PAARL MEDIA

ORGANOGRAM
Paarl Media Group (Pty) Ltd
A BUSINESS
UNFOLDING
05
CORPORIATE
SOCIAL
INVESTMENT
40
PAARL MEDIA
ACADEMY
42
PRINTING
RESPONSIBILITY
45
SPONSORS
49
STEERING
THE FUTURE
49
2010 AND INTO
THE FUTURE
06
PAARL MEDIA
PAARL
19
PAARL MEDIA
KZN
25
PAARL MEDIA
GAUTENG
31
PAARL MEDIA
COLDSET
35
PAARL MEDIA
LABELS
38
SHOPPERS
FRIEND
08
PAARL MEDIA
CAPE
12
COLLAGE
OF STAFF
MEMBERS
4
It is our absolute passion for printing
and exceeding our clients expectations
that has seen us grow in just ten years
to become the largest printing network
in South Africa.
While Y2K was the buzzword at the
start of the new millennium, the year
2000 heralded the founding of the Paarl
Media Group. The merger of National
Magazines (which became Paarl
Gravure) and Paarl Web to create Paarl
Media Holdings, established a printing
powerhouse, operating independently
from publishers.
In 2001, Paarl Media further acquired National Book
Printers in Paarl and under Paarl Print's name, which
were consolidated in 2002. The following year saw the
frst Black Economic Empowerment deal, with Vakazi
Holdings and Edu Access gaining a 26% stake in Paarl
Print. Paarl Media also led the way as the frst South
African printer to roll out 100% computer-to-plate pre-
press processes in all their plants.
New presses were the highlights of 2004 with a new
Cerutti press at Paarl Gravure and three of the latest
manroland sheetfed presses for Paarl Print.
2005 saw LoveLifes Kurisani acquire the empowerment
shareholding from Vakazi Holdings & Edu Access and
partner in the launch of Paal Web Gauteng. The substantial
A BUSINESS UNFOLDING
investment in establishing this new plant was in response
to client demand in the region. This year also saw the
frst installation in the country of Regenerative Thermal
Oxidisers on heatset web offset presses to eliminate
harmful emissions in line with stringent international
standards.
The Groups BEE credentials were enhanced by
combining with Media24 in a 50% empowerment
shareholding through Welkom/Yinzani in 2006.
In 2007, our national service network was expanded
when new sales offces were opened in Durban and
Port Elizabeth. Paarl Medias substantial investment
in environmentally sustainable practices was
acknowledged as the frst printing organisation on the
continent to receive Forestry Stewardship Council (FSC)
Chain of Custody Certifcation (CoC).
Media24s Coldset printing operations, Print24 and
Paarl Post (Pty) Limited were acquired by the group
in 2008 and renamed Paarl Coldset, giving clients
access to the full range of printing methods through
one group. The need for critical skills to keep pace
with advancements in technology prompted the
development of Paarl Media Academy. An entirely new
curriculum has been developed by the Paarl Media
Group which sees qualifcations being received from
both local and international accredited bureaus.
The Paarl Media Academy can accommodate up to X
number of full-time students. The Paarl Media R10
million bursary trust was also launched to provide
funding for previously disadvantaged students to study
at a tertiary level.
2009 saw the Paarl Media Group embark on a fve year
strategy to radically enhance the business plan to morph
the evolving print media landscape. The embellishment
of this strategy commenced with the merger of Paarl
Web and Paarl Gravure into one plant, Paarl Media Cape.
In ongoing support of the Paarl community, Paarl
Print was re-established at the existing Paarl Web
premises. A further decision was made to merge Paarl
Web and Paarl Gravure into one plant, Paarl Media
Cape. This consolidation gives clients access to the
increased effciencies and convenience of both printing
capabilities as well as the largest bindery in the country
under one roof. It further untied resources to meets
the increased demand in the Gauteng region with the
installation of the largest heatset web offset press in
the country, the 80-page manroland Lithoman and the
acquisition of a second building to enhance square
back binding capacity together with polyurethane
plastic wrap. Paarl Coldset followed the same strategy,
focusing their plants in the main business centres
through amalgamating Paarl Coldset Cape Town and
Paarl Coldset Paarl, amalgamating Paarl Coldset
Johannesburg and Paarl Coldset Potchefstroom and
purchasing the coldset printing division of the Natal
Witness Group. This provides extensive core printing
capability for reliable and fast delivery and allows
further investment in the development of people and
an injection of new technology. This has been evident
by the automation of mailrooms in both Paarl Coldset
Port Elizabeth and Paarl Coldset Bloemfontein.
2010 sees the establishment of a new era plant in the form
of Paarl Media Paarl which was born out of the ashes of
the Paarl Media Groups previous book printing business,
Paarl Print. The Paarl Media Group also understands that
distribution is to fundamentally change in line with the
altered print media environment. Therefore, in the
form of a major diversifcation, Shoppers Friend has
been launched. The Paarl Media Group believes this to
be pivotal in the future of South African print media.
Shoppers Friend is detailed more extensively later in
this publication.
5
The emergence of digital
and internet technologies
in the past 10 years has
impacted on printing trends
and infuenced the way
companies do business, from
the design to the printing
phase of operations.
2010 AND INTO
THE FUTURE
This, together with increased competition for readership
and advertising spend by non-print and online media,
global recession and more complex distribution
requirements has necessitated a shift in thinking in the
industry as a whole.
