAA’s annual industry event, the focus was on the crucial aspects of sustainability.

22 Society Honors Seven 24 Environmental Update

Studying Sustainability

GAA’s annual workshop focuses on biomass value, water scarcity, “print is bad” attitudes, and seven “greenwashing” sins.

28 Champions Win the Gold

Gravure-printed entries in three major categories, plus entries in a technical innovation segment, win top awards.

30 2010 Golden Cylinder Awards Departments

Cover photo by David Hermann, Quad/Graphics; page 12.

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Bill Martin, GAA President & CEO, Publisher of Gravure Magazine

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Roger Ynostroza, Editor of Gravure Magazine

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Industry News • Premedia Spectrum Conference Returns • Changes at Paper Giant • TAGA Announcements

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The Times Are Changing; So Too Must Associations Print’s Strengths Endure Even in an Online World

Worldview • Abril Orders “Aurora” Press • Color Standard for Packaging Gravure September 2010

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A Publishing Message from...

Bill Martin GAA President & CEO, Publisher of Gravure Magazine

The Times Are Changing; So Too Must Associations

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very for-profit business operating today in any segment of the gravure industry is, if its management is on top of its game, striving to reinvent itself, working hard to stay ahead not only of competitors—that perennial threat—but of sudden economic shifts and changes that few managers have ever seen before. Staying in the game on a daily basis isn’t just a challenge anymore; it’s a necessity in today’s economic environment, an effort that requires full commitment to overcome obstacles and threats, and to meet the new expectations and goals the economy has created. For us at the Gravure Association of America, who do our daily work on behalf of our members and sponsors, our focus must be— and each of us at GAA strives daily to make it so—to help the market segments we serve, whether they’re clients in the Packaging, Product, or Publicaton Gravure segments. To serve our members and sponsors, we must continue every day to provide these stakeholders with real value and specific technical and market knowledge, as well as information on the emerging technologies that are sure to have an impact on their future. So, you may justifiably ask, what are we at the industry’s leading trade association actually doing to meet these challenges on a daily basis in our role as the reigning technical, marketing, and educational resource for the gravure industry? Simply expressed, this effort starts with doing what recent history shows that we do 2

Gravure Magazine • September 2010

best: providing continuing education to our members through conferences, seminars, and our website. We’ve revised and expanded our industry-famous Basic and Advanced Seminars to better prepare today’s employees with information that helps reduce costs and improve productivity, in addition to educating them on the ever-evolving rotogravure process and its markets and opportunities. But a wonderful example of going beyond simply fine-tuning our existing seminars from year to year is the ground-breaking GAA Packaging & Products Technology Conference, scheduled to take place this fall at Clemson University in South Carolina. Interested individuals should relish this added feature of the new conference: the convenient co-location at Clemson of the Sonoco Institute, a really wonderful and, because of its newness, a somewhat underrated industry resource. The Sonoco Institute provides a full coverage of technologies, extending from plating and engraving through press, security printing, and consumer packaging goods. There are other valid examples of how GAA does its part to add real proven value. One project few people are aware of involves our work, achieved largely behind the scenes, with seven industry resource centers in providing regular updates to the industry-standard 550-page Gravure Process & Technology Textbook. Be assured that GAA is achieving its goal of adding value that benefits members through education, conferences, and various opportunities to prepare future employees of your businesses.

President & CEO: Bill Martin, Publisher of Gravure Magazine Director of Conference Planning & Administration: Pamela W. Schenk Business Manager/CPA: Linda Pfingst Executive Assistant and Event Coordinator and Administrator: Michelle Giuliano Database & Website Management: Allen Krusenstjerna

Publisher: Bill Martin Editor & Associate Publisher: Roger Ynostroza Art Director & Production Manager: Rani Levy Manager of Magazine Advertising & Promotions: Emily Dominguez, (201) 523-6042

Gravure Association of America, Inc. 75 W. Century Rd Paramus, NJ 07652 Phone: (201) 523-6042 Fax: (201) 523-6048 Website: www.gaa.org E-mail: gaa@gaa.org Volume 24, Number 2 ISSN 08944946 USPS 000-565 Gravure Magazine is published by the Gravure Association of America, Inc., 75 W. Century Rd., Paramus, NJ 07652. Copyright ©2010 by GAA, Inc. Periodicals postage paid at Paramus, NJ, and additional mailing offices. Postmaster: Please send address changes to Gravure Association of America, Inc., 75 W. Century Rd., Paramus, NJ 07652. Gravure Magazine is printed sheetfed offset by Canfield & Tack, Rochester, NY, on 70# stock provided courtesy of Myllykoski.


Inaugural Event

New GAA Conference Covers What’s New

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GAA’s November meeting features laboratory sessions and a post-election assessment.

he gravure industry’s inaugural Packaging & Products Technology Conference, offered in response to accelerating industry interest in each of these topics, will be sponsored this fall by the Gravure Association of America. The meeting will take place October 25-27, 2010 at the Conference Center & Inn on the campus of Clemson University, Clemson, SC. Meeting delegates will be able to tour the industry’s newly opened Sonoco Institute of Packaging Design & Graphics, which is located at the university (see the April 2009 issue of Gravure Magazine).

Interest meets resources Says Chip Tonkin, director of the Sonoco Institute, “Given the soaring interest in packaging and products throughout the gravure industry, plus the great educational and research resources here at Clemson, holding this conference here makes perfect sense. Attendees will learn a lot about their area of interest, plus appreciate the context of that area within the industry at large.” Adds Tonkin, “We’re very

excited about this event, which is now just around the corner.” Says Bill Martin, head of GAA, “The conference chairs are developing a program that covers all aspects, from the visionary to the practical, from technology and substrates to new applications, plus how printed electronics is poised to change the packaging market itself.”

Next big things in gravure Martin continues, “At this conference we’re truly covering the next big things in gravure, on a campus that’s leading the study of gravure packaging design technology, presenting speakers who are experts and expert in asking the right questions for the next crucial breakthroughs.” In his scheduled opening keynote address, consultant Mike Ferrari, Ferrari Innovation Solutions, is to discuss the gaps in gravure between vision and reality. An extended session covers technology companies, from prepress and cylinders to the press, inks, and substrates. A second keynoter is Wendell Smith, president of Technology Transfer Group, who will describe new applications

for packaging security. Later presentations will emphasize new applications for the gravure process, how printed electronics is expected to change the overall packaging market, and a role of logistics. A final keynoter is Ron Malloy, vice president of strategy and sales for Kodak Solutions for Business, who will speak on enterprise marketing automation. To register for the Packaging & Products Technology Conference, visit www.gaa.org or call (201) 523-6042.

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An Editorial Message from...

Roger Ynostroza Editor of Gravure Magazine Publisher: Bill Martin Editor & Associate Publisher: Roger Ynostroza

Print’s Strengths Endure Even in an Online World

Art Director & Production Manager: Rani Levy Gravure Magazine Advisory Board Betsy Barker Castillo,

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ope in all quarters for that long-awaited economic recovery sure has been challenged this year, with government economists continuing to do the math and predicting an “any week now” turnaround, all while helplessly watching those pesky twin barometers—consumer disposable spending and jobless figures—still not budging an inch. So there’s ominous talk about a “recalibrated” U.S. economy and a new business world that may not look very much like the old business world, to the detriment of the working masses. In all this soul-searching about the big economic picture, it’s understandable that both observers and practitioners in the printing industry wonder if, in a world continually abuzz about the instantaneous nature of social media, mobile communications, and the Internet, print still has a future, or in fact, even much of a present. We’ve all heard the grim descriptors about print: it’s a dead medium, or at the very least a passive one, which is regarded as a curse and a fatal flaw in an era of active messaging, rightnow broad communications, and immediate, continual dialogue. But print has its loyal advocates and undiminished strengths. I recently came across a print design survey of creative professionals—conducted annually for nearly 50 years by Graphic Design USA magazine for and about its readers—that is both instructive and reassuring about the continuing strength of print in an increasingly online world. 4

Gravure Magazine • September 2010

RR Donnelley & Sons Victor Basile Jr., Publicis

GDUSA survey findings reveal why, “in a world of endless media options, print remains an essential piece of the puzzle” by providing a human connection via everything from permanence, tangibility, and sensuality to convenience, portability, and authenticity. While print and collateral still anchor the business of graphic design, more than one survey respondent explains that assignments in new media—website, flash banner, or mobile site—have a way of expanding other areas of promotion, regularly including a print project such as a logo update or direct-mail piece. Others note that, as more consumers become desensitized to online and electronic visual solutions, clients realize that paper still captures the full impact of a designer’s concept. Another respondent says electronic communications actually drive requests for print projects, from point-of-sale and event projects to direct mail, collateral, and catalog work. In its respondents’ comments section, the GDUSA survey yields some interesting findings, from generational ones—that adults feel less comfortable reading on screen than on paper—to business-related responses, that while online advertising can target demographics better than can traditional media, these ads don’t necessarily translate into greater profits. In their general commentary, survey respondents reveal their focus on print, noting that a tangible printed piece helps a customer better remember the experience of viewing it and that print can also serve as a good supporting piece to direct people online for an extension of the experience.

Miriam O. Frawley, e-Diner Design & Marketing, Inc. Terrence Frawley, e-Diner Design & Marketing, Inc. Thomas Meisel, Parade Publications, Inc. Cathy Merolle, Hearst Corporation Walter D. Vail, St. Marys Paper Ltd. /St. Marys Sales Robert G. Whitton Jr., Arellton Group, LLC Stephen F. Young, Mundet Inc. Technology Advisory Board Ken Bower, Hallmark Cards, Inc. Gerd Koehler, Gravure Tech Subscriptions Gravure Magazine is available free of charge to employees of Gravure Association of America member companies. Subscriptions for nonmembers in the U.S. and Canada are $ 60 a year, $110 for two years; subscriptions elsewhere are $110 a year, $220 for two years. Business, Advertising & Editorial Offices Gravure Association of America, Inc. 75 W. Century Rd. Paramus, NJ 07652 Phone: (201) 523-6042 Fax: (201) 523-6048 Website: www.gaa.org E-mail: gaa@gaa.org Reprints: edominguez@gaa.org


Wide-Ranging Content

Annual Publishing Conference Profiles Clients & Paper Market

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GAA’s November meeting will feature laboratory sessions and a post-election assessment.

urviving—indeed, prospering—in the evolving world of digital communications and social media is the theme of the 2010 Gravure Publishing Conference, set to take place November 17-19 in Naples, FL. The meeting, presented by the Gravure Association of America’s Gravure Publishing Council, features wide-ranging content that includes insider profiles of three customer companies, six special indepth laboratory sessions, a dynamic audience-participation session, an annual paper market update, a post-election assessment, plus a session on the U.S. Postal Service. The conference opens with a motivational message by Pittsburgh Steelers football star Rocky Bleier, who has held audiences in rapt attention for years. Describing his Vietnamera experiences and football achievements, Bleier tells how ordinary people can become extraordinary achievers even in today’s complex business environment.

