Contract Signing Schibsted

SCHIBSTED TRYKK BOOSTS ITS OSLO PRINTING PLANT WITH DCOS CLOSED-LOOP INSPECTION SYSTEM

KINNA, May 28th, 2020 – In the middle of the blooming area of Nydalen in Oslo where new apartment buildings, stores, supermarkets, hotels and office buildings are constantly being developed, one of northern Europe’s largest printing facilities is still an impressive landmark. With twenty-two Goss Colorliner 80S towers and five Quad-Former folders, Schibsted Trykk has the largest printing press in the Nordics. Today three folders and 12 towers are in daily use, producing around 4.5 million copes every week.

In the continuous strive to increase productivity and reduce cost of consumables, Schibsted Trykk decided in 2019 to take a closer look at upgrading its press with closed-loop density control. Just before Christmas last year, Schibsted decided DCOS would be their best choice of partner for the project.

We have high ambitions with this investment and DCOS has appeared to be the best fit for us to reach our set goals. DCOS has a huge install base and we have got nothing but positive feedback from other DCOS users and the ROI is well within our expectation”, says Bjarne Andersen, CEO Schibsted Trykk.

DCOS will install its proven concept of a complete Print Inspection System (density, color register and cut-off) on one section plus Digital Presetting across twelve towers. The press has Goss Digital Inking System (Page Packs) and the project involves a partial retrofit of existing Honeywell Digital Inking control system.

Patrik Martinsson, Sales Manager at DCOS adds, “I´m very pleased we have been awarded this project by Bjarne and his team, we will make sure this becomes a success. This order also marks the seventh consecutive Inspection System order in Norway won by DCOS, a fact that gives us even more motivation to continue doing our utmost to find solutions that make our customer more productive”.

Installation is ongoing and will be completed in June.

Jussi Talvi at Suomalainen Lehthipaino

SUOMALAINEN LEHTIPAINO’S bold move switching to DCOS pays off, month-by-month

KINNA, May 7th, 2020 – In 2008 Suomalainen Lehtipaino, based in Kajaani in northern Finland, invested in a new printing press. A seven tower and two folders Tensor T400BE press with DCOS drive and control system was installed and substantially increased the color and pagination capacity compared to the Solna press it replaced. The press was originally equipped with Inventor Spray Dampening and Perretta Remote Inking and Register System.

In 2016 it was announced that Suomalainen Lehtipaino invests in additional automation as the Perretta closed-loop register system was replaced by a closed-loop Color, Register and Cut-off system from Dutch company QI Press Controls. The customer’s expectations were to increase the quality and obtain savings in ink and waste paper. The system was installed in the end of 2016.

Starting at the end of 2018 we were in contact with Marja and her team discussing future retrofit needs and we could see that the efficiency and savings was not at a level we normally expect on a press with Closed-loop Color control. Start-up waste was almost doubled compared to equivalent DCOS installations. This encouraged us to investigate if there is a financial incitement to replace the new QI system with a DCOS system”,says Marcus Juselius, DCOS Agent in Finland.

A detailed ROI study was made and presented. This was followed up with two reference visits to demonstrate the DCOS Inspection system to highlight the differences. In late summer 2019 Suomalainen Lehtipaino decided to place the order with DCOS to replace the Closed-loop Inspection System.

The target for the investment was for the start-up waste to be almost halved, reduced by 47,5% with DCOS Technology.

We were thrilled about this opportunity. We know our technology is unrivaled when it comes to ROI and waste savings, we have seen this trend for years, but it’s always hard to compare different systems on different type of jobs, presses and pressrooms. Here we finally got a chance to compare apple-to-apple. Replacing the old system with the new and monitor the result.”, says Mattias Andersson, CEO and DCOS.

The QI Press control system was dismantled as the DCOS system was installed and commissioned in December 2019. The first full month waste report for January showed a 39% start-up waste reduction from the previous year and the start-up waste has continued to decline since.