Print runs have become more focused on target audiences,
expectations for quality and fast turnaround higher, and
more creative solutions are required as clients strive
to create a competitive edge in a challenging business
environment. Clients also want to print differentiated
products by region or the same product on the same
platform in different regional centres to reduce
distribution costs and time.
Having always been driven by our core aim to deliver
the most competitive products for our clients, we have
continuously invested in the optimisation of our workfow
and production, as well as in leading technology and
skills development.
That is why this 10-year anniversary is such a signifcant
milestone and highlight for us. It serves as a review of
our growth over a decade and a benchmark for an ethos
of innovation and commitment that will drive us forward.
This publication is designed to give you some insight into
the highlights and future of our organisation.
To best refect our new business structure, we have
consolidated our brand for our heatset, gravure, book
and sheetfed businesses under the Paarl Media name.
Seamless integration between plants ensures clients
have access to the groups full capability and expertise,
no matter where they are based.
This will now include clients based in KwaZulu-Natal
with the establishment of our new heatset web offset
plant, KwaZulu-Natal Paarl Media KZN in Pinetown, and
our acquisition of the Natal Witness coldset printing
operation.
The Coldset operations are consolidated under Paarl
Coldset and now include the acquisition of the Natal
Witness Coldset printing operation.
We are also pleased to announce our launch of Shoppers
Friend, an innovative, value added distribution solution
for retailers, providing them with an extended, powerful
channel to distribute their promotional inserts directly
to more than 2.1 million households in Gauteng.
The next 10 years and beyond holds many future growth
opportunities for us to continue to evolve the service
that we offer and lead the direction of the printing
industry and related distribution as a whole.
Looking ahead, we are confdent that Paarl Media is
well positioned to develop highly skilled people, invest
in leading edge technology, create sustainable and
environmentally friendly printing solutions, and serve
you - our valued client.
6
THERE IS MORE TO PRINT THAN INK.
SHOPPERS
FRIEND
Revolution in retail advertising
Neither a newspaper, magazine nor knock
n drop product, Shoppers Friend is uniquely
aimed at the consumer, bringing convenience,
choice and savings directly to the home in
a fun and entertaining way. Most of all, it is
changing the face of retail advertising forever.
Jacques Coetzee, General Manager, Shoppers Friend
8
Shoppers Friend is one of Paarl Medias most signifcant
investments to date, worth R100 million in overall
spend, this branded weekly ad-paper is set to shift the
trends of retail advertising.
Being an all-in-one tabloid, it provides a convenient
mechanism for consumers to window-shop for deals and
brands and their advertisers can enjoy a new, highly
targeted way of reaching their prospects and customers.
As the brainchild of Paarl Media, Shoppers Friend
ensures that leafets are distributed more effectively
using interactive games and competitions to generate
new levels of customer interaction and involvement. The
cover of the publication is the most important element
of the paper, providing a section for loose inserts to
showcase specials and promotions.
Its ability to target different demographics amounts
to better market penetration, with 94 different
distribution pockets based on geographic proximity and
average income. Shoppers Friend is proud to be making
marketing headway in areas that have previously been
untapped by the loose insert media translating into key
benefts for retailers.
Particularly, shoppers living outside the traditional
distribution channels, such as those in informal settle-
ments and outlying townships or gated communities, will
now be able to receive these weekly consumer papers.
When clients choose Shoppers Friend as a marketing
tool, a tight quality control process kicks in to ensure
delivery of a top service and total satisfaction.
The complete process - from receipt of client order,
packing of the correct inserts into the selected pocket,
delivering to the right pocket right through to invoicing
the client is designed in conjunction with Deloittes in
terms of recognised audit procedures. Internal audit staff
of 33 trained auditors provides weekly audit reports.
Facilities & Equipment
The heart of the operation is a massive Inserting and
Distribution facility in Alrode with 3 Schur packaging lines
imported from Denmark. These machines are dedicated
inserting lines that are widely used in Europe and the
frst of their kind in South Africa.
Packing 12 inserts into the Shoppers Friend at a
combined speed of 60,000 copies per hour, each line also
has a plastic wrapping functionality.
The Shoppers Friend cover is printed at Paarl Media
Gauteng on 80gsm Matt Sappi Triple Green paper and
the cover is produced on a press that runs up to 65 000
copies per hour.
Printed loose inserts are delivered from Paarl Media
Plants.The bundles are labelled and clearly traceable
via barcodes and handed over to a dedicated team with
3 days per week distribution to 2 million households in
Gauteng alone.
Shoppers Friend offers retailers and advertiser a full
competition management service, which includes
assistance with the design of competitions and the
logistical operations thereof. It also provides a well-
equipped call centre aimed at alleviating administrative
headaches for the advertisers and providing an interface
with customers who have queries about deliveries,
competitions and store locations.
In short, Shoppers Friend offers all the benefts of brand
recognition and frequency, with a whole lot more added
value too. It means better marketing penetration, better
targeting, better consumer interaction and better value,
which of course ultimately translate into a better return
on investment for the retailer.
For more information on Shoppers Friend,
call 0861 02 03 04 or email sales@shoppersfriend.co.za
GRAVURE
WEB
STREAM
PAARL MEDIA CAPE
publication gra-vure
adjective
A method of printing with engraved copper cylinders.
Provides crisp, full spectrum colours and registration, which hold true over millions of copies.
Ideally suited for very high volume production of publications and commercial products,
including weekly, fortnightly and monthly magazines, catalogues and magazines.
heatset web offset
adjective
Heatset web offset is an offset printing process in which a continuous roll of paper is fed
through the printing press Pages are separated and cut to size after they have been printed.