Three customer profiles OfficeMax’s marketing and advertising senior vice pres-

ident, Bob Thacker, will tell how the company implemented some great ideas on a restricted budget. Linda LoRe, president of Frederick’s of Hollywood, is to tell how the company emerged from Chapter 11 reorganization in January 2003 after its strongest growth period in more than 10 years. Frederick’s pending merger with Movie Star Inc., she notes, could create a billion-dollar fashion company. Finally, Stage Stores, Inc.’s marketing vice president, Tom Kail, will present, “Thinking Big in Small Town America,” describing the retail chain that operates more than 770 apparel stores in 39 states under such names as Bealls, Goody’s, Palais Royal, Peebles, and Stage.

Six intensive sessions The intensive lab sessions cover six topics: cylinder engraving, the pressroom, finishing, distribution, integrating your brand via an innovative premedia matrix lab, and print redefined. The interactive audienceparticipation session, featuring John McBride and Sharon Lucius, engages attendees in group dynamics to discover ways to manage through con-

flict and pressure and to develop their ability to be responsive to ever-changing market demands. John Maine, vice president of RISI, will offer a two-year outlook for North American publishing papers, with a focus on gravure papers and end uses, plus paper usage trends in magazines, catalogs, and inserts, along with insights into how offshore supply might be affected by tariffs and excessive capacity growth in some markets. Bud Weinstein of Southern Methodist University will assess post-election results and ponder if the newly elected Congress will pursue policy changes to spur economic growth.

er of print production services for Best Buy Co. Inc., and Jennifer Young, catalog/magazine segment manager for Verso Paper. To register, visit www.gaa. org or call GAA at (201) 5236042.

Defining postal needs Finally, Gene Del Polito of the Association for Postal Commerce will share his thoughts about how America must define its future postal needs and the actions it needs to take now. Mike Schilaci, catalog production specialist for OfficeMax, serves as conference chair. Co-chairs include Nancy Cushman, print production manager for Crate & Barrel; Mark Walston, senior managSeptember 2 010

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Industry News

Premedia Spectrum Conference Returns

GEF Scholarship Recipients Named

The industry’s second annual Premedia Spectrum conference will take place January 19-21, 2011, returning to the Naples Beach Hotel & Golf Club, Naples, FL. The event, co-produced by the Gravure Association of America and IDEAlliance, addresses the convergence of cross-media workflows and enables attendees to take full advantage of new business opportunities and evolving brand and customer needs in the media supply chain. Early this year, the initial Premedia Spectrum 2.0 conference offered GAA and IDEAlliance members an expanded resource for news, knowledge, and networking opportunities.

The Gravure Education Foundation recently announced student recipients of memorial and corporate gravure scholarships for 2010-11: Sharon Moore (Arizona State), Gravure Publishing Council; Jessica Roethle (University of Wisconsin Stout), Harry V. Quadracci Memorial; and four Clemson University students who won a total of five scholarships: Joshua Boland, both Werner B. Thiele Memorial and Alcoa Foundation; Susannah Coblentz, K. Walter Services Corporate; Meghan Foley, NewPage Corporate; and Zenobia Staley, Cerutti Group Corporate.

“The upcoming Premedia Spectrum 2.1 meeting will bring new energy to the business challenges of premedia in a cross-media and multichannel world,” says conference chair Penny Sullivan of Meredith Corporation. “It will showcase industry visionaries who will share their insights on new and important breakthroughs to adapt to and thrive with digital premedia.” Sullivan is being joined in conference preparation by vice chairs Darren Cotch of Target, Josh Courtney of Voda Brands, and Dennis Davidson of QuadSystems, plus Matt Huber of JCPenney, past chair. Visit www.gaa.org for complete conference information.

Basic Gravure Seminar The Basic Gravure Seminar, titled “Putting All the Pieces Together,” will be held October 4-6 at Western Michigan University, Kalamazoo, MI. The event, presented by the Gravure Association of America, is intended specifically to benefit pressroom supervisors and press operators, but offers insights of value to print buyers, designers, ink and paper suppliers, and engravers, as well as various levels of management. Primary emphasis is in 6

three areas: —overview, including color theory, separations and prepress, comparison of printing processes, uniqueness of gravure, and safety; —process control, i.e. environmental issues, fingerprinting, identification and use of standards, workflows, quality assurance, and troubleshooting; and —equipment, including presses, dryers, and converting systems.

Gravure Magazine • September 2010

Instructors include Gary White, GAA technical advisor, who has been a print professional for 40 years, with gravure experience in graphics, cylinder plating and finishing, prepress, engraving, proofing, quality control, and customer service, in both publication and packaging operations. The assisting instructor is Dr. Alexandra Pekarovicova, a professor at WMU, where she has taught the rotogravure process since 1997. She has received prestigious grants and awards, written more than 130

Changes at WMU Pilot Plant Joel Kendrick is now directing the Pilot Plants at Western Michigan University, Kalamazoo, MI, replacing John D. Meyer, who has left WMU. Gravure training continues under the direction of Dr. Alexandra Pekarovicova, WMU professor, while Michael Glenn is running presses for clients and research projects funded by the school’s Center for Advancement of Printed Electronics.

GAA Names New Technical Advisors JD Harris, Mark Prescott, and Gary White have joined the Gravure Association of America as technical advisors, assigned to work in such areas as consulting, operator certification, and training.

peer-reviewed publications and conference articles, and holds five patents. Attendees will be lodged at the nearby Radisson Plaza Hotel. For fees and enrollment information, write to gwhite@ gaa.org or call (201) 5236042.


Changes at Paper Giant In mid-June, NewPage Corporation, the largest coated paper manufacturer in North America based on production capacity, announced a search for new executive leadership following the resignations of E. Thomas Curley as president and CEO, Mark A. Suwyn as chairman and a director, and Michael Edicola as vice president of human resources. In the interim, NewPage appointed Robert L. Nardelli (CEO of Cerberus Operating and Advisory Company, an affiliate of the controlling stockholder of NewPage) as a director and nonexecutive chairman of NewPage and its affiliates.

The company, based in Miamisburg, OH, posted $3.1 billion in net sales for 2009. Its product portfolio includes coated freesheet, coated groundwood, supercalendered, newsprint, and specialty papers. The papers

NewPage headquarters are located in Miamisburg, Ohio.

TAGA Announcements North American schools with printing programs and student print chapters were recently honored for their achievements by the Technical Association of the Graphic Arts at its annual conference, held in Pittsburgh. The Helmut Kipphan Student Publication Cup was awarded to the ryeTAGA team from Ryerson University, Toronto, for the editorial content and print production of its student magazine. TAGA’s Harvey R. Levenson Student Paper Award went to Rebecca Dykopf, Gloria Leung, and Pauline

Wut, all of Ryerson University, for their report, “The Effect of Ink Tack in FourColour Printing”. The organization’s Dusty Rhodes Graduate Student Paper Award was won by students attending Clemson University, Clemson, SC, for “All Paper Membrane Switch,” written by John Jay Jacobs, Sarah Stafford, and Andy Walker. Finally, students earned Special Recognition Awards for their schools in four categories: Technical Writing: Western Michigan University;

are used for corporate collateral, commercial printing, magazines, catalogs, books, coupons, inserts, newspapers, packaging applications, and direct mail advertising. NewPage owns 10 paper mills in Kentucky, Maine, Maryland, Michigan, Minnesota, Wisconsin, and Nova Scotia. The mills have a total annual production capacity of about 4.4 million tons of paper, mainly coated paper, but including a million tons of uncoated paper and about 200,000 tons of specialty paper. Visit www.newpagecorp.com for more.

Publication Design: Rochester Institute of Technology; Production Quality: Rochester Institute of Technology; and Conference Attendees’ Choice: Clemson University.

GAA Advanced Pressroom Seminar Set for September The Gravure Association of America’s new and expanded Advanced Pressroom Technology Seminar will be held September 14-17 at Western Michigan University, Kalamazoo, MI. Program topics range from advanced color theory, proofing, and color management to sustainability, how fingerprinting can improve your process, test cylinder design and print evaluation, involving your suppliers, tracking performance with Six Sigma, and GAA’s online Press Operator Certification program. Register online at www. gaa.org; for more, call (201) 523-6042.

Passing Is Noted K. Walter Service Corporation, Inman, SC, announced the passing on July 26 of Siggy Graul, a longtime rotogravure consultant and engineer who was instrumental in the growth of the company in the late 1970s and early ’80s. He later started his own consultancy in the U.S. Bob Speiss of K. Walter Service, who recalls Graul as hardworking and gruff but warm-hearted, announced the creation of a blog, www. kwalter.com/blog1 dedicated to Graul, where friends and colleagues can post or read recollections. K. Walter Service, which specializes in cylinder processing equipment, is affiliated with Kaspar Walter GmbH & Co. KG of Krailling/ Munich, Germany.

September 2010

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Worldview

Abril Orders “Aurora” Press Abril Group, São Paulo, Brazil, plans to install a new two-meter-wide Cerutti publication press, the first to feature the manufacturer’s new “Aurora” performance concept, by early next year in its plant in São Paulo. It will be the group’s fifth Cerutti press. The company’s Editora Abril business, which leads in 21 of 25 segments in which it is active, annually publishes more than 370 titles, with total circulation approaching 200 million copies. Its Veja title is the world’s third-largest weekly information magazine and the largest outside the U.S. Cerutti describes its midsize Aurora press for magazines and catalogs, available in six web widths from 78″ to 121″,

Management Changes at Arvato On August 1, Mauro Cosani was to rise from managing director of Eurogravure in Treviglio, Italy, to chief operating officer of Arvato Print Iberica and Printer Indústria Gráfica. He is to report to Santos Alvarez, chief executive of Arvato Print Iberica, who was also to become CEO of Printer Indústria Gráfica. Dr. Oliver Kranert continues as CEO of Arvato Print Italy and Eurogravure, where he takes on Cosani’s duties. 8

as typically extremely efficient (21% increase in net production speed), requiring 25% less manning, featuring 33% less waste at startup, and enabling job changeover in one hour. The press requires less power and steam, uses up to 33% fewer cylinder revolutions at start-up, and is described as versatile, compact, self-diagnostic, format variable, and extremely swift, up to 60,000 revolutions per hour in production.

Equipped with a folder, the Aurora press has any-size format range from 144×150mm up to 250×400mm, and allows stitched-in-line products of 28 to 132 pages. The press, equipped with a former folder cutter, allows four to 24 stitched-in-line pages, at output rates exceeding 168,000 copies per hour. Cerutti is also active in packaging printing. To unveil its advances in this sector, the company will host an eight-day open house at its research and development facility in Vercelli, Italy in late October and early November.

