Last week some 250 customers, prospects and guests toured the latest in digital inkjet book printing and automated binding technology—part of a recent $12 million investment—at the Webcom printing facility in Toronto.
The tours were part of the company’s two-day Game Changers 2011 event where attendees also heard insiders speak about the current state of the book publishing business—an industry in the midst of transition where supply chain efficiencies and streamlined manufacturing process, like those on display at Webcom, represent the future.
The Toronto-based book printer, founded in 1975, has a steady history of investing in leading-edge technology leading to business growth, achieving annual sales of over $70 million by the mid-2000s.
Webcom’s leadership changed in 2006 when founder Warren Wilkins retired and Mike Collinge was appointed president and CEO. And in 2008 mortgage banking veteran and winery owner Moray Tawse acquired the printing company—initiating the new path Webcom has been forging over the last few years.
The Game Changers event was a culmination of activities including the introduction of Webcom’s new logo and colours (seen above) along with a fresh company slogan, “We’re on the same page”. The company is going through a true re-branding, positioning itself as a progressive partner for its customers.
“The rules of the game have changed in the publishing industry with no shortage of worldwide economic problems pushing all of us,” noted Collinge (pictured). “We’re challenged daily in our businesses with ‘e’ and digital change, as well as rapidly advancing consumer demands. Print must change and improve its value. Today’s announcement signifies our readiness to change the rules of the game in favour of winning strategies for book publishers.”
The centerpiece of Webcom’s new approach is its BookFWD program announced last September, based on an entire production platform which includes the first HP T-300 Inkjet Web Press installed in Canada (the ninth in the world) along with an HP Indigo 7000 sheetfed digital press for book covers. Attached to the back of the T-300 is a Flexbook system from Magnum Manufacturing in Barrie, Ont. to create book blocks and a unique book block stacker by Maxxera of Montreal.
To complement the print production is an all-new automated bindery setup including two Müller Martini perfect binding lines, the Bolero and Acoro (getting set to utilize PUR adhesives) and a Standard Horizon StitchLiner 6000 from KBR Graphics Canada for saddle stitching requirements.
The finishing line also includes an automated packaging and palletizing set up.
Critical to Webcom’s future is the digital workflow infrastructure the company is putting in place. The printing technology puts the marks on the pages, but the integrated digital content management, able to virtually warehouse their customers’ titles and enable clients to order and track their shipments online, in real time, will be key to the super-efficient supply chain of the future.
“We’re in progress with larger publishers to build a ‘cloud’ inventory, to enable print-on-demand books,” says Collinge.
At the event Webcom announced a multi-year strategic alliance with the North American education business of Pearson, building on an earlier agreement and working together to leverage an integrated workflow system.
The company’s BookFWD initiative also involves taking a consultative approach with publishers, analyzing existing processes, identifying efficiencies and cost savings, and then locking customers into contractual agreements to improve their supply chain.
Webcom’s current production still relies heavily upon its traditional web offset printing technologies (Timson heatset presses and a Goss coldset press). Collinge notes that only around 20% of the company’s work is being done on the inkjet press now (it was started up in mid-December), although he foresees that growing rapidly, and there is a footprint for another inkjet press beside the existing press.
“I wouldn’t be surprised if it’s up to 40 or 50% of our total production within two years,” says Collinge, “and if it’s not well over that in five years then my vision is a little off.”
He believes the book publishing industry is at a tipping point right now.
In early 2000 Webcom first introduced digital printing into its traditional book factory with the installation of an Océ 8080 monochrome digital printer (which is still installed and running) and an Agfa Chromapress digital colour print engine (no longer around). Collinge suggests that the digital platform installed then didn’t take off because both publishers and Webcom’s internal team didn’t understand the applications—they were more focused on traditional unit cost and couldn’t see the need to completely alter the supply chain.
“Ten years ago the traditional models were still working so there was no urgency to change,” explains Collinge, who’s been with Webcom since 1980. “Now some of the publishers are beginning to change so that’s pushing the rest.”
“By 2015 I believe there will be 50% less printed books sold in Indigo/Chapters and Barnes and Noble stores across North America,” says Collinge. “That’s what our BookFWD investments are all about. It’s to handle that shrinking volume more productively and profitably and support the supply chain.”