Heatset web offset printing is used for high-volume magazines, retail inserts, catalogues
and brochures.
True quality, high volume magazine and commercial work
Paarl Media Cape
The amalgamation of Paarl Gravure and Paarl Web into Paarl Media
Cape has enabled us to achieve the most effcient production of
different formats, paper and fnishing requirements.
Our consolidated technology platforms provide more than 125 000
tons annual printing capacity.
In addition to high volume and higher standard of quality production,
we offer our clients, ranging from magazine publishers to retailers,
additional onsite value added services, such as inserting and mailing.
Our focus is always to deliver the fnal product exactly
to our clients requirements every time. This is achieved
through the implementation of advanced technology and
the dedicated focus on staff skills training and development.
DEVELOPING OUR PEOPLE
Core to our success are our people. To enhance the
business effectiveness of our employees, systematically
planned interventions, including effective personal
development planning, performance measurement
and strong communication channels, will provide a
platform for both the organisation and the individual
to grow and develop. This will enable the creation of a
healthy and effective culture, climate and environment,
as well as improve organisational problem solving and
renewal processes through effective and collaborative
management of organisational culture.
PRE-PRESS
Our advanced computer-to-plate technology increases
effciency and eliminates waste. The installation of the
latest Kodak Prinergy Connect PDF workfow and Kodak
Insite remote soft proofng approval system ensures
full integration of both gravure and heatset web offset pre-
press departments so that clients have ready access to both
technologies to print their products. Clients can send material
electronically and sign off their fnal printers proof via a
securitised website from anywhere in the world.
GRAVURE
Paarl Media Cape offers high-tech industrial reproduction
processes for high volume gravure production together with
stringent checks and cylinder proofng measures to ensure
consistent and perfect quality before going to print.
HEATSET WEB OFFSET
Two Kodak Magnus VLF platesetters for heatset web offset
plate production, provide clients with backup capability
to ensure no delays in plate production to get material to
press as fast as possible. New System Brnner spectometer
technology provides accurate plate colour measurement to
meet international Fogra ISO 12647-2 certifcation standards.
The PECOM station automatically transfers ink tonal values
to the press and automatically resets the folder structure to
facilitate fast, consistently accurate production.
More to print than ink...
Automatic cassette loading produces up to forty
64-page manroland Lithoman plates per hour on
the Kodak Magnus VLF platesetters.
One hour from material fle received to press.
The frst web printer in South Africa to obtain
Fogra ISO 12647-2 certifcation for colour proofng.
Dedicated backup server rooms to protect
clients material.
14
64-PAGE
manroland
LITHOMAN
HEATSET WEB OFFSET
The 64-page manroland Lithoman with
1156mm cut-off is suitable for commercial
work and magazine printing.
The 48-page manroland Lithoman with
1156mm cut-off is ideal for magazines and
catalogues. It features inline gluing,
stitching, trimming and stacking
capabilities, and is equipped with a double
parallel folder to accommodate folding of
publications.
The 16-page manroland Rotoman with
578mm cut-off prints up to 65 000 full
colour copies per hour. Equipped with a
sheeter, it is perfect for magazine cover
work up to 250gsm. It allows for a ffth
colour, encapsulated fragrance applications
or spot varnish fnishes.
72-PAGE
CERUTTI
GRAVURE
PRESS
The 72-page Cerutti includes
broadsheet, inline folding
and fnishing capability. Its
unique dual folder system
provides additional fexibility in
production.
The 48-page Cerutti includes an
inline folder.
The 48-page KBA gravure has
inline fnishing and broadsheet
capability.
PRINTING
GRAVURE
The fexibility of Paarl Medias gravure presses allows for
an extensive range of formats and pagination including
4- to 72-page A4, A5, tabloid and broadsheet printing.
A wide variety of paper from 45gsm typical newsprint to
115gsm high quality coated paper can be accommodated
with high quality fnishes delivered on even low
grammage paper. Inline gluing, trimming and stitching
capabilities enable the delivery of fnal products directly
off the press.
More to print than ink....
72-Page Cerutti Gravure Press weighs 400
tons and is 3-storeys high.
It takes only 45 minutes to print paper reels
weighing up to 3 tons.
It can print 3 million pages per hour.
WEB
The heatset web offset presses offer quick makeready
and fexible formats from A4, A5, tabloid, broadsheet
and delta sizes. High quality coated, uncoated or
mechanical and newsprint paper ranging in thickness
from 40gsm to 200 gsm can be accommodated. They
are equipped with a QuadTech Colour Control system,
Brnner Flight Instrument Control, Multicam cut-off
and Register Control System, which simultaneously
manage dot gains, mid-tones and gray balance. Each
print copy matches the signed-off proofs according
to ISO certifed standards. All the heatset web offset
presses are equipped with Planatol inline gluing and
log stackers and automatic palletisers to speed up the
delivery of material.
More to print than ink...
The 64-page manroland Lithoman can deliver
up to 45 000 64-page copies per hour.
The 48-page manroland Lithoman delivers a
full colour stitched or glued 48-page A4 in a
single process.
Scanning cameras on heatset web offset press
check colour and print registration 30 times
per second and automatically adjust the press.
POST-PRESS
A comprehensive fnishing facility ensures products
are folded, bound and packed ready for distribution.
Two Steinemann UV coaters have been installed for
convenient in-house production and three Kolbus Publica
PUR Binders (18 000 speed) provide huge perfect binding
capacity. Their image recognition software automatically
reviews each section to guarantee accurate collation.