Big Proofing Deal The world’s biggest producer of gravure cylinders, the Yuncheng Plate Making Group of China, signed a strategic partnership recently with color management solutions provider GMG GmbH & Co. KG of Germany. In the agreement, Yuncheng will migrate 300 of its existing digital proofing systems to GMG’s ColorProof solution. Yuncheng will also adopt GMG ProofControl as a quality control process to monitor digital proofs from all its manufacturing facilities. Yuncheng consists of 83 companies, 54 in China and 29 in 14 other countries; its 500 gravure engravers can pro-

Gravure Magazine • September 2010

duce more than three million cylinders a year. The group accounts for three-fourths of the Chinese gravure prepress market, plus it exports to customers elsewhere. “For years GMG has been the de facto standard for Europe’s extensive gravure printing industry,” says Paul Willems, chief executive of GMG. “This close collaboration with Yuncheng will have a big impact on the Chinese and Asian markets.” Since its founding in 1984, GMG has sold more than 10,000 systems to ad agencies, prepress houses, and printers. In the U.S., GMG is based in Hingham, MA.

Color Standard for Packaging Gravure A workshop on understanding and using the European Rotogravure Association’s PaC.Space color standard for packaging gravure took place in late June at the GMG Academy in Tübingen, Germany. Participants from Germany and Austria obtained details of the free-of-charge downloadable PaC:Space Color Management Set, how to install the ICC profile into Photoshop CS, and how to use the set in a production workflow. ERA may offer a workshop in English, depending on demand.

Cylinder Capabilities Inseco Metalltechnik, a partner company of Helio Service Ahaus in Germany for cylinder base manufacture, has invested in new equipment for cylinder manufacture, plating, and surface finishing. Manufacture, diameter modifications, and repairs are available for cylinders of up to 6 meters in total length and 1.2 meters in diameter.


Sagawa Printing Marks 40th Year More than 400 people attended a ceremony marking the 40th anniversary of Sagawa Printing, held in its home city of Kyoto, Japan on July 6, including the governor, the mayor, and the former president of Sony Corporation, along with many company employees and key suppliers. Muneaki Kinoshita, chairman of Sagawa Printing, welcomed the visitors and described the development of the company, which today is one of Japan’s most consolidated media groups. He underlined Sagawa’s breadth as a publication printing house serving diverse market seg-

ments, from catalogs and business forms to labels and supermarket advertisements. On hand to help celebrate were representatives of Italian press manufacturer Cerutti, which had its first contact with Sagawa at the international Drupa exposition held in Germany in 1995. Sagawa commenced production on its first Cerutti gravure press in the Hino plant in November 1996, which was followed by a second machine in 1997 and a third in 2001. Anniversary festivities concluded with local artists performing in traditional kimono dress.

New Product News Align Rollers with Nip-Pressure Film Pressurex®, offered by Sensor Products Inc., is a pressure-indicating sensor film that instantly reveals pressure magnitude and distribution between two contacting rollers. When Pressurex is placed in the nip, applying force causes the film to instantly change color proportional to the actual pressure applied (conceptually similar to interpreting litmus paper). The precise pressure magnitude (PSI or kg/cm2) is then easily determined by comparing color variation results to a supplied color correlation chart (again similar to interpreting lit-

mus paper). The nip impression film reveals pressure-mapping impressions of patterned, grooved, and smooth rollers. Variations in nip pressure can be corrected quickly. Since the sensor film is used while the nip is engaged, it requires no equipment downtime, unlike use of conventional dyes or carbon paper. The film, specified by the foot or the roll, is available in seven pressure ranges and can measure contact surface pressures up to 43,000 psi. Visit www.sensorprod.com/ sample or e-mail info@sensorprod.com.

Packaging Award

ERA secretary general James Siever (left) presents the ERA Packaging Gravure Award for 2009 to Stephen F. Young of Mundet, Inc., Richmond, VA, during the Gravure Association of America’s Leadership Summit held in April. The award is for the Bush’s Best Grillin’ Beans ‘Steakhouse Recipe’ label produced by Mundet Tennessee Inc., which won “Best of the Best” honors in GAA’s 2008 Golden Cylinder Awards program. Young was unable to attend the ERA awards ceremony, held in October 2009 in St. Petersburg, Russia, where the label also won ERA’s award for best entry from a newcomer.

ERA Annual Meeting The European Rotogravure Association will hold its annual meeting, titled “Print’s Future in the Media Mix,” on Tuesday, September 28 at the Swisshôtel in Zurich-Orelikon, Switzerland. A dozen presenters will speak on publication gravure, paper, advertising, stability of the euro, the mail order industry, press technology, the future

September 2010

of magazines, and sustainability. On September 27, an associate members’ annual meeting, ERA management meeting, European Publication Gravure Award Ceremony, and conference welcome reception are to take place. Visit www.era.eu.org for details and registration information.

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Worldview

Milestone Event Draws An International Crowd

The SL 850 laminator applied two clear 20-micron BOPP films with solventless adhesive at a speed of 600 m/min.

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About 250 converting professionals from 34 nations attended Rotomec’s 50th anniversary celebration in late May to witness the world introduction of the RS 4003 MP multipurpose gravure press. Described as compact and cost-effective yet productive and versatile, the system is designed for medium to longrun production of high-quality printed flexible materials and applications, which can range from wallcoverings to security printing. The event took place at Rotomec’s technology center in San Giorgio Monferrato, Italy. Also demonstrated was a minimized-waste MW 80 medium-web press running an 800-mm-wide web in six colors on a 20-micron BOPP substrate, plus two web laminators, the solventless SL 850 and a multi-technology CL 850 system, each running in

Gravure Magazine • September 2010

Open-house attendees witness Rotomec’s new versatile RS 4003 MP press in operation.

duplex configuration. The RS 4003 MP press, demonstrated running a sixcolor job on a 12-micron PET substrate, accommodates a 20% shorter web length and

can be changed over rapidly and easily without tools for rapid work sequencing. For example, the press can be quickly reconfigured for solvent-based or solventless lamination or inregister cold-seal coating, in line with printing. The system, rated at up to 500 m/min production speed, features proprietary electronic shaft technology and total automatic preregister setting, as well as a new inking system and newly designed inking roller. Its other innovations include an automatic “Smart Sample” function for fast color matching (enabling up to 35% savings for each color sampling), “Smart Shaft” system (retrofittable to older machines), a quick-changeover trolley design, and color-coded touch panels on each printing unit. The MW 80 press, shown operational from floor level and run at its maximum production speed of 250 m/min, performed an automatic splice on the rewinder at full speed. The CL 850 laminator, which has more than 30 installations worldwide, was shown utilizing Rotomec’s flexo coating system for laminating a 6.35-micron aluminum substrate to a 12-micron PET film, which enables minimal coating weight of solventbased adhesive directly on the foil.


classified ad

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ICR IOANNOU S.A. Tel. +30 22620 32484 Fax. +30 22620 31874 email: sales@icr-ioannou.gr www.icr-ioannou.gr

Help Wanted We are looking for people to represent us in your vicinity to work for us from home. NO SIGN UP FEE. No working experience needed. You earn $3,000 monthly. Work from your computer. We will be sending you capital to start the job if you can’t afford it. You are qualified if you are 18 years or above. Interested, please send your resumes to revs.stephenimmanuel@gmail.com


Cover Feature

Quad/Graphics Acquires Worldcolor The largest acquisition involving two printing companies promises to offer more print and related multichannel solutions on a global scale.

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Quad/Graphics, whose common stock trades under the symbol QUAD, was recently highlighted at the New York Stock Exchange.

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arly in July, Quad/ Graphics, Inc. completed its planned acquisition of World Color Press Inc. (known commonly as Worldcolor), following approval by shareholders of both companies as well as final court approval. “This is a defining moment in our company’s history and for the future of our industry,” said Joel Quadracci, chairman, president, and chief executive of Quad/Graphics, which is based in Sussex, WI. “We believe in the power of print in a multichannel media world, and we now have more talent,

Gravure Magazine • September 2010

technology, and solutions in more places to better serve our clients well into the future. “Our new leadership includes the best and the brightest from both companies, building a unique team of innovative people who will redefine print for the benefit of all our stakeholders.” The “new” Quad, as he describes it, offers three main benefits: a broader variety of product types and revenue-generating solutions; an enhanced manufacturing platform that makes available Quad/Graphics’ industry-leading technology and automation to the combined platform; and an expanded geographic footprint and customer service presence. In addition, he adds, the company will gain significant mailing and distribution efficiencies, and offer clients improved speed-to-market and product integrity for U.S. Postal Service-delivered products as well as volume-driven postage savings through programs such as co-mailing. Within two years, Quadracci notes, the company intends to generate some $225 million pretax net annualized

synergies.

Annual sales: $4.8 billion Based on pro forma unaudited revenues of both companies for the 12 months ending March 31, 2010, the newly expanded Quad/Graphics has sales of $4.8 billion. It has approximately 28,000 employees working in more than 80 facilities in North America, Latin America, and Europe. Quad/Graphics is now the second-largest provider of print and related multichannel solutions in the Americas, behind RR Donnelley, which posted overall sales of $9.8 billion in 2009. On the day of the announcement, Quadracci described the new company as “off to a running start in our quest to redefine print and transform the printing industry.” He added, “We have a comprehensive plan designed to smoothly integrate the two companies’ operations while ensuring that our customers continue to receive top-quality, on-time services. We are keenly focused on achieving the synergies that make this


transaction so compelling for our shareholders. “However, our plans don’t stop there. We expect to advance all aspects of our business through technology and innovation.”

Five months of planning Noted Mark Angelson, former chairman and CEO of Worldcolor, who joined the new company as a member of the board of directors, Quad/ Graphics had five months to plan the integration, and, he said, is better prepared than any management team with which he’s been associated over the years. Angelson said, “Harry Quadracci [Joel’s father, who founded Quad/Graphics in 1971] would be beaming with pride, as I am, at having passed the torch of leadership to such a remarkable group. They bring to this acquisition a seamless will to win, the best technology, and the clearest strategic vision that I have seen. “With Joel Quadracci at the helm, surrounded by the best of the best from these two great companies, Quad/ Graphics should go from strength to strength, and all of our constituent groups will benefit.” Quad goes public To complete its acquisition of Worldcolor, Quad/Graphics, which earned notoriety for being privately held, became a publicly traded company on May 27. Starting July 6, its class A common stock has been listed on the New York

Stock Exchange under the symbol QUAD. The Quadracci family continues to hold a large majority of the stock and therefore voting control of the company. On July 7, Joel Quadracci, family members, and Quad/ Graphics leaders convened in New York City to join in ringing the Stock Exchange’s opening bell.

The company rang the stock exchange opening bell on July 7.