Marja Niemi, Production Manager Suomalainen Lehtipaino says; “I have to admit it was not easy to make the decision to replace the system we installed in 2016, but the DCOS reference visits were very convincing and we felt confident the ROI was there. Today I’m very pleased to see the promises come through, resulting in savings for us. Additionally,our operators give me very positive feedback on a fully automatic and user-friendly system”.

This is DCOS second Closed-Loop Inspection System installation in Finland.

covid_19

Update from DCOS, TENSOR & AMAL on the current COVID-19 situation

KINNA, March 24th, 2020 – The COVID-19 situation is the primary subject in almost all conversations today, the global impact is huge and we are all affected, by the virus or by the consequences of the means to defeat the spread of the virus.

At DCOS, Tensor and Amal, the safety and health of our employees, their families, customers and business relations are our top priority. We are currently operating almost as normal with a high order volume and focused to ensure business continuity, but obviously with restrictions due to the COVID-19 situation. These restrictions involve travel restrictions, social distancing, establishing methods and best practice to limit the spread of the virus in our workspace.

We will experience some delays in ongoing projects, mainly due to travel restrictions, but we also seek individual solutions to keep project going to the best of our ability. We are open to explore new ways to run installations in difficult times like these and we are amazed by the initiatives and openminded support shown by our customer in a uniform approach to keep the projects going.

Our hotline support and parts service operate as normal, we are not seeing any major impact in supply chain or logistics that would affect our ability to support our customers in their day-to-day operation.

The situation is changing rapidly, and we follow the development closely and adapt to the guideline of our authorities. Should you have any questions to us, feel free to contact me.

I like to express our deepest concerns for those who are affected by the crisis. Stay Safe!

DCOS IGA MD´s

DCOS sets new footprint in the GERMAN MARKET

KINNA, February 6th, 2020 – Automation House Sweden AB, the holding company of DCOS Sweden AB, Tensor International LLC and Amal Webline AB has acquired a majority of shares in IGA Plauen GmbH Ingenieurgemeinshaft Automatisierung based in Plauen Germany. The acquisition follows many years of successful cooperation between DCOS and IGA and the company will be renamed to DCOS IGA Automation GmbH.

IGA is an automation company with roots in the former Manroland Plauen operation specializing in electrical design, software development, machine safety and project management. IGA is well established as a solution provider to printers and partners in the global market.

DCOS has in recent years developed a global leadership position in closed-loop density control for offset printing. Combined with its retrofit solutions, DCOS is unique in being a single-source, brand-independent automation provider for the printing industry.

DCOS has a proven record of success in the seamless integration of press drives, controls, and closed loop density, register and cut-off control equipment to all existing OEM offset presses. The acquisition of IGA further enhances our capabilities.

DCOS completed its first retrofit project in the DACH region (Germany, Austria and Switzerland) back in 2011 and several presses in this market have been equipped with DCOS automation. However, it has always been obvious that a local organization would be advantageous to support sales, project and service efforts, not least due to language.

“This acquisition and partnership with IGA is a strategic step for DCOS. I see an excellent growth potential in the DACH market for our automation solutions and being able to run projects, service and support from our Plauen office will certainly strengthen our position. Secondly, partnering with IGA not only helps us grow our organization with qualified and experienced engineers, it also adds new competences to our group that gives edge to our offer.” says Mattias Andersson, CEO DCOS.

Stefan Leissner, founder and MD at IGA adds; “After working together with DCOS for many years I´m pleased that we have taken the decision to become part of the same company. With this acquisition we want to merge the strengths of each individual company to further improve our capability and capacity in our projects to the benefit for our new and existing customer base.”

Stuart team

DCOS wins another DGM press project

KINNA, October 31th, 2019 – DCOS Automation has been awarded a contract to install closed loop ink density / color registration equipment to a DGM 440/430 press at Stuart Web, located in Stuart, Florida. Working with imPressions Worldwide on a comprehensive press addition and system upgrade project, Stuart Web will also add 3-used DGM 430 4-high towers to their existing press.