Two Mller Martini Tempo (18 000 speed) and two Mller
Martini Prima Plus (14 000 speed) saddle stitchers cater
for large volumes and different formats.
Versatile mailing equipment is used for inserting,
bagging and labelling, and an expanded store and
handfnishing area, staffed by enterprise development
initiatives, cater for all the hand inserting and fnishing
requirements whilst providing employment for previously
disadvantaged people.
AWARD-WINNING PERFORMANCE
Recipient of the 2006/7 International European Roto-
gravure Associations (ERA) Publication Gravure award
and ERA commendation.
More to print than ink...
Largest binding facility in Africa.
Kolbus Publica PUR binders can perfectly
bind 300 tons per hour.
12 million inserts per week.
5 generators produce 4.5KW of backup power.
PRINTING RESPONSIBLY
The solvent, Toluene, is recovered during the
gravure printing process and sold back to the
ink manufacturers for re-use while the used
gravure copper skins from engraved cylinders
are recycled.
Integrated Regenerative Thermal Oxidiser on all
the heatset web offset presses eliminate harmful
emissions and improve energy comsumption.
All the heatset web offset presses run alcohol-free.
100% clean air is recirculated back into the
work place with the new energy effcient
HCKER waste and dust extraction system.
14 000 tons of paper recycled per annum.
1. LOWRES
THE
manroland
OCTOMAN
8-PAGE
PAARL MEDIA PAARL
sheetfed
adjective
A printing press that feeds sheets of paper rather than a continuous roll or web. Including an inline reel-
to-sheeter on a sheetfed press provides the fexibility of formats and folds of a sheetfed press with the
effciencies of printing on reel material.
Using special inks and varnish, a combination of sheetfed presses provides fexibility in delivering high
quality results for books, specialised magazines, commercial work and fnancial reports.
book web
adjective
Specialised book press that combines the fexibility of a sheetfed press and the cost benefts of the heat-
set web offset technology.
High quality books, magazines and commercial work
Paarl Media Paarl
The development of our business involved a detailed analysis of our
prospective clients work, as well as a comprehensive evaluation of the
industrys leading products to ensure that the best available technology
and systems were selected for pre-press, press and bindery.
PRE-PRESS
Advanced computer-to-plate technology with the latest
Prinergy Connect PDF Workfow and Kodak Insite remote
soft proofng approval systems optimises effciency and
turnaround.
Content approval is simplifed with fast, high quality
proofs in 16 A4 page sections, imposed and stapled. The
proofng system produces double-sided paginated proofs
for complete accuracy on every job.
PRINTING - Sheetfed
The Komori high-performance press-inking system and
fully automated plate changing capability reduces
job change over time and keeps waste to an absolute
minimum. The double-sized perfecting cylinder systems
and a unique sheet path design ensure smooth, consistent
sheet fow, preventing sheet curl, reduced scuffng with
high register accuracy for superb quality double-sided
printing. Reel to sheet systems cut down turnaround
times, as paper no longer needs to be sheeted before
printing can start.
PRINTING - Heatset Web Offset
The manroland Octoman 8-page true A4 heatset press
with 6 colour printing is perfect for long run A4, A5,
A6, DL and square commercial work, such as direct
marketing and promotional material. The additional
printing units allow for the application of a spot
colour, varnish or encapsulated fragrance. Further
inline capabilities include folding, gluing, trimming,
perforating, die-cutting and numbering units. Re-
wettable glue can be applied on specialised products.
The manroland Polyman 16-page true A4 heatset press
offers multicolour printing for long run commercial
and bookwork.
More to print than ink...
An Epson 9900 ISO proofer with built-in colour
spectrophotometer produces full size colour
certifed proofs.
The Alwan print standardiser system
constantly calibrates the presses to ensure
that printing always matches the ISO 12647-2
standard proof.
Coated and uncoated paper stocks from 90gsm
to 350gsm, including certifed environmentally
sustainable paper stock options.
Innovation and a dynamic range of press and fnishing
capabilities, continue to give us the fexibility to deliver
high quality end results of nearly any format, from direct
mail to sophisticated coffee table books.
Our strong client focus and partnership approach ensures
we develop effcient, creative printing solutions that add
true value for each clients specifc requirements both
locally and across the continent.
20
The Komori Lithrone S104P 10-colour long
perfector with reel to sheet system is used
for high quality, full colour magazine or
commercial work. A 5th and 10th unit can
add an additional spot colour to achieve a
specifc colour spectrum or oil varnish. The
perfector unit allows for printing on both
sides of a sheet.
The Komori Lithrone S840P 8-colour long
perfector with reel to sheet system delivers
four over four printing and is ideal for high
quality, full colour magazine or commercial
work, including long and short run
specialised products.
The Komori Lithrone S640C 6-colour with
anilox coater provides high gloss printing
and heaving ink loading for covers and high
quality commercial work, including two
spot or corporate ISO certifed colours.
KOMORI
LITHRONE
S104P
IMAGE 901 backprinter
Specialised Book Press
In addition to full colour publications, Paarl Media Paarl has invested
in a unique hybrid, high volume book press, especially designed for
fast turnaround of single colour books. It combines the fexibility of
formats and folds of a sheetfed press with the cost benefts of heatset
web offset technology, catering for A4, A5 and narrow crown sizes.
This press is capable of printing back to back, resulting in a 64-page
section produced in one impression. An inline Mabeg reel to sheeter
allows for longer production runs, less stoppages and more accurate
folding. Reel material is also often more cost effective and reduces
trim waste. An inline slitter increases volume output by slicing the
sheets in half before they reach the delivery so that two 32-page
sections can be printed at once.