The business rationale Quad acquired Worldcolor to blunt the effects of excess manufacturing capacity throughout the printing industry that was created by shrinkage caused by the global economic recession, explains Quadracci. He adds, “Quad/Graphics believes its success has been fueled by its efficient and modern manufacturing platform, its distribution capabilities, its commitment to ongoing innovation and rapid adoption of technology, its intense customer service focus, its distinct corporate culture, and the continuity in its ownership and management. “Through the acquisition, [we] intend to realize increased manufacturing and distribution efficiencies, a greater geographic reach, and a much broader product and service offering. [We have] invested heavily in new technologies that deliver targeted and customized print solutions to in-

tegrate [our] products within multichannel campaigns.” Worldcolor’s employees— talented professionals—performed well in challenging and turbulent times, Quadracci continues, which is why Quad is glad they are strengthening

its industry-leading team. “In short,” Quadracci notes, “our company will be better positioned to win in the vibrant, competitive printing industry, and, correspondingly, better positioned to help our clients succeed.”

Quad Trims Plants On August 5, Quad/Graphics announced that it will close five manufacturing plants by the end of 2010: Clarksville and Dyersburg, TN; Corinth, MS; Lebanon, OH; and Reno, NV. Before its acquisition by Quad, Worldcolor had announced plans to close the Dyersburg operation early next year. The five plants encompass nearly 2.7 million square feet and employ about 2,200 persons. Most equipment will be shut down and scrapped, permanently removing excess capacity; affected employees will be offered assistance in finding new jobs or transferring to other locations with available positions. “This is a major step in integrating operations [with Worldcolor] and creating the most efficient and modern manufacturing platform in the industry,” said Joel Quadracci, head of Quad/Graphics, who noted the stated target of generating some $225 million pretax net annualized synergies within 24 months. He emphasized that no plant is closing because of employee performance or client service issues.

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Obituary

Requiem for an Expert The Gravure Association of America—and the industry at large—bids farewell to a technical specialist.

B Outsize personality with character to spare: Bruce G. Beyer, 1955-2010.

ruce G. Beyer, who had served the Gravure Association of America as technical director since January 2006, died of cancer on April 29 at age 54, leaving his wife, his mother, a daughter, three sons, and six grandchildren. For GAA he regularly conducted Basic and Advanced Gravure Seminars, formally certified Gravure Press Operators in the first such nationally recognized program, reviewed in-depth articles for publication, and oversaw preparation of the association’s technical manuals. As the industry’s goto technical expert, Bruce also fielded members’ technical questions and visited plants on troubleshooting missions.

Crucial role for GAA GAA seminars—intensive five-day, small-class sessions held at Western Michigan University in Kalamazoo—are designed to advance the technical knowledge and on-thejob skills of new and veteran gravure industry employees.

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Doing so is crucial for GAA, as he once explained: “Gravure is a robust printing process that over the years has been subject to more than its share of what we might politely call ‘folklore’ solutions. However, the present-day challenges of the process and today’s customer demands make it crucial that we formalize how the gravure process is best practiced.”

Value to students Of the benefits of GAA’s Basic and Advanced Gravure Seminars, he said, “We think the best value we can impart to students is to separate out the ‘myths and legends’ and focus on actual working theory and field-proven best practices of the process.” Bruce’s vast technical knowledge made him the logical choice to emcee GAA’s annual Golden Cylinder Awards presentations. Those who attended the gala in the fall of 2008 no doubt still remember Bruce. Big and boisterous anyway, he really didn’t need to top off his black-tie tuxedo—but he did so, with a huge black Stetson

that didn’t come off for the entire evening. He dominated the head table, with wife Sheila glittering as his perfect foil for the evening, as he awaited his turn at the mike to announce three dozen of the industry’s “bestof-the-best” winning entries. That evening, it was clear he was proud of being Texan and no doubt thrilled that, as a college football team captain and defensive end in black tie, he had just learned of his induction into the school’s Athletic Hall of Fame. And here he was, he might well have been thinking that evening, all dressed up in formal wear and granted the special privilege of announcing the winners of a major international competition. Surely not lost on him that night was his own role in the occasion of an industry celebrating gravure as a preferred print process for publications, packaging, and decorative products—with no myths, legends, or folklore solutions anywhere in sight.


Leadership

is action, not position. – Donald H. McGannon

We extend our congratulations to the GAA Persons of the Year: Kim L. Feil Walgreens

Charles L. Sullivan Jr. Sonoco

Innovative People Redefining Print www.QG.com


Conference Report

Leaders Attend Summit At GAA’s annual industry event, the focus was on the crucial aspects of sustainability.

T Robert G. Whitton, accompanied by fellow co-chair Dr. Jacquelyn McNutt, asks conference attendees to fill out critique form.

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oday’s worldwide emphasis on pursuing environmental and business sustainability was evident in many speakers’ presentations and informal delegate discussions taking place at the GAA Leadership Summit, convened in April in Parsippany, NJ by the Gravure Association of America. As in the past, the conference featured a big emphasis on education via the attendance of graphic arts college students and their instructors, plus presentation by GAA and the Gravure Education Foundation of two Person of the Year Awards. In addition, seven individuals were inducted into the

Gravure Magazine • September 2 010

By Roger Ynostroza, Editor

Gravure Cylinder Society. A highlight of the annual summit was presentation at a black-tie gala of the gravure industry’s prestigious Golden Cylinder Awards across all three major print categories (see page 28).

Sustainability goal The conference’s first keynote speaker, George Weyerhaeuser Jr., noted the importance of the highest goal of sustainability: “My grandfather and his 16 partners liked to say that when they established what was to become a big and very successful forest products company, they did it for their grandchildren.” Later, conference co-chair Dr. Jacquelyn McNutt of the Center for Paper Business and Industry Studies said she foresees unprecedented pressures on fiber resources for new products, many of those demands coming from new users. Both water and land resources are certain to become crucial in usage battles in coming years, she adds, noting the global emphasis on food, fiber, and fuel. McNutt also observed, “Our national energy security is equally important: would we

now be in Iraq or Afghanistan or defending Kuwait without this in mind?”

Misuse of fiber? She also said, “Studies reveal serious problems in fiber usage: of all trees cut each year for purpose, 45% are used to make wood and paper products, and almost all of these trees are replanted. By contrast, 55% of cut trees are burned openly as fuel—but this provides only 20% efficiency, plus almost none of these trees are replanted.” Tom Rosser of Natural Resources Canada stated, “Growing public preoccupation with climate change gives the forest sector the opportunity to rebrand itself and its products.” Later, conference co-chair Robert G. Whitton (Arellton Group, LLC) moderated a session on the state of the gravure industry. Worldwide recession As Europe continues to be plagued by the effects of the worldwide recession, reported James Siever, head of the European Rotogravure Association, printers and print product usages continue to struggle. Cata-


WE’RE KICKING UP OUR HEELS RR Donnelley congratulates Kim Feil, VP and Chief Marketing Officer, Walgreens Company, and Charles Sullivan, EVP, Global Consumer Products, Sonoco, for being honored by the GAA with their Gravure Person of the Year Award. We’re happy to celebrate this achievement with you! 800.742.4455

www.rrdonnelley.com

Copyright K 2010 R. R. Donnelley & Sons Company. All rights reserved.


Conference Report

log frequencies and volumes are way down, he adds, and magazine advertising and readership levels are slumping. “Bauer had to close its huge printing plant in Cologne,” he said, “although it opened a new facility in Poland.” Within five years, Siever speculated, the number of leading gravure publication companies will fall by half, to less than 10, although gravure packaging operations are growing. In giant retailer Walmart’s aggressive corporate sustainability vision, said executive Chet Rutledge, the company intends to be supplied 100% by renewable energy, to drive waste to zero, and by 2013 to reduce by 5% its use of packaging across all brands. Rutledge is director of packaging food and consumables in Walmart’s Global Merchandising Center.

Packaging Scorecard “To guide customers’ decisionmaking at the shelf,” said Rutledge, “we need to clearly communicate our goals and accomplishments. Our Sustainability Product Index Initiative, launched in 2009, is one example of doing this, as is our well-known Packaging Scorecard, which already involves 250,000 individual items.” A few weeks before the Leadership Summit, Rutledge said, Walmart conducted its fifth annual Sustainable Packaging Expo in Rogers, AR, which drew 2,000 attendees and 170 exhibitors. Executive VP Michael J. Potts of Orion Energy Sys18

tems reported that world energy demand is expected to grow by 35% in the next 20 years as developing nations modernize and expand their economic output. “This demand creates a nearly impossible situation for Americans, who want and expect access to low-cost energy at any time in any place,” he said. Orion’s solutions include a lightpipe extending through a factory roof that provides

process cooling and energy load shifting. RR Donnelley, Quad/Graphics, The Milwaukee Journal, and a number of smaller printers are already using the technology. With challenges affecting traditional markets, the conference session on printed electronics drew attendee interest. Session moderator Dr. Bill Ray of NthDegree Technologies Worldwide commented, “I’m really excited

that I’ve lived long enough to see a CPU printable on a substrate as the components assemble themselves. [In this development area] print is in an excellent position to serve as an imaging medium combining the conductor and substrate.” Developers are pursuing various avenues, including animated advertising “neons” and addressable displays in larger formats.

Person of the Year Awards As previously announced, Kimberly L. Feil and Charles L. Sullivan Jr. were each presented a GAA/GEF Person of the Year Award during a special luncheon event at the Leadership Summit. Feil is VP and chief marketing officer of Walgreens Company, and Sullivan until recently was executive VP of Sonoco Products Company. In accepting her award, Feil said she was “humbled” but added that she has long been a proponent of print. “We at Walgreens produce many billions of inserts for newspapers and magazines every year so no one can tell us that print is dead,” she said. “Print continues to offer consumers a lot of advantages they simply can’t get by any other means.” “And,” Feil added, “print continues to improve. When our print supplier RR Donnelley took over premedia work from our in-house department, they shortened our production cycle by two months. I’m just thrilled that we rely so heavily on print.” Sullivan, who retired in March after 40 years with Sonoco, was introduced by Sonoco’s chairman, president, and CEO, Harris E. DeLoach Jr. Noted DeLoach, “In his 10 years as leader of our consumer business, Charles completely flipped our balance, from a 58% focus on industrial packaging to a 58% fo-

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cus on consumer packaging, which not unimportantly was accompanied by an 80% increase in sales and a 90% gain in profits.” In his comments, Sullivan pointed out gravure’s key attributes in serving Sonoco’s consumer packaging segment: accuracy, print clarity, and superior color in long print runs. “But,” he added, “gravure can also print tactile inks that can emulate an orange peel for a juice carton, special inks for flexible displays, or now new conductive inks for smart packaging—the next generation.” GAA and GEF present the awards every two years to individuals in the publication category and in the packaging/product category.