This project is the second DCOS closed loop automation system installed on a press with UV curing in North America.

Stuart Web’s DGM 440 tower is dedicated to UV curing. Due to the higher operational costs of UV printing, smart UV printers are realizing the benefits of the lower waste that our proven closed loop automation systems provide” adds Ron Ehrhardt, Sales Director for DCOS.

Delivery and installation will commence in January 2020.

BTT Retrofit

SWEDISH PRINTER picks DCOS for complete retrofit of its KBA COLORA PRESS

KINNA, October 3rd, 2019 – For almost two decades, Borås Tidning Tryckeri (BTT) has been a cornerstone in Bold Printing Group, one of the largest printing groups in Nordic countries. The printshop in Viared (west of Borås) was established in 2002 following a joint venture between media groups Bold Printing and Gota Media.

Gota Media is also the owner of the local newspaper Borås Tidning, who used to operate its own printshop in downtown Borås prior the joint venture.

As a result of the ongoing changes in the media landscape in Sweden, Gota Media decided to buy Bold Printing out of BTT and regain ownership of the printing plant, this transaction is ongoing and will be concluded prior end of the year.

The KBA Colora press, installed in 2002, is unique in its design. It consists of three four-high printing towers, one five-high, and one folder. The five-high was not part of the original press order but at the time the press was manufactured in Würzburg, BTT secured another print contract requiring 80 pages and needed one additional web, the result was extending one four-high to a five-high.

The press automation was typical for this time, a solution called “Leittechnik” that is a mix of KBA on-press automation and EAE´s section controller, control desks, planning and reporting. The drive system is a Bosch Rexroth SYNAX system. In 2012 BTT placed the order with DCOS to equip the press with its Closed-loop inspection system, this included the replacement of the EAE ink-preset system. This created a situation where the main automation systems on the press are from four different vendors based four different technology platforms.

For some years BBT has seen the emerging need to retrofit its automation systems to fight obsolescence and to future-proof its operations. The decision was delayed due to the ongoing change in ownership, but with the new owner in place earlier this year, BTT decided to put their plans into action and DCOS was awarded the contract to become the automation partner for all the press automation.

We have been very pleased with the original systems from KBA, EAE and Bosch Rexroth but for us this was an opportunity to unify our automations systems into one hardware and software platform. The openness and push towards standard non-proprietary components by DCOS were also important for us”, says Måns Källqvist, Production & Technical Manager at BTT.

DCOS has developed a drive and control system solution for the “Leittechnik” presses which involves a complete change in technology, the many fieldbus systems in the “Leittechnik” concept will be removed and the new systems will run only over Ethernet. The complete EAE system will be replaced, the obsolete ABB KT98 and KT94 PLC on the press will be replaced by standard I/O systems, and the Bosch Rexroth motion controllers will be removed and integrated in on unified drive and control system by DCOS.

Tommy Johnsson, CEO at BTT; “We invested in DCOS Closed-loop system in 2012 and have been very happy with both system and support. DCOS is a very dynamic and flexible company that well fit our needs for future, we are very pleased to extend and intensify our partnership with them”.

The project preparation phase is ongoing, the retrofit will start on-site beginning of 2020, and last for about 3 months.

Interesting enough, this is the third KBA press within a one-hour drive to undergo a retrofit by DCOS. In 2012 Henreco press choose DCOS to retrofit and extended their KBA Express pres,s and in 2017 V-TAB Landvetter contracted DCOS for the retrofit and extension of their Manroland Colorman press with three stacked KBA Commander Satellites.