More to print than ink...
Printed and packed 35 million ballots in 3 days Nigerian presidential
election.
Fully automated plate-changing systems on the Komori press change
eight plates in less than four minutes at the touch of a button.
Start-up paper waste reduced to only ten sheets on sheetfed presses.
The manroland 901/1 is the frst specialised book press of its type in Africa.
A full colour 16-page A5 brochure can be delivered fully completed with
inline variable numbering, spine gluing, perforation, re-wetabble gluing,
spot varnish and encapsulated fragrance directly off the manroland
Octoman press.
Full Bindery
Paarl Media Paarls extensive bindery offers stitching,
sewing, trimming and folding equipment, as well as the
advanced Kolbus Publica PUR binder which can process
up to 12 000 copies per hour.
The Kolbus contains a bookblock ready system for soft
cover books and features image recognition software
that automatically reviews each section to guarantee
accurate collation. PUR binding provides a product
with signifcantly higher page pulls and fex capability,
thereby enhancing the lay fat effect of the book. PUR
will not give way like the hot melt glue used in perfect
binding. It provides the same pull test strength as thread
sewing and is extremely strong and durable, lasting the
same time than thread sewn, at about half the cost.
Additional fnishes such as UV varnishing, laminating,
foiling and embossing ensure high end results.
PAARL MEDIA KZN
Effcient, high quality delivery of magazines and commercial work
Heatset Web Offset
adjective
Heatset web offset is an offset printing process in which a continuous roll of paper is fed through the printing
press. Pages are separated and cut to size after they have been printed.
Heatset web offset printing is used for high-volume magazines, retail inserts, catalogues and brochures.
PRE-PRESS
Our Kwa-Zulu Natal plant is equipped with a fully automated
pre-press set-up incorporating stringent colour controls,
which carries International Standards Organisation (ISO)
accreditation.
It is also equipped with the latest Prinergy Connect PDF
Workfow that facilitates seamless digital fle transfer
between operations. The Kodak InSite soft proofng systems
enable our clients to have full ownership and control of
their material. Additionally, our online remote proofng
approval system facilitates the checking and approval of
Clients fles on a virtual platform prior to the generation
of printing plates.
Our high-tech large format printers using UltraChrome
HDR pigment inks are backed by EFi proof rip and built in
SpectroProofer to meet Fogra ISO certifcation standards.
We use the Luscher Dual Xpose Plate setter. This is advanced
computer-to-plate technology whereby printing plates are
imaged on a fully automated line using the latest Thermal
Laser Technology, thus enabling us to achieve optimum
accuracy and maximum productivity.
Creating a national footprint
Over the past 10 years, our growth has seen
the Paarl Media Group expand from our original
business in the Cape to regional plants nationwide.
Our proud milestone has been the commissioning of the Gauteng heatset web offset factory, which only in its ffth year
of operation, is looking to a third expansion phase.
The establishment of sales offces in Durban and Port Elizabeth in 2007 further broadened our national footprint and
intensifed regional demand in KwaZulu-Natal necessitated the opening of a new plant in the area.
Paarl Media KwaZulu-Natal
PRINTING
To leverage our competitive service, we have installed
two manroland Rotoman heatset web offset presses.
These are extremely reliable and effcient in delivering a
vast range of print formats to match market requirements
at 50 000 copies per hour.
They are also linked to the production planning offce
through the Technical Pre Press (TPP) station, which
enables the planning personnel to preset the parameters
before the order is sent to the press.
Both presses are equipped with innovative QuadTech
register and ink control systems with System Brnner
gray balance control to guarantee consistent, accurate
ISO certifed colour throughout the press runs.
Furthermore, they have long drying ovens that allow the
drying temperatures to be lowered. This ensures that
the end result is colours of richer and truer hues than
would otherwise have been possible when running at
high speeds.
The quality enhancement features of these presses are
further emphasised by the installation of multiple chill
rolls that help to reduce thermal shock during the high
speed printing process.
The Rotoman 2 is also equipped with a dedicated JetWeb
coating unit, which provides a further enhancement on
this press by giving it the ability to provide high gloss
coating through an in-line aqueous varnish facility for
covers of self-cover brochures.
One press is also equipped with in-line fnishing capability
since the advanced folders are able to provide a wide
range of folding options and the capabilities of glue and
trim off press. It is also equipped with a high speed
VITS sheeter, which further facilitates the extension of
folding and downstream fnishing options.
Printing responsibility
Megtecs Dual-Dry TNV Regenerative Ther-
mal Oxidiser (RTO) technology installed on
the web presses to eliminate emissions inline
with stringent international standards.
A HOCKER paper waste and dust extraction
sysem offers reliable, energy effcient opera-
tion for the collection of all paper waste for
recycling.
26
The advanced Lscher Dual Xpose! Platesetter
with plate handling system and unique violet
laser technology ensures fast, accurate repro-
duction of plates to get material as quickly as
possibly to press.
LSCHER
DUAL XPOSE!
PLATESETTER
The two 16-page manroland Rotoman
N presses have the Power Plate
Loading (PPL) feature that facilitates
the fast changeover of 8 plates in
less than 5 minutes without causing
web break. As well as being able to
offer clients a wide range of print
formats, these presses are also able
to accommodate a comprehensive
list of paper grammage options -
from 45gsm up to a 200gsm stock.