GAA/GEF Person of the Year awardees (at center), Charles L. Sullivan Jr. and Kimberly L. Feil of Walgreens, are flanked by their award presenters (left) Harris E. DeLoach Jr. of Sonoco and RR Donnelley’s Gary Cole.


Advancing printed electronics The Center for Advancement of Printed Electronics, located at Western Michigan University, has begun exploring printing of functional inks on an AccuPress gravure system provided by Daetwyler R&D Corporation, reported Dr. Margaret Joyce, director. Twelve faculty researchers and their students are testing the conductive characteristics of a variety of special inks, which contain carbon, silver, graphene, and bio-sensors. Meanwhile, at Swansea University in Wales, researchers in the Welsh Center for Printing & Coating

International presence at GAA Leadership Summit: from left, James Siever, ERA; Kurt Oegerli and Ralph Daetwyler, Max Daetwyler Corporation; and Erik Ohls, UPM.

are testing wide-area OLED lighting for smart packaging,

security, RFID, and sensing applications. Reported Dr.

Tim C. Claypole, “Printed polymer electronics could develop into a major disruptive technology. Even graphic printers might be able to add value to products by integrating electronics. But we need to conduct a lot more research into these complex technologies.” Concluded session moderator Dr. Ray, “Everyone is striving to integrate conductivity into products, and the fact is that this can’t be done inexpensively enough unless we use printing. So I’m convinced that the printing industry is on the verge of tremendous innovation and spectacular achievement.”

Congratulations Charles Sullivan On winning the GAA 2010 Person of the Year Award From your friends at APC! American Packaging Corporation 777 Driving Park Avenue Rochester, NY 14613 www.ampkcorp.com

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Conference Report

Benefits to Education To replenish its scholarship fund to benefit students studying the graphic arts, the Gravure Education Foundation held a live auction event during the Leadership Summit and also hosted the GAA/GEF Person of the Year Awards program (see coverage on page 18). Returning this year to conduct the live auction was Clarence (“Butch”) Hoover, vice president of SGS International, Louisville, KY. Items available for bidding included a set of four electronic engraved cylinders, a set of four laser-engraved cylinders, Florida hotel accommodations, a kaleidoscope, rare gravure prints, gift baskets, and other prizes. “Thanks to donors’ generosity in providing auction items and attendees’ spirited bidding during the auction, we raised more than

To open bidding, auctioneer “Butch” Hoover offers a gravure handbook, provided by GAA.

$32,000,” said Hoover. “This funding will benefit graphic arts students in their studies at GAA partner colleges and universities involving rotogravure.” Added Bernadette Carlson, GEF executive director, “Business conditions are still tough out there but people stepped up in the name of education to help provide a future for our industry.”

Thirteen university students, representing five schools, attended GAA’s Leadership Summit in Parsippany, NJ.

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Ralph Daetwyler displays his purchase: a special gravure print on an aluminum base.

She said in 31 years of fundraising, the industry has contributed $3.5 million, enabling GEF thus far to award 530 scholarships to students at nine universities. At the 2010 Leadership Summit, she noted from the podium, “By their grades and achievements, attending students earned their places at this conference. And as a sign of their commitment, several are having to study tonight for their final exams tomorrow…”

Michael Green (Flint Ink VP and general manager of its publication inks division) presides at GEF Educators Breakfast one morning.

Attending the GEF Educators Breakfast, sponsored by Cerutti: from left, James K. Tenorio, University of Wisconsin-Stout; Margaret Joyce and Alexandra Pekarovicova, Western Michigan University; Nancy Cullins, Cal Poly; Thomas E. Schildgen, Arizona State; and Samuel T. Ingram, Clemson.


Congratulations Kim! NSA Media, Wahlstrom, and Geomentum congratulate Kim Feil, Chief Marketing Officer, Walgreens Company, on being recognized as "Person of the Year" by the Gravure Association of America.

NSA Media


Headline Induction Ceremony

Society Honors Seven

Individuals are recognized for rendering outstanding contributions to the gravure industry and its association.

D

uring the GAA Leadership Summit in April, seven individuals were inducted into the Gravure Cylinder Society, an honorary organization recognizing individuals who render outstanding contributions to the industry and the association. The organization was founded in 1981 by two GAA predecessor organizations, the Gravure Technical Association and the Gravure Research Institute. The society is chaired by Hubert Metzger, head of Chema Technology, Inc. Conducting the induction ceremony was vice chair Liz Scherer, director of publication gravure technology for ink and pigment manufacturer Sun Chemical. Dave Byrnes (not pictured in induction ceremony) is senior purchasing manager for Accenture, New York City, a global management consulting, technology services, and outsourcing company. He has specialized in graphics, quality management, purchasing, and print production management for more than 30 years, starting at Time, Inc., then moving to L.L. Bean, where he was responsible for the purchasing of

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gravure printing. Bernadette Carlson, executive director of the Gravure Education Foundation, has long been active in the printing and publishing of catalogs and the retail market, including as director of print advertising for Sears, Roebuck and Co., responsible for all Sears retail paper, print, and transportation. As president of a newspaper outsource paper and print management business, she managed nearly $500 million in purchases. She joined GEF in early 2008. Steve Heffler began his career at Alco Gravure in Glen Burnie, MD, then moved to plants in Providence, RI; Memphis, TN; and Fernley, NV, before returning to Tennessee, where he is now vice president and general manager of Worldcolor, Dickson, TN. While working for the same company, he served Alco, Maxwell, Quebecor, Quebecor World, and Worldcolor. A GAA supporter, he has hosted technical conferences and opened plants for pressroom tours. Michael Osesek, executive vice president of Worldcolor, Franklin, KY, grew up in a printing family, with several uncles employed at Cuneo and Berlin Press in Chicago. Fol-

lowing a training program at RR Donnelley, he worked his way up to division director and head of manufacturing for the Gallatin, TN plant. In 2000, after 27 years with Donnelley, he joined Quebecor as senior vice president of gravure catalog operations. He is now responsible for eight gravure plants, as well as group quality. James Siever, appointed secretary general of the European Rotogravure Association, Munich, in 2000, began serving the printing industry in Germany 25 years ago, as an association corporate attorney. Later he served associations in Germany for manufacturers of aluminum and of drink cartons, then joined TetraPak Deutschland. He regularly attends GAA functions to keep the group informed on gravure activities worldwide, while promoting the process. Hans Wegner, vice president of production services for the National Geographic Society, is responsible for the manufacture, quality control, and distribution of National Geographic magazine, which has an international reputation for the finest in gravure printing. The Society is one of the world’s largest nonprofit educational and scientific organizations. Wegn-


er’s newest passion is the Society’s Green Initiative, intended to reduce overall carbon impact and “green” its operations. Robert W. Zumbiel is president of C.W. Zumbiel Co., Cincinnati, a family-owned company started in 1876 as a sheetfed letterpress house that is today one of the nation’s largest privately owned and operated paperboard packaging companies. After earning an MBA from the University of Cincinnati, he worked his way through the ranks and was elected president in 1974. The company installed its first gravure press, a six-color 36″ Champlain, in 1955.

Vice chair Liz Scherer, top left, inducted six members into the GAA Cylinder Society for 2010. From left: Hans Wegner, Steve Heffler, Bernadette Carlson, James Siever, Michael Osesek, and Robert W. Zumbiel. Inducted but not pictured: Dave Byrnes of Accenture. The coonskin caps? A gag reference to a well-known segment depicting an honorary society in “The Honeymooners” TV program.

Sullivan ad_outl.indd 1

8/4/10 1:20 PM

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Environmental Update

Studying Sustainability GAA’s annual workshop focuses on biomass value, water scarcity, “print is bad” attitudes, and seven “greenwashing” sins.

T

Bernadette Carlson, executive director of the Gravure Education Foundation, accepts the conference’s carbon-neutral certificate from Barry W. Graden, manager of sustainable forestry for AbitibiBowater. AbiBow donated carbon credits accumulated through its energy-saving initiatives to offset the event’s greenhouse gas emissions, which are mainly generated by delegate travel, hotel stays, meals, and overall on-site energy consumption.

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he GAA Environmental Workshop conference, held in Milwaukee in mid-June, began with the unveiling of Canada’s “Future Bio-pathways Project” study, presented by Avrim Lazar, head of the Forest Products Association of Canada (FPAC). The project is intended to show how Canada’s forest products industry can emerge from the current recession as an engine of growth in the emerging bioeconomy. It was conducted by FPAC and FPInnovations and involved more than 65 top Canadian experts in fields as diverse as biotechnology, investment banking,

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and carbon pricing. “This study focuses on the triple bottom line: clean energy, high employment, and economic recovery,” said Lazar. “It places traditional products, especially lumber and pulp, at the heart of a new green business model that can make the forest products industry a pivotal force in Canada’s effort to become a clean energy superpower. “If we follow this new model, we’ll be able to produce power on the scale of nine nuclear reactors, enough to meet the energy needs of 2.5 million homes, or one out of every five homes across Canada.” In Canada, the forests and forest products are considered owned by the people. Lazar says research shows that an integrated mill, one that produces wood, pulp, or paper as well as bioenergy and biomaterials, provides five times as many jobs as a standalone biooperation. It also shows that the industry’s 270,000 jobs will be best sustained by following this integrated road to recovery. Biomass, it is noted, is both renewable and carbon-neutral after burning or use, when trees are replanted. Pierre Lapointe, chief of

FPInnovations, has been quoted as saying, “Years of intensive R&D have shown how we can now rapidly convert wood fibre into a wide variety of highvalue products, such as biofuels to heat homes or power vehicles, as well as biochemicals to make cosmetics, solvents, food additives, and renewable plastics.” Concludes Lazar, “Our current economic situation requires that we no longer can just get better at what we do. We have to alter what we do, to change the business model itself.”

Differences in the U.S. Speaker Paul E. Pingrey, who retired in December from the Wisconsin Department of Natural Resources after 35 years, described a much different situation in the U.S. Here, while there’s much forestland—half of Wisconsin is forested—most of it is owned privately, by about 10 million parties. To encourage forest certification in the U.S., Pingrey helped develop the Managed Forest Law Group. Rick Kuester, an executive with Wisconsin Energy Corporation and head of WEGeneration, pointed out that,


The town of Myllykoski, nestling on the banks of the River Kymi, was where Finnish paper manufacturer MYLLYKOSKI first began back in 1892. Now part of an international group and responsible for issues pertaining to the local environment and nature, Myllykoski mill currently boasts high levels performance and competence. Today the Myllykoski Group, together with alliance partner Rhein Papier, has nine paper mills. Each year, approximately 2.8 million tonnes of paper leave the factory gates and are distributed to 50 countries.


