The case for press retrofits was made in a very persuasive manner at WAN-Ifra's World Publishing Expo, with three speakers at the Print World conference stream promoting the strategy.
"This is the best way to enhance the lifespan of your machines," says Hans Jorg Maurer, managing director of PME Maurer in Germany, but there are risks.
"The failure of your machines depends on how you run them. They are designed for eight to ten years, but many will run for up to 20 years," he says.
"Outside factors such as no enough cleaning and maintenance, and using the wrong products will impact the life of your press."
Retrofit means giving your press more life and can include electronic as well as a technical refits. To decide whether a new machine or retrofit is the way to go, get your machine checked thoroughly, including the use of infrared, ultrasound, vibration and thermography equipment to fully understand its condition, and take into consideration the cost of repairs and consumables, and the cost and availability of spare parts, he says.
Robert Heitzer told of the retrofit of several presses at Suddeutscher Verlag Zeitungsdruck in Germany, where he is head of the print department. Among issues faced were the training of staff - particularly to detect errors in the new control systems - teaching electricians the new systems, and obtaining spare parts.
Consultant at Kirchner & Robrecht, Moritz Schwarz (pictured) told of two retrofit projects he had been involved in - one of three KBA-equipped plants in Central Europe and another in Saudi Arabia, where 16-year-old Goss presses were given "the full treatment".
Retrofits can be mechanical and or electronic, but an upgrade means adding more functions to your existing press, and Schwarz says it is important to distinguish between the two.
Problems to be overcome include the longevity of the printing press supplier, the availability of spare parts for "closed box" systems, and the possible knowledge gaps in your machine team. "In some cases a retrofit is the best solution, but cost savings can often be made by using a professional project manager to ensure a stable future for the machine," Schwarz says.
Maggie Coleman