16-PAGE
manroland
ROTOMAN N
MAGAZINE A4
DIGEST A5 4/8/16/32 pp
4/8/16 pp
4/8/16/32 pp
12 pp
4/8 pp
4/8 pp
4/8/16/31 pp
4/8/16 pp
4/8/12/24 pp
8/16/24/48 pp
24pp
SADDLE STITCHED
PERFECT BOUND
TRIMMED
UNTRIMMED
DIGEST A5
KING SIZE
TABLOID A3
TABLOID A3
LANDSCAPE A5
LANDSCAPE A4
TALL BOY
DL
DELTA
275 x 210
210 x 137
210 x 135
280 x 280
420 x 280
410 x 289
135 x 210
210 x 280
275 x 137
180 x 100
180 x 210
SIZE DESCRIPTION PAGINATION FINISH
Products direct from the Rotoman Presses Launch of Kwazulu-Natal Operations
Before considerable investment into the Kwa-Zulu Natal
Heat set Web Offset facility could be made, some key
criteria had to be met to justify this level of spend during
an economic downturn.
This was mostly satisfed by the need to maintain our
commitment to an ethos of printing is personal. The
establishment of this facility would help maintain and
strengthen our client relationships and the business
model would link in with our continued efforts to advance
environmentally sound solutions in an effort to reduce our
carbon footprint.
The KwaZulu-Natal plant a R200 million investment - also
represents our business confdence in the region, and to
which we will initially contribute in excess of 70 direct
permanent jobs and 120 indirect and semi-permanent jobs.
POST-PRESS
Two Mller Martini saddlestitchers and a Muller Martini
Normbinder, provide saddlestitching and perfect binding
capacity. Further capabilities include the handling of
specialised fnishes, insertions and bagging.
PAARL MEDIA GAUTENG
heatset web offset
adjective
Heatset web offset is a printing method is which a continuous rolls of paper is fed through the printing press.
It is a heatset process whereby ink is dried rapidly by forced-air heating.
Used for medium to high volume magazines, retail inserts, catalogues and brochures.
High quality commercial and magazine web printing
Our plant was established fve years ago to specifcally
service the Johannesburg market. Critical to our clients
is our ability to deliver high quality products with fast
turnaround. Being geographically closer and equipped
with powerful technology allows us to cut production
lead times and deliver quicker to them.
Paarl Media Gauteng
We have seen tremendous growth and to meet demand, we have added a new printing press each year and expanded
our bindery to provide up to 70 000 tons of capacity annually. Developing our people is also a core focus as the
expertise of our team is a key differentiator in the service we offer. Through innovative thinking, we will continue to
adapt our business to most effectively meet the business opportunities that will arise moving forward.
PRE-PRESS
Designed to deliver fast, accurate pre-press and our
advanced computer-to-plate technology, including
remote digital proofng, increases effciency and
eliminates waste. Stringent colour checks are carried to
meet ISO certifcation standards.
PRINTING
With our focus on the printing of high to medium volume
commercial and magazine work, including the 80-page
heatset web offset press, and the three manroland
Rotoman presses enables a wider range of formats and
pagination on nearly any stock of paper from 40gsm to
200gsm.
All the presses are equipped with the latest QuadTech
Colour Control System with Brnner Flight Instrument
Control, Multicam cut-off and Register Control system to
deliver perfect colour and registration from start to fnish.
BINDERY
Saddlestitching, perfect binding and Bhrs polywrapping
and bagging capabilities ensure we are able to deliver
a wide variety of products. Large capacity is offered
with three fully automated Prima Plus saddle stitchers,
a Mller Martini Normbinder and a Kolbus Publica PUR
binder. The image recognition software on the Kolbus
automatically reviews each section to guarantee
accurate collation, and additional hoppers on Prima
Plus saddle stitchers cater for higher pagination.
High-gloss fnishing is provided by the Steinemann UV
varnishing machine.
More to Print than Ink
Two Screen Platerite Ultima 63 000 ZX
platesetters with fully automated plate loading
can produce 689 Rotoman plates or 33 very large
format Lithoman plates per hour.
The 80-page manroland Lithoman prints up to
45 000 80-page copies per hour.
Largest press of its kind in Africa.
The Kolbus Publica PUR binder can process up to
15 000 copies per hour.
32
The 80-page manroland Lithoman
has varying reel widths of 860mm to
2060mm, providing extended capacity
and format fexibility for A4, tabloids,
broadsheets as well as narrower
formats. Inline gluing, trimming,
stitching and inserting functionality
ensures quick turnaround times with
a unique balloon folder, which allows
for tabloid sections to be inserted
into broadsheet sections.
Three 16-page manroland Rotomans
with 578mm and 620mm cut-off offer
quick make-ready and printing speeds
of up to 65 000 full colour copies
per hour. A ffth colour and/or spot
varnish are provided for products
such as magazine covers.
80-PAGE
manroland
LITHOMAN
PAARL COLDSET
coldset web offset
adjective
A heatset web offset printing process in which ink is allowed to dry naturally through
absorption.
Five of the most technologically advanced coldset plants across the country deliver
fast, economical printing of uncoated papers for newspapers and commercial products.
Fast, economical printing of uncoated papers
Paarl Coldset
At Paarl Coldset, we cater for large and smaller print runs in broadsheet, tabloid and quarter fold formats for
high pagination and thinner newspaper and commercial products.
The consolidation of the Paarl Coldset infrastructure to centralised operations in fve major plants based
in Johannesburg, Cape Town, Durban and Port Elizabeth, untied the resources to enhance the technology
implemented across the operation and focus on the skills development of our team.