Environmental Update

compared to unreliable wind or solar energy, energy from biomass—the woody residue from forest products production—has far higher promise and potential. WE-Generation, he adds, plans construction of a 50-megawatt brownfield biomass project. Meantime, in many regions UPM The Biofore Company is creating fuel from consumer waste and woody residue—sometimes called “ur-

ban wood”—reports Andrew Heald, the company’s Scotland-based head of assurance.

Water: not everywhere Publication printing giant Quad/Graphics considers water to be often overlooked as an endangered supply item, says Joe Muehlbach, director of facilities and environmental policy. But through diligence and close measurement, he says, Quad has increased its pages produced per gallon

Visits to Printer & Mill Environmental Workshop registrants participating in a post-conference field trip visited the Quad/Graphics plant in Lomira, WI, with 2.2 million square feet the largest print-production facility in the Western Hemisphere. The plant operates a dozen gravure presses and many web offset and bindery lines. For its staff of 1,200 associates, the facility features a fitness center, a fullservice primary clinic, dental and optical clinics, a pharmacy, and a day-care center.

Twelve gravure presses operate in the Quad/Graphics publication plant in Lomira, WI, site of a postconference field trip.

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of water from 1,249 in 2000 to 2,919 in 2009, an improvement of 134%. The company, he adds, is also striving to become landfill-free. Speaker Don Carli of the Institute for Sustainable Communication decries the misguided—sometimes intentional—guilt about forest destruction caused by the use of paper. “Everyone is being led to believe that digital information technology and electronic media are either resource-free or

A second tour featured a visit to NewPage Corporation’s Biron Operation, a mill near Wisconsin Rapids begun in 1873 as a sawmill. The plant is now equipped with two paper machines capable of producing 400,000 tons per year of medium and lightweight coated papers used primarily for magazines and catalogs. NewPage is the largest coated paper manufacturer in North America, based on production capacity, with $3.1 billion in net sales last year.

GAA tour visitors at NewPage’s Biron Operation included client representatives and paper buyers representing OfficeMax, Target Corporation, McGraw-Hill, and other companies, shown here with host personnel. The giant stone cylinders mounted in iron frames, used to process pulp, date from the 1800s.

minimally impactful,” he says. “The little-mentioned fact is that U.S. servers and data centers consume about 59 billion kilowatt hours per year, which is an enormous drain on natural resources.” Diligent lifecycle analysis, along with eco-labeling, says Carli, is the best defense against erroneous allegations regarding print media.

Seven sins Scot Case of TerraChoice Environmental Marketing noted the “Seven Sins of Greenwashing,” i.e., labeling ploys used by consumer goods suppliers to capitalize on buyers’ willingness to choose products that appear to have “green” benefits. The labeling sins include: —fibbing (misleading consumers); —no proof (“Just trust us”); —irrelevance (factually correct but not relevant); —the hidden tradeoff (focusing on one or two environmental facts while ignoring significantly more important environmental concerns); —vagueness (broad, poorly defined environmental claims: “100% natural”); —lesser of two evils (for example, organic cigarettes, which may be environmentally preferable but are still an inappropriate choice); and —worshipping false labels (suggests third-party endorsements). Barry Nelson, senior vice president of sales for NewPage Corporation, described the company’s Project Potico


(derived from the terms palm oil, timber, and carbon offsets), a joint initiative with the World Resources Institute. The goal of the Potico Project: to help protect and conserve virgin rainforests in Indonesia by creating opportunities for ecologically and fiscally sustainable palm oil production, an activity that is endangering certified forestlands.

EPAT update In an update session covering Version 2 of the Environmental Paper Assessment Tool, conference co-chairman David A. Schirmer, vice president and general manager of

GAA conference delegates enjoyed dinner and a private viewing of exhibits at the Milwaukee Art Museum, hosted by NewPage Corporation. The iconic Burke Brise Soleil attraction, whose Boeing 747-comparable “wings” are opened and closed twice daily, sits atop the Quadracci Pavilion, site of lakefront art festivals, attractions, and special museum events.

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media giant Hearst Corporation, joined other speakers in cautioning not to use EPAT as a “scorecard” but as a datadriven evaluation tool for improving paper usage on a sustainable basis. Top goals for Hearst and other publishers, he said, include reduced carbon emissions (via less energy use, plus use of renewable fuels), sustainable forestry (via thirdparty forest and chain-of-custody certification), clean manufacturing, and recovery and reuse of fiber. Schirmer and other publishers note that recycled fiber continues to be in short supply.

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2010 Golden Cylinder Awards

Champions Win the Gold Gravure-printed entries in three major categories, plus entries in a technical innovation segment, win top awards. By Roger Ynostroza, Editor

S

eventeen companies won 27 top awards in this year’s Golden Cylinder Awards program, an international competition launched by the Gravure Association of America in 1987. Big winners dominated the publication category, with RR Donnelley and Worldcolor each winning four prizes (interestingly, two of Worldcolor’s entries tied in the same category). Meanwhile, publication printer Quad/Graphics tied in one category while another of its entries not only won in one

Editor’s Note: The information presented here about GAA’s Golden Cylinder Awards, including process descriptions, is as provided by the submitting company and edited solely for clarity and conciseness. Entries were not submitted in all competition categories. Reprint CDs of individual pages are available; to order, contact Emily Dominguez of GAA at (201) 523-6042.

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category but was judged the best single piece in the competition and awarded overall Best of the Best recognition. Also, in a unique achievement, a printer from Ukraine— Ukrplastic—won two awards, one for printing in the flexible packaging/film category, the other in the technical innovation category for its image preparation expertise. The latter award is an accomplishment for Ukrplastic given that the category is usually dominated by suppliers. The coveted Golden Cylinder Awards were present-

ed to company representatives attending a black-tie gala in April. A total of 22 printing awards were bestowed: six in the packaging category, four in the product grouping, and a dozen in the publication segment. In addition, two printers and two suppliers earned top prizes for technical innovation.

“Best of the Best” An overall “Best of the Best” award went to Quad/Graphics, Inc. for its production of the December 2009 issue of National Geographic magazine.


Linda Allen-Hawkins of Altria and Bill Martin of GAA announce and present the awards.

“These annual awards are such a crucial part of the American gravure industry because they represent the true state-of-the-art of quality and production capability across all three major segments,” observes Bill Martin, head of GAA. “Plus, the program recognized significant technical achievements by four diverse companies.” He adds, “As they are every year, the judges were visibly challenged by the extremely high caliber of all the competition entries, but then they look for the unique challenges and subtle touches that set the true winners apart from the others. “My hat’s off to the judging team this year for selecting a field of winners we can all be proud of in the gravure industry.”

A range of achievement This year’s range of production achievement in the

competition is especially broad in terms of product scale, from paperboard packaging for a giant flat-screen TV and the dazzlingly colorful vinyl swimming pool liners to cigarette packs and small labels for hair products and bottled beer. Substrate range was equally extensive, from flexible and

rigid synthetic materials to newsprint, coated, and lightweight supercalendered papers for various types of long-run publications. Golden Cylinder Awards were presented one evening during GAA’s Leadership Summit, which took place in Parsippany, NJ. Sharing announcement and presentation duties were Linda AllenHawkins of Altria and GAA’s Bill Martin. (In a poignant moment at the microphone, Martin made mention of the loss in late April of Bruce G. Beyer, GAA technical director, who customarily announced Golden Cylinder Award winners at the gala and presented the prizes to recipients. See Beyer’s obituary in this issue, which appears on page 14.)

Competition judges Judging this year’s competition were the following: Trish Goffredo, Fres-Co System USA, Inc.; Bob Kikkert, Altria; Ken Kingston, Parade Publications, Inc.; Reba Meek, Mundet Inc.; Howard Nelson, Arizona State University; Aaron Satterfield, Quad/Imaging, Inc.; Ron Williamson, National Geographic Society; and Danny Yates, UPM. For a group photo of the judges, see page 16 of the April issue. Concludes Martin, “We had just finished this year’s competition when we started talking about the milestone event next year. For the 25th anniversary of the Golden Cylinder Awards, the industry should expect something really special.”

Dozens of GAA’s coveted Golden Cylinder Awards await final presentation.

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2010 Golden Cylinder Awards

Best of the Best Publication Coated (over 40#), Magazine

National Geographic, December 2009 Issue Submitted by: Quad/Graphics, Inc., Sussex, WI For its members, the National Geographic Society has built and enhanced a reputation for quality for 120 years. This expectation of perfection is uniquely fulfilled in the December 2009 issue of National Geographic magazine, which utilizes many of gravure’s capabilities to both excel and to blend with web offset. The gravure portion of the issue spanning pages 29-148 is printed on a 50-lb. coated #4 dual-purpose sheet, developed specifically to minimize noticeable differences between the processes. The story “Worlds Apart” on pages 78-93 uses gatefolds to illustrate the span of the galaxy, achieved by printing two signatures, each with a gate (one high-folio, the other low-folio), and binding them next to each other. Printing the signatures and marrying them up in the bindery with exact crossovers for the multiple-panel effect is a major achievement. Another achievement involved “The Hazda” story on pages 94-119, which included seven close-up portraits and required exact flesh tone reproduction from the gravure process. Client, Designer, Separator: National Geographic Society, Washington, DC Engraver, Printer: Quad/Graphics, Inc., Martinsburg, WV Press: Cerutti Substrate: Verso Paper, Jay, ME Ink: CR/T, Hartford, WI

Ron Williamson of National Geographic Society and Lisa Arias of Quad/Graphics accept Best of the Best award.

Copyright 2010 Harry Butler, for photos of the Golden Cylinder entries, and Copyright 2010 Greg Bashara/ HBP for awards photos.

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GAA’s Basic Gravure Seminar

Packaging Flexible Packaging, Film Item: Packaging for Coffee “Montego” Submitted by: Ukrplastic Key to this entry are the high-tech approaches applied at the prepress stage to show core features of the packed product and its filling, from processing of the photo images to manufacturing of the printed forms. For cylindermaking, Ukrplastic technicians utilized stochastic screening, a practice that is quite unique in the European market for rotogravure-printed packaging. Precise ink register in printing, made possible by the efforts of the prepress engineer, delivers intensity and contrast to the image, fulfilling the expectation of the designer. In sum, the high-quality printed package reflects the appearance of the packed product, thereby appealing to the widest buyer age profile. Printer: Ukrplastic, Kyiv, Ukraine Ukrplastic’s Alexandr M. Kozik (left), chief expert in printing and prepress, and Andriy Gora-Gorovskyy, cylinder production manager, accept award.