We are honored to win the trust of BTT for yet another project. For many years BTT has been our most frequently used showroom for our Inspection system and a prefect place for our “Leittechnik” retrofit”, says Mattias Andersson, CEO DCOS Sweden AB.

tradeshow

DCOS to showcase its AUTOMATION SOLUTIONS at IFRA 2019

KINNA, September 26, 2019 – DCOS is very excited to be exhibiting at the upcoming IFRA 2019! This past year DCOS has achieved great success and increased market penetration in Europe, Africa, and North America for our closed loop automation/inspection upgrades, and for our drive and controls retrofits.

Closed loop density, color register and cut-off control upgrades have been installed on Tensor, KBA, manroland, DGM & Goss presses world-wide this past year. We have also seen a keen interest in retrofitting drive and controls system on most press types as printers continue to look for newer, more modern systems with increased supportability to extend the operational life of their presses.

We´ll we have live demo of our Inspection system and our operator control desk.

Please visit us at Hall 21A, stand E.16, to learn how DCOS Automation can work for you!

OTM Avistryk, Bosch Rexroth Retrofit by DCOS

OTM AVISTRYK taps DCOS for large BOSCH REXROTH retrofit

KINNA, August 22, 2019 – DCOS Sweden AB is proud to announce a substantial contract to retrofit the existing Bosch Rexroth drive system at OTM Avistryk Herning-Ikast A/S in Ikast, Denmark. The existing equipment consists of two Goss Universal 45 presses, with a total of twelve 4-high printing towers and two folders installed in early 2000, comprise over 70 drives and motors. The presses are by an EAE press control system and AMAL splicers.

In the 1990’s, Bosch Rexroth, with its well-known brand Indramat, took part in transforming the graphic arts industry from traditional mechanical line shafts to shaftless drive transmission. In the last 20+ years, Shaftless technology has been the predominant method to run and control printing presses and industry leading OEMs like KBA, Goss, DGM, and Solna has relied on Bosch Rexroth´s technology.

Many of these presses were equipped with the DIAX series of drives and the CLC motion controller. All based on SERCOS II fiber optics. Like all electronics, the service life of components is limited and especially on power electronics making the DIAX system a challenge to maintain today. There are many short-term solutions available to extend service life for a few years, but most do not involve any change in technology. This approach only delays the inevitable, which is a complete retrofit in the near future.

In 2015 DCOS developed an industry unique Retrofit concept for the DIAX platform, a step-by-step migration of the old DIAX system to a modern drive system platform, the same platform we use on new presses toady. The investment is targeted towards a new state-of-the-art technology, and gradually the old SERCOS II fiber optic system is removed and replaced with a standardized, non-proprietary Ethernet based bus system.

OTM Avistryk realized a few years back that they needed to extend the operational life of the Bosch Rexroth system on their Goss presses to fight obsolescence and to ensure uptime of their presses.

Frank Haberstroh, Managing Director says; “We are dedicated to printing and predict to do so for a long time. We heard about the DCOS retrofit solution for the DIAX drive system and got very interested as we were seeking for a more long-term approach than what was previously offered to us. We saw a DCOS retrofit on a Universal press and it was very convincing. Originally, we talked about step-by-step retrofit, but in the end, we decide it was more cost effective for us to do a complete retrofit on our six tower, one folder press.”

In April the contact was signed for the retrofit of thirty-two drives and four CLC motion controllers. The proprietary motor encoders will also be replaced by standard encoders. The retrofit will start in the end of August and will be competed in four weeks.

“Creating cost effective solutions with a technical edge has always been the strength of DCOS. I´m particularly proud of this solution. It’s the only truly future-proof solution offered today, completely based on standard hardware, cost-effective, and adaptable step-by-step. OTM Avistryk is the seventh press undergoing an DCOS retrofit of Bosch Rexroth system and we are thankful for the trust Frank and his team relies on us”, says Mattias Andersson, CEO DCOS Sweden AB.

V-TAB Landvetter DCOS Retrofit

V-TAB LANDVETTER turns to DCOS for their second retrofit project

KINNA, May 22, 2019 – The V-TAB group with headquarters in Göteborg, Sweden, is a major player for printed media in Nordic countries. With Newspapers, Inserts, Magazines and other Commercial products and a total of four coldest printing plants across in the south of Sweden, newspaper production is their largest business.