Clients, therefore, beneft from the highest quality coldset printing delivered more effciently.
Newspapers:
Size: Broadsheet: 410mm x 578mm;
Tabloid 410mm x 289mm.
Pagination: Minimum 2 Page tabloid (trimmed);
Maximum 144 page tabloid (single section).
Inserts: 4 to 6 inserts mechanically inserted into one
section, then pre-inserted or by hand depending on
production window; Maximum Size - main body size
(standard 410mm x 289mm); Minimum Size A5.
Compact Product:
Size: 340mm x 240mm; 350mm x 250mm.
Trimmed and stitched.
Quantity: 500 000 copies per day subject to press
availability (only Cape Town & Johannesburg).
Paper: 48.8gsm newsprint, 70g Constat.
Retail:
Size: Broadsheet: 410mm x 578mm; Tabloid:
410mm x 289mm; Square Tabloid: 380mm x 289mm;
350mm x 289mm; Quarter Folded: 268mm x 195mm.
Inline high- speed trimming.
Paper: 48.8gsm newsprint, 70g Constat Bond.
Inline high speed stitching in Johannesburg.
Mechanically inserted.
Advanced workfow and colour reproduction
The installation of Agfas Arkitex, a powerful workfow
system for newspaper production across all the plants,
reduces turnaround times.
Advanced production tools allow fast, more effcient,
complete layout, page pairing and soft proofng to
accelerate the approval places. Pages can be viewed,
corrections made and approvals tracked to eliminate
errors.
Web-based communication keeps all the departments
informed for increased productivity. The Arkitex
Sublima advanced screening delivers exceptional colour
reproduction in newspaper printing, capturing the fnest
details and the most vibrant colours.
Natal Witness Printing Plant
The Paarl Media Groups geographic positioning strategy
will be completed with the proposed acquisition of the
Natal Witness printing plant in Pietermaritzburg, subject
to regulatory approval. This technologically advanced
production facility consists of 2 Kodak Trendsetter NEWS
thermal computer-to-plate lines with the capacity of
140 plates per hour/ This serves the KBA Comet 70 press
installation, consisting of 6 towers and 2 folders, capable of
producing 60000 copies per hour. Planned capacity upgrades
include the installation of 4 Cromoman towers and 2
additional folders with 2/3 mechanised inserting lines.
Award winning performance
In testimony to their level of skills and technology
employed, Paarl Coldset won awards for the printing of
Die Burger, Volksblad and Naweek Beeld at the 2010 Mondi
Shanduka Awards.
The Naweek Beeld was also awarded membership to the
prestigious International Newspaper Colour Quality Club
(INCQC), the only worldwide quality benchmarking test
for international newspaper printing, was awarded for the
printing of the Naweek Beeld for 2010, 2011 and 2012.
More to print than ink
Agfa and Krause plate making equipment can
sustain an output speed of more than 200
plates an hour per line.
1 000 000 copies printed per hour.
Capacity to produce 12.1 tonnes per hour
across the fve plants.
The height of the largest press is 16 metres,
approximately 5 storeys.
800 tabloid pages printed simultaneously.
Longest press is 54,5 metres.
36
Johannesburg
manroland Geoman 8 Towers
3 Folders Uniset 9 Towers
2 Folders
Cape Town
manroland Geoman
4 Towers 2 Folders
Uniset 4 Towers 2 Folders
Port Elizabeth
manroland Uniset 3 Towers
1 Folder Cromoman 1 Tower
1 Folder
Durban
manroland Cromoman
4 Towers 2 Folders
KBA Comet 6 Towers 2
label
noun
An item such as a small piece of paper
attached to an article to designate its
origin, contents, owner, use or destination.
Award winning UV fexo self-adhesive
label printing solutions.
PAARL LABELS
Innovation in label printing
From cost effective solutions for high volume/low price producers
to technologically advanced innovations to enhance products in the
premium price ranges, Paarl Labels innovative approach is to push
the boundaries of technology to exceed their clients' expectations.
We have invested substantially in equipment, time and new
materials to fnd market-related solutions for all price categories,
keeping a close eye on clients needs to fnd the right solutions
for them.
With our ISO 9001:2000 certifcation, Paarl Labels has
implemented effective quality management throughout
the production process to focus on continually
improving client satisfaction and deliver award winning
performance.
Using the same print technology that produces UV-fexo
self-adhesives, Paarl Labels is also now able to offer a
wet glue format. These are easier to wash off so that
bottles can be reused. Furthermore, higher production
speeds and lower costs per label are possible.
More to print than ink....
Security holograms prevent fakes and
imitations, giving the label an authentic look.
Naturally torn effect at the top of the label
to provide a more earthy look.
Creating art images on metal foils to give cost
effective subtle details to for example a logo.
Speciality papers including recycled and top
of the range paper with a more fbrous fnish.
A super white uncoated paper, ICE, providing
unrivalled ice bucket properties, opacity and
application qualities.
Back printing whereby the print image
appears clearly on the adhesive side of the
label as well.
Variable data can be added on the Smartdate
overprinter.
Repeated recipients of the Rafatac Wine
Labels of Excellence Awards.
38
MPS
9-COLOUR EC
REEL TO REEL
The MPS 9-colour EC reel to reel UV
fexo press allows the most intricate
of designs to be produced effciently.
Hot foil, cold foil, rotary screen,
laminating, embossing, UV varnishing
and die-cutting done inline give a high
quality fnish to the product in the best
possible time.