Packaging Labels/Wrappers, Film Item: Leinenkugel’s Oktoberfest Submitted by: Multi-Color Corporation Leinenkugel’s has once again created a picture-perfect scene for its consumers: a beautiful autumn scene with a variety of reds, yellows, and oranges complement its seasonal Oktoberfest beer. Slight vignettes along the edge of the label help create a feeling of the arriving season, and tight registration, particularly in the leaves, tent, and hat details, brings this scene to life. The combination of great graphics and superior printing won the prize. Printer: Multi-Color Corporation, Batavia, OH

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2010 Golden Cylinder Awards

Packaging Labels/Wrappers, Film Item: got2b Smooth Operator Lotion Submitted by: Multi-Color Corporation Cosmetics producer Henkel AG & Co. and the Schwarzkopf brand, which favor gravure because of its high-quality results on consumer products labels, had high requirements for color matching and for maintaining the light reproductions and tight registration on press. The combination of solids and vignettes required the most versatility of printing processes, says Multi-Color Corporation. The true achievement and success of this packaging product, the printer notes, is in keeping the central element solid and vibrant in appearance while capturing the same color tones in a soft and subtle manner in the background. Printer: Multi-Color Corporation, Batavia, OH

Packaging Labels/Wrappers, Paperboard

Item: Marlboro 100’s Blend #54 Submitted by: Trident Americas, Charlotte, NC In gravure printing of vignettes, a common phenomenon is the linking of cells that occurs where ink stops flooding over the cell walls and creates a hard line. But in this project, by varying the cell depth instead of the width, the conventional cell shape produced using Direct Laser Engraving leads to a near continuous-tone reproduction of the dark green, resulting in a smooth vignette that shows no linking and thus no hard lines. Combined with electronically engraved linework cylinders, this printed sample exceeded the customer’s expectations for this new product launch. Client: Phillip Morris USA Designer: Leo Burnett Company, Inc. Separator: Trident Americas, Chester, VA Engraver: Trident Americas, Charlotte, NC Printer: Shorewood Packaging, Newport News, VA Press: Rotomec, Bobst Group Substrate: MeadWestvaco, Covington, VA Ink: Sun Chemical, Colonial Heights, VA

Kenn Akers of Trident Americas, Chester, VA, accepts award.

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Packaging Paperboard

Item: VIZIO TV packaging Submitted by: Packaging Corporation of America The top-quality color-registration demands of this packaging project over its enormous size represented a huge challenge—and ultimately a tremendous quality and technical achievement—for gravure printing. The job required application of four fine-screen process colors and a special orange, plus a water-based coating. As the finished packaging size exceeded the limits of both the printer’s maximum cylinder circumference of 82″ and maximum web width of 55″, technicians had to separate the project into two pieces, two panels per piece, by using 58″-circumference cylinders. In prepress, the continuous-tone image files were fairly large, with minimal printer and detail enhancement applied to the background and image areas, while UCR was applied to shadow areas. The project required the engraving of 11 cylinders, each requiring from five to nine hours. The result: impeccable detail and color balance on multiple sheets comprising a large-format packaging project. Customer, Designer: VIZIO, Inc. Separator, Engraver, Printer: Packaging Corporation of America, Waco, TX Substrate: MeadWestvaco Ink: Sun Chemical

Joseph Pozek of Packaging Corporation of America accepts award.

Packaging Up to 26″ Web, on any substrate

Item: Spray-It Curly Submitted by: SleeveCo, Inc. The challenge of this entry is the balance between the model’s flesh tones and hair. Because the end-user views the image with a highly critical eye, the print quality was a significant key during the production. There was an emphasis on the highlights in the hair to emphasize the usage of the product, hence the necessary use of rotogravure-printed labels. Separator, Printer: SleeveCo., Inc., Dawsonville, GA Engraver: Alliance Graphics, Alpharetta, GA Press: W.R. Chestnut Engineering, Fairfield, NJ Substrate: Bonset, Brown Summit, NC Ink: Sun Inks, Atlanta, GA

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2010 Golden Cylinder Awards

Product Floor Coverings

Item: City Square Submitted by: Armstrong World Industries Through a unique combination of technical, print, and manufacturing achievements, the high-end City Square vinyl design appears as real as any stone or concrete blocks in a metropolitan setting. The combination of colors and high-end engraving provides detail in both depth and texture, making the design appealing to consumers as well as pleasant for any home. Astonishingly, City Square was manufactured with five spot colors on a 144″wide press. Designer: Linda Abrams, Armstrong Separator: Mark Zeamer, Armstrong Engraver: Standex Engraving Printer: Armstrong World Industries, Lancaster, PA Press: Kochsiek KOM261 Substrate: Armstrong Ink: Penn Color

Rod Sosa, technical design manager of Armstrong World Industries, accepts the Golden Cylinder Award in the Product— Floor Coverings category.

Product Postage Stamps & Security Printing Item: Edgar Allan Poe/Gary Cooper Stamps Submitted by: Avery Dennison, Specialty Printing Division These two postage stamps are both printed in 300- to 400-line screens in panes of 20, yet they clearly depict the marked evolution in portrait photography from the 18th century to the 19th century. Reproducing the flesh tones in Poe’s face and controlling overall color were significant challenges, yet Avery Dennison’s continually upgraded press still holds register tolerances below .006″. Superior register of the poet’s eyes and color consistency of the outer border area, requiring fine viscosity control, earned the printer praise from the art director and the U.S. Postal Service. For the Gary Cooper stamp issue, the detailing in the facial tones and the color/register control of Cooper’s blue eyes made the stamp a hit with the art director and Postal Service. The stamp, featuring the actor’s name in small reverse type and the USA 44, made precise register a must. Client: United States Postal Service Separator, Engraver: Trident Americas, Richmond, VA Printer: Avery Dennison, SPD, Clinton, SC Press: DaiNippon Kiko Substrate: Fasson Roll Division Ink: Siegwerk, Inman, SC

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Product Party Products

Item: iCarly Kids Plates Submitted by: American Greetings The assignment: to accurately reproduce a licensed color design for kids serveware products, which originally had been gravure-printed on 1.25-gauge polystyrene film using solvent-based inks. The challenge: with relocation of the press and its conversion to water-based inks, American Greetings engineers had to develop an ink system that would print on film with acceptable adhesion and transparency and, as the product is thermalformed, withstand laminating temperatures exceeding 400 degrees F. The outcome: colors matched original specifications featuring web star Carly Shay, and the product withstood high-temperature adhesion. Printer: American Greetings, Greeneville, TN Engraver: Image Print Technologies, Wilmington, NC Press: Hy Roto Ink: American Ink Technology, Pine Bluff, AR

Product Other, Gravure

Item: CGT Tower Collection, 2010 Submitted by: Canadian General-Tower Limited For its new line of premium vinyl liners for above-ground and inground swimming pools, printed on a variety of substrate colors and gauges, CGT maximized the versatility of four-color gravure to achieve both print quality and the market appeal of new, realistic, and creative printed surface designs. The company also created custom exclusive variants of specific designs. Despite heightened demand for new tile designs each year, CGT designers must be mindful that the designs match with one or more of CGT’s existing floor prints, and that the four spot colors incorporate the inks used in the floor artwork into the tile artwork, which requires critical color matching. A final challenge: achieving the realistic textures of each design requires tones as low as 10% in some areas. Printer: Canadian General-Tower Limited, Cambridge, ON

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2010 Golden Cylinder Awards

Publication Newsprint

Item: PARADE Magazine, October 26, 2008 issue Submitted by: Worldcolor Mt. Morris Printed by gravure 52 issues a year and distributed in more than 400 newspapers, PARADE is the largest weekly magazine by circulation in the U.S. The October 26, 2010 issue, which features specialized flexographic imprinting on the cover and a unique “Dutch” door in the center, exhibits the versatility of publication gravure: weekly multimillion-copy runs, quality color reproduction throughout the run, and production innovations that appeal to readers and advertisers. Once the publication completes all prepress production, it transmits data to Worldcolor via the printer’s data network for distribution to multiple print locations. In cylinder engraving, Worldcolor applies ICC color profiles to match paper and ink color reproduction to the customer’s in-house proofing systems. Client: PARADE Publications, New York City Printer: Worldcolor Mt. Morris, Mt. Morris, IL Press: Motter Substrate: Alberta Ink: GPI Sun Chemical

At left, David Miller of Worldcolor joins Tom Meisel of PARADE Publications in accepting award.

Publication Newsprint

Item: USA WEEKEND Magazine, September 28, 2008 issue Submitted by: Worldcolor Mt. Morris The U.S.’s second-largest weekly magazine by circulation is an example of the rich color and smooth gradation of tones that only gravure printing can achieve. It also makes use of on-press flexographic imprinting for eye-catching editorial content, as well as two advertising “Dutch” door features within the product. Publication staffs handle layout, design, and prepress production, then transmit electronic data via Worldcolor’s network to the printer’s multiple plant locations. In cylinder engraving, Worldcolor applies ICC color profiles to match paper and ink color reproduction to the customer’s in-house proofing systems. Client: USA TODAY/USA WEEKEND Magazine, McLean, VA Printer: Worldcolor Mt. Morris, Mt. Morris, IL Press: Motter Substrate: Alberta Ink: GPI Sun Chemical David Miller of Worldcolor and Deborah Stoken of USA WEEKEND accept award.

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Publication Supercalendered, Retail

Item: Target circular, December 20, 2009 Issue Submitted by: RR Donnelley Lancaster Achieve a “coated look” on a “super-cal” sheet? This was the challenge laid down by the Target organization. Naysayers say it’s impossible to make printing on super-cal paper look like a lightweight coated sheet. This circular scores with a delicate balance of putting just the right amount of ink on the sheet without putting on too much, which would plug the image and eliminate all shape and detail. It also uses exceptional gray balance by which an array of featured products are displayed in their best light while realistic flesh tones are maintained. The result—which looks both smooth and glossy—is a coated look on super-cal paper, achievable only by a strong customer/printer commitment and the gravure process. Engraver, Printer: RR Donnelley, Lancaster, PA Press: Cerutti Substrate: Madison Paper Ink: Flint Ink

Al Westbrook of RR DonnelleyLancaster poses with Golden Cylinder Award in the Publication— Supercalendered Retail category.

Publication Supercalendered, Catalog

Item: Sears Canada Christmas Wishbook 2008 Submitted by: Worldcolor Mt. Morris The 864 body pages of this catalog—most of which were printed on SC-A stock, with lightweight coated on select signatures adding punch to feature products—were framed by the diecut window of an Offset cover. The contents, printed in both English and French, showcased merchandise ranging from fashion and electronics to home products and tools. As it utilized five gravure presses and multiple paper stocks, Worldcolor called on its ICC conversion in the production flow to match SWOP #5 PDF files to the substrates for optimum print quality. The printer matched and monitored color using its awardwinning Quality database, tracked press-side measurements, maintained standards, and analyzed L*a*b gray patches to optimize the gravure process. Client: Sears Canada, Toronto, CA Printer: Worldcolor Mt. Morris, Mt. Morris, IL Presses: Motter, KBA Substrates: IP Verso, Myllykoski Ink: GPI Sun Chemical

David Miller of Worldcolor Mt. Morris and Enza Marella of Sears Canada accept award.

