Technical Presentation "Komori's Smart factory Concept"

Even after the end of the COVID-19 pandemic, the printing industry continues to face difficult conditions, including declining sales due to the spread of alternative media, rising material and energy costs, and ongoing labor shortages. In response to these challenges, Komori is developing solutions based on three core pillars: reducing environmental impact, automation and labor-saving, and developing equipment that anyone can operate.

Among these, automation is particularly crucial. It is essential not only to improve efficiency within individual processes but also to optimize the entire workflow--including production data collection. At the core of this initiative is KP-Connect Pro, a Manufacturing Execution System (MES) that provides integrated management from prepress to postpress.

KP-Connect Pro automatically streamlines overall production flow by allocating jobs to offset or digital presses based on job information and production-condition rules, as well as by generating schedules that link upstream and downstream processes. In addition, by recording and consolidating real-time progress and operating results across the entire workflow--from printing through finishing--KP-Connect Pro enables full factory visualization. This creates an environment in which printing sites can pursue continuous improvement with a clear awareness of production costs.

Demonstration 1（Digital Printing Solution）

[Machines]

●29-inch Sheetfed UV Inkjet Digital Printing Press J-throne 29
●Manufacturing Execution System, KP-Connect Pro
●Rotary Die Cutting System RD-N4055DM（Horizon International Inc.）

In the digital solutions demonstration, three jobs were showcased using J-throne 29: variable printing for single-sided packaging, variable printing for single-sided posters, and double-sided printing on special substrates. From loading the job data into KP‑Connect Pro to printing all three jobs and performing die‑cutting, the entire workflow was executed by a single operator. Attendees saw how the press delivers high productivity with a printing speed of 6,000 sheets per hour (single‑sided), along with its swift changeover capability from single‑ to double‑sided printing.

For the packaging print job, hand‑towel packaging was produced on 0.43 mm paper. After high‑speed printing, the sheets were processed on Horizon International Inc.'s RD‑N4055DM rotary die‑cutting system, which performed die‑cutting and creasing--demonstrating the strong postpress compatibility of the J‑throne 29. Furthermore, through integration between Horizon International Inc.'s Post-press Management System iCE LiNK and KP‑Connect Pro, job progress across each machine was visualized in real time, contributing to shorter delivery times and more effective cost control.

In parallel with the rotary die‑cutting demonstration, the KGC Smart Factory showcased true multi‑process parallel operation: second‑job printing on the J‑throne 29 ran simultaneously with register adjustment and color matching on an offset press, highlighting end‑to‑end workflow orchestration.

For the double-sided special substrates demonstration, restaurant menus were printed on "New YUPO FGS 300". Because this substrate is the same offset‑grade synthetic paper used for conventional offset printing--rather than digital‑exclusive substrates--it enables more efficient substrate management and reduces paper costs. In addition, since the J‑throne 29 uses the same paper‑transport mechanism as offset presses, it delivers stable register accuracy even with special substrates.

Demonstration ２（Commercial Printing Solution）

[Machines]

●40" Dedicated Two-sided Multi-color Offset Printing Press, Lithrone GX40RP advance EX Edition (GLX-840RP-A)
●Manufacturing Execution System, KP-Connect Pro
●B1 size Combi Folder, MBO K80
●Collaborative robot, MBO CoBo-Stack
●Programmable Hydraulic Clamp Cutting System, Apressia CTX132
●Automated Guided Forklift for Heavy Pallet Goods Handling, AiTEN

In the commercial solutions demonstration, we showcased how sequential processes in commercial printing work together to optimize production. This time, assuming the workflow of a printing company operating an online order business, we demonstrated continuous printing of three different jobs. Job ganging, imposition, plate output, and job‑data registration on the press were all completed automatically through system integration between KP‑Connect Pro, Horizon International Inc., and SCREEN Holdings Co., Ltd..

In addition, Komori's Auto‑Pilot technology enabled fully automated operation--including job changeover, test printing, and production printing--without any operator intervention. The changeovers to the second and third jobs were completed in approximately 2 minutes and 30 seconds. The Parallel Make‑Ready function allows plate changing, blanket washing, and pre‑inking to proceed simultaneously.

Furthermore, while the job changeovers were taking place, folding was performed on the MBO K80, palletizing on the MBO CoBo‑Stack, and cutting on the Apressia CTX132. Postpress tasks that previously required two operators can now be handled smoothly by a single person, achieving both labor savings and improved operating efficiency.

■Demonstration３（Package Printing Solution）

[Machines]

●40" Offset Printing Press, Lithrone GX40 advance EX Edition (GLX-740A)
●Manufacturing Execution System, KP-Connect Pro
●High Performance Blanking System, Apressia MB110E
●Automated Guided Forklift for Heavy Pallet Goods Handling, AiTEN

In the package‑printing solutions demonstration, we highlighted how automation enables fast job changeovers and consistently stable print quality--even without reliance on operator skill. The first job, a food‑packaging application, was printed at a high speed of 18,000 sheets per hour, maintaining uniform quality throughout and demonstrating excellent in‑sheet stability. The pallet transport of printed sheets was handled by the lightweight, compact industrial transport robot AiTEN.

For the second job, we printed a highly embellished whisky package featuring multiple varnish coatings. Thanks to the Super Short Make‑Ready system, the job changeover was completed in approximately 12 minutes. In addition to the conventional parallel control of plate changing, blanket washing, and ink‑roller washing, the system also simplifies and parallelizes traditionally manual tasks such as ink‑fountain film and coater plate replacement. This reduces changeover time to levels comparable with commercial printing.

Furthermore, misprinted sheets detected by the PQA‑S V5 inspection system were automatically sorted by the double‑pile delivery system, reducing inspection workload, reprint time, and material waste.

Packaging workflows typically involve many postpress processes--such as die‑cutting, stripping, and gluing--making scheduling and progress tracking extremely complex. The scheduler function within KP‑Connect Pro enables unified management of all these processes.

We also held mini‑seminars on after‑service support and KP‑Connect, allowing attendees to deepen their understanding according to their interests and areas of concern.

In addition, two special seminars were conducted over the two‑day event. These featured presentations on real‑world examples of digital transformation (DX) implemented at printing companies, as well as practical guidance on how to effectively utilize government subsidies--making the program particularly valuable.

Left: Naoyuki Muraoka, Executive Officer, Director of Operations, Japan Carbon Management Co., Ltd.
"How to Successfully Utilize Subsidies for Equipment Upgrades"

Right: Takeshi Oku, Chief Strategy Officer (CSO), Bunseikaku Co., Ltd.
"DX That Doesn't Stop at the Concept Stage - How KP‑Connect Transforms On‑Site Operations"

The Komori New Year Special Open House 2026 proved to be a valuable opportunity to showcase the latest printing technologies and the potential of smart factories, all aimed at shaping the future of the printing industry. Komori will continue to support our customers' businesses over the long term and contribute to the ongoing development of the printing industry as a trusted partner.

We extend our sincere gratitude to everyone who attended the open house.