In 2010 V-TAB made a large investment in building a new printing facility in Landvetter Sweden. A used manroland Colorman press (originally from Stockholm) was purchased, refurbished and installed, including a press control system Retrofit and a conversion to shaftless by the German company EAE.

In 2016, V-TAB saw the emerging need to address the increasing print quality challenges on its 9-cylinder Colorman satellite units. At the same time V-TAB shuttered its printing plant in Örebro which had three Koenig & Bauer (K&B) Commander satellite towers in good condition.

In the end of March 2017, things became more critical and V-TAB reached out to DCOS and asked for urgent assistance in their retrofit project. The first K&B tower was mechanically installed and ready for electrical retrofit and installation with the intent to commission in early summer. Question was placed if DCOS could manage the project in the given short time frame.

After two weeks of intensive technical study and negotiations, the contract was signed and DCOS immediately assigned an engineering team to the project.

“This is the first time we experienced executing a project this size in such short notice. It´s obviously a huge challenge and the close proximity to V-TAB Landvetter was important. Four weeks after the contract signing, we started retrofitting hardware on the tower and another 4 weeks later we were running”, says Mattias Andersson, managing director at DCOS.

Since the project began in April 2017 two identical towers have been installed, retrofitted and commissioned. In the next weeks the third and last tower will be commissioned. In addition, V-TAB also decided to invest in DCOS Closed-Loop Density, Register and Cut-off control for the three K&B Satellite towers.

Dan Eriksson, Project Manager V-TAB, added; “Getting DCOS involved in our project turned into a huge success for us, not only did they help us keep our critical schedule in place, but they also brought our level of automation to a higher standard, with a full scale closed-loop system. We had a worry that two different control and operator systems on a single press could cause challenges for the operators, but the way DCOS implemented their system made this transition easy, and our operators are very pleased with the solution.”

The final press layout is six Manroland Colorman satellite towers, three K&B Commander satellite towers, two Manroland folders and one K&B folder.

carson_city

CARSON CITY taps DCOS for drive and control retrofit

KINNA, May 15, 2019 – PressWorks Ink, a subsidiary of Swift Communications, Inc., has contracted DCOS Automation Sweden for a complete drives and controls retrofit on its DGM 440 press. PressWorks Ink prints the Carson City “Nevada Appeal” and the Reno “Gazette-Journal” along with several other weekly, monthly, tabloid, and specialty products.

DCOS will replace the existing six Eurotherm SSD drives with new digital drives. The existing DGM consoles will be replaced with new DCOS consoles that integrate all press functions, ink presetting and remote inking control, dampening, splicers and infeed’s to new touchscreen control. The existing fiber optic loop will be replaced with a new EtherCat star-network with direct communication to each drive.

The drives and controls are supported by DCOS 24/7 remote support. Chris Johnson, Director of Print Manufacturing for Swift Communications adds; “for years we have spent too much time and effort troubleshooting our drive and controls issues. These older systems now have very limited technical support and spare parts availability. We felt the time was right to upgrade to a more modern, supportable platform. The feedback we received from DCOS customers with similar projects gave us the confidence to move forward with them.”

DCOS will also assist in the scavenging of useful spare parts from the old Eurotherm drives and DGM console to be used at another Swift Communications site.

While DCOS has a strong history of drives and controls retrofits in Europe on nearly all types of newspaper presses, this is the most extensive drives and controls project so far in the USA. “Obviously we are very excited to be awarded this project. It will demonstrate all our capabilities as we assist centralized newspaper printers like PressWorks Ink in the long-term performance and supportability of their presses” adds Ron Ehrhardt, Sales Director for DCOS in North and South America. “We now have recent drive, controls, and closed loop automation customers in the USA, and look forward to demonstrating our capabilities to this market.”

The installation will begin in September 2019.