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2010 Golden Cylinder Awards

Publication Supercalendered, Magazine

Item: The New York Times T Style Magazine, Women’s Fashion, Fall 2008 Submitted by: RR Donnelley New York Bold use of rich and vibrant colors, excellent separation, fine contrast and detail, and photographic-quality reproductions printed page after page—all of this, Donnelley notes, appearing on nearly two million copies on lightweight supercalendered paper, remarkably produced as five print forms across three presses. In ads for high-end fashion and accessories that fill the first half of the magazine, says Donnelley, luxury advertisers sought and obtained smooth reproduction, shape, detail, vibrant color, and consistent quality via the gravure process. In the “Dream States” section of the magazine, gravure quality specially showcases a wet eyelid, a glistening black snake, a goldfish, eye shadows, and a colorful feather. Customer, Designer: The New York Times Separator, Engraver, Printer: RR Donnelley, Lancaster, PA Presses: Cerutti, KBA Substrate: UPM Ink: Flint Ink

Al Westbrook of RR Donnelley accepts award.

Publication Lightweight Coated (under 40#), Retail Item: Saturday Bonus Sale Submitted by: JCPenney Media L.P., Plano, TX Production of this job was called a “printer’s challenge” as it required tight tolerances to achieve high-quality reproduction of both rich background standards and flesh tones, which had to be balanced across a 60″-wide web in order to print smoothly. Client and printer specialists averted background compromises by addressing issues before files were completed in the premedia department. All partners worked together to achieve a successful result, says one participant, so as to not have to compromise the printed product on press.

Paul Jensen of JCPenney Media accepts award.

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Publication Lightweight Coated (under 40#), Retail Item: White Flower Farm, The Garden Book, Spring 2010 Submitted by: Meredith Print Advantage, Des Moines, IA The 60th anniversary edition of this catalog features the rich depth of color, subtle highlights, shape, detail, and contrast that are all achievable today on lightweight stock by the gravure process. Meredith worked with the Quad/Graphics preliminary department to adjust gradations and finalize corrections to avert on-cylinder adjustments, and with Quad/Graphics specialists to maximize solvent recovery. Too, use of automated blending systems for batching inks and color bars for quick analysis and color adjustment allowed this job to be approved for color in a very short period of time. Separator: Group 360 Engraver: Quad/Graphics, Martinsburg, WV Printer: Quad/Graphics Press: Cerutti Substrate: NewPage Corporation Ink: Quad/Graphics CR/T

Joseph Kohler of Meredith Print Advantage accepts award.

Publication Lightweight Coated (under 40#), Retail Item: L.L. Bean, October Women’s Catalog Submitted by: Quad/Graphics, Inc., Sussex, WI The most notable feature of L.L. Bean’s October Women’s Catalog was an actual fabric dot swatch (sometimes called a “fabric dot whack”) placed on page 3 of the gravure signature and intended to show through a round die-cut on the cover of the catalog. Applying the swatch required extensive testing of the adhesive, correct and consistent placement of the swatch, ensuring that the paper under the swatch would lie flat to avert bindery jams and a poor product appearance, and of course color-matching the swatch to the printed image. Successful production of the catalog demonstrated use of the gravure process with the application of a special fabric swatch. Client and Designer: L.L. Bean, Inc., Freeport, ME Separator: Quad/Graphics, Inc., Freeport, ME Engraver, Printer: Quad/Graphics, Martinsburg, WV Press: Cerutti Substrate: NewPage Corporation Ink: CR/T (Quad/Graphics)

Accepting the award for Quad/Graphics are Dan Dunn (Alexandria, VA) and Lisa Arias (Martinsburg, WV).

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2010 Golden Cylinder Awards

Publication Lightweight Coated (under 40#), Magazine Item: Better Homes and Gardens, October 2009 Submitted by: RR Donnelley, Mattoon, IL This premier home and family publication helps people turn home, cooking, and gardening inspiration into action. The magazine focuses on decorating, building and remodeling, crafts, cooking, and gardening while providing extensive information for women and families. The color range in this 276-page issue—extending from very subtle flesh tones in light and airy editorials to dense ink coverage found in some of the food and garden stories—lends itself perfectly to gravure. Unique challenges are everywhere, from two- and four-color editorial type to complex crossovers to color balance throughout the press run. Measurement of ink viscosity, temperature, and density are crucial to print success on 38-lb. coated paper, as are fold and line-up, coupled with a demanding production schedule. Client: Meredith Corporation, Des Moines, IA Designer: Michael Belknap, Des Moines, IA Separator: Meredith Imaging Center, Des Moines, IA Engraver, Printer: RR Donnelley, Mattoon, IL Presses: Cerutti, Motter Substrate: UPM, Neoga, IL Ink: Flint Ink, Warsaw, IN

Dave Wolvek of Meredith Corporation accepts award.

Publication Coated (over 40#), Retail

Item: Sears Canada Fall Flyer Submitted by: Worldcolor Mt. Morris This Sears Canada publication, produced in English and French, is called an outstanding example of gravure print quality on 60-lb. coated paper printed to SWOP #3 standards and delivered as a stitched, press-finished product. Gravure, the client’s process of choice for its subtle but saturated tone transition, presents women’s and men’s fall fashions with detailed photographic clarity unique to the process. SWOP PDF files matched to the gravure process through ICC profiles produce the impact and predictable high quality that Sears Canada requires. Worldcolor monitors color through its award-winning Quality database, tracks press-side measurements, maintains standards, and analyzes L*a*b* gray patches for mid-tone optimization of the gravure process. Client: Sears Canada, Toronto, CA Printer: Worldcolor Mt. Morris, Mt. Morris, IL Press: Motter Substrate: IP Verso (Influence 60#) Ink: GPI Sun Chemical

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Sears Canada’s Enza Marella and Worldcolor’s David Miller accept award.


Publication Coated (cover), Lightweight Coated (body), Catalog Victoria’s Secret: The Little Book of Lingerie Submitted by: RR Donnelley, Lynchburg, PA This catalog was particularly challenging in that it combined very high quality expectations while maintaining an extremely aggressive production schedule. Through its proprietary color management system, Donnelley was able to achieve gray balance control and provide “top notch” quality very quickly. Flesh tone smoothness is given top priority, as are swatch-matched products throughout. Lightweight coated paper can present printability challenges, as well as show-through concerns. Small reverse type on dark backgrounds requires tight register control and constant monitoring. Experienced craftsmanship and constant focus are musts to meet the customer’s high quality expectations and tight schedule requirements.

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2010 Golden Cylinder Awards

Technical Innovation Image Preparation (prior to engraving)

Packaging for chocolate Pergale Submitted by: Ukrplastic This entry shows how a mixture of innovative prepress approaches, including stochastic screening and cylinder imaging via indirect laser exposure, can uniquely enhance the gravure process so as to achieve exclusive product packaging that projects quality and is eye-catching. Moreover, selective matte-lacquer dot coating combined with a matte-achieved logotype results in packaging that is clearly of VIP caliber, particularly on a supermarket shelf. Designer, Engraver, Printer: Ukrplastic, Kyiv, Ukraine

Ukrplastic’s Alexandr M. Kozik (left) and Andriy GoraGorovskyy accept award.

Technical Innovation Inks & Substrates

UPM Paper Sommelier Submitted by: UPM, Helsinki, Finland UPM developed its Paper Sommelier to make paper selection easier for people who are not familiar with paper properties that are typically expressed in numbers. Paper Sommelier describes five general characteristics of paper, then offers four easy-to-understand alternatives (words or feelings) within each category. The five general characteristics include: color experience, sharpness and feel, body and posture, print gloss, and print through. Based on the choices provided, the prospective paper specifier, who usually would use the tool when accompanied by a UPM paper specialist, is given three bestmatching choices from UPM’s product array.

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UPM’s Erik Ohls, visiting from Helsinki, accepts award.


GAA’s Basic Gravure Seminar

Technical Innovation Press New Developments in Rotogravure Presses for Publication Printing Submitted by: Officine Meccaniche Giovanni Cerutti For installation on its new rotogravure publication presses, the Cerutti organization has developed a variable cutter, dedicated to low-pagination products, in response to market needs for flexibility and productivity. Already, two new Cerutti variable cutters have been installed in Europe, the latest at Eurohueco, Barcelona, Spain, which started up in September 2009. The second, brand-new technical development consists of improvements, designed by the company’s Technical Department, which involve (a) belt removal from the reelstand, and (b) introduction of an electronic lineshaft.

Massimo Genio, representing North American Cerutti, New Berlin, WI, accepts award.

Technical Innovation Packaging

Oreo Halloween Edition Submitted by: Sonoco Flexible Packaging, Charlotte, NC In developing packaging for a seasonal consumer item, Sonoco started with vibrant graphics to enhance shelf appeal, then devised special inline-applied, patterned permanent and resealable adhesives that combine to provide “easy open” access to the product tray. The two-ply laminate, applied using deep-cell engraving produced on the direct laser systems at Trident Americas, is precision diecut to create an opening on the top and bottom surfaces. By not applying adhesive to the thumb-pull area, the tab is used to open the resealable layer, which exposes the contents of the package. The opening can be reclosed to preserve product freshness. The package is described as very classy, and is made possible only by the gravure process. Developer: Sonoco Flexible Packaging, Charlotte, NC Separator: Southern Graphic Systems, Florence, KY Engraver: Trident Americas, Charlotte, NC Printer: Sonoco Flexible Packaging, Edinburgh, IN Press: Cerutti Substrate: SKC, Inc., Covington, KY Ink: Flint Ink

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The Gravure Association of America congratulates winners in its 2010 Golden Cylinder Awards competition: Best of the Best:

Quad/Graphics, Sussex, WI

Packaging Category

Multi-Color Corporation, Batavia, OH Packaging Corporation of America, Waco, TX SleeveCo, Inc., Dawsonville, GA Trident Americas, Charlotte, NC Ukrplastic, Kyiv, Ukraine

Product Category

American Greetings, Greeneville, TN Armstrong World Industries, Lancaster, PA Avery Dennison, SPD, Clinton, SC Canadian General-Tower Limited, Cambridge, ON

Publication Category

RR Donnelley, Lancaster, PA RR Donnelley, Lynchburg, PA RR Donnelley, Mattoon, IL RR Donnelley, New York, NY Meredith Print Advantage, Des Moines, IA JCPenney Media L.P., Plano, TX Quad/Graphics, Sussex, WI

Technical Innovation Category

Officine Meccaniche Giovanni Cerutti Sonoco Flexible Packaging, Charlotte, NC UPM, Helsinki, Finland Worldcolor, Mt. Morris, IL


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GRAVURE September 2010  

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