The Nilpeter FA 2500 8-colour UV
Flexo reel to reel press is capable of
doing hot foil, laminating, backprinting,
embossing, UV varnishing and die-
cutting inline.
The Nilpeter FA 2500 6-colour UV
Flexo reel to reel press offers hot
foil, embossing, UV varnishing and die-
cutting inline.
CORPORATE SOCIAL
INVESTMENT
Investing To Create Change
Our expanding Corporate Social Investment programmes are
aimed at driving development and creating positive change
through a combination of printing support and/or fnancial
investment in projects. We are proud to highlight some of
these initiatives.
Established a R10 million Bursary trust for
previously disadvantaged students from the
Paarl community.
Assisted the Miqlat learning centre in Paarl
East with much needed learning and computer
resources.
Sponsor the printing of the Big Issue, whose
vendor force is comprised of mainly long-term,
unemployed people from informal settlements
on the outskirts of Cape Town.
Supports the International Federation of the
Red Cross and Red Crescent Societies for food
security programmes.
Implemented a Food Tent at The House
orphanage in Berea, assisting with the provision
of nutritional food and skills development.
Provided fnancial support and blankets to The
Haven Care Centre.
Sponsored a vehicle for Amado, an organisation
that empowers disabled children through animal-
assisted therapy.
Donated School clothes, stationery, food and
blankets for HIV/Aids orphans cared for by
Prissked Charities.
Provided support to the Carel du Toit Centre,
which cares for children with hearing disabilities.
Contribute annually to the Boland Christmas
fundraising project in aid of the Western Cape
Community Chest.
Subsidised printing for the Society of the Blind
and Tsiba College.
Assisted Monte Christo Ministries Food centre in
their feeding schemes at schools, soup kitchens
and hospitals.
Continuously donate to the National Sea Rescue
Institute and SOS Childrens Village.
Partnered with the Paarl Mountain Project to
create employment opportunities through
clearing the mountain from alien vegetation.
40
PAARL MEDIA ACADEMY
OF PRINT
As the most technologically progressive printing group in the country,
Paarl Media have worked hard to develop skills and provide the expertise
that will harness the talent of new generations.
As part of this initiative, a full college, with premises in Paarl, will
offer the most modern training facilities available in the country,
accomodating up to 450 students.
The Paarl Media Group learnership programme is
frmly entrenched at all our plants offering training by
experienced facilitators, coaches and mentors from
within the group, to provide critical skills to keep pace
with the rapid advancements in technology.
In collaboration with the Printing Industries Federation
of South Africa (PIFSA), a revised and upgraded printers
trade curriculum was completed in 2009. Training
Modules carry local and international accreditation from
the South African Qualifcations Authority (SAQA) and the
City and Guilds of London Institute.
Moreover, the group Management Trainee Programme
offers previously disadvantaged graduates an opportunity
to enter the organisation at trainee management
employment level.
Skills transfer and shared learning
A vision of shared learning, cross training and constant
assessment, based on specifc set standards, will ensure
critical skills transfer to facilitate the development of
highly skilled and effective employees.
The curriculums holistic approach includes an overview
of Paarl Medias Conditions of Employment, Health
& Safety, Technical Training Theory and the Practical
Application thereof.
A range of assessment tools and criteria are monitored
to demonstrate and establish competence for trainees.
Skills development focuses on the following
core felds:
Heatset
Heatset Web Offset Coldset
Roll Label Flexography
Mechanised Bookbinding
Gravure Machine Minding
Photogravure Cylinder Processing
Sheetfed Offset
Soft Skills Training
42
Apprenticeship Prospectus and Information
The Paarl Media website offers comprehensive
information and our recruitment process is
conducted online.
Advertisements are placed internally and
externally, on Paarl Medias website and in
local newspapers.
Applicants complete psychometric
assessments and interviews are conducted to
determine trade readiness.
The frst 6 months of training are spent at the
Academy of Print where the Fundamental
component is completed.
The following 18 months are spent at one of
Paarl Medias plants where the core component
of the training is completed.
The last 12 months are spent at another Paarl
Media plant where the experiential learning
component is undergone.
Learner competence is assessed on completion
of training.
To apply, prospective candidates can visit our
website on www.careers paarlmedia.co.za
When printing, there is more to consider than just the
job itself. Here, at Paarl Media, we realise that without
natural resources there would be no printing, and thats
why we strive to be an environmentally responsible group.
We are minimising our carbon footprint by eliminating
harmful emissions and recycling waste products.
In fact, we were the frst printer in Africa to achieve
FSC CoC certifcation, an independent international
verifcation. This means we can trace any of the products
we print back to their point of origin. As a result, you
can be assured of well-managed forestry and recycled
sources when partnering with Paarl Media.
Leaders in green
Green Print Technology
Our approach to business is one that merges the
best solutions for our clients and the industry as
a whole.
At Paarl Media, we have recognised the impact of
print production processes on natural resources
and are proactively implementing practices and
policies to minimise these effects.
PRINTING RESPONSIBLY
With over R100 million invested in environmentally responsible
practices, our clients are reassured that their work will be delivered
with the least impact to the natural environment without compromising
on the quality of printing.
Our green logo is a symbol of this commitment, and reinforcement
of our proactive management when it comes to:
Effcient production
Reduced energy and water consumption
Eliminating emissions
Continuous waste reduction
Recycling
Eliminating Emissions
In 2005, Paarl Media led the way with the installation
of centralised Regenerative Thermal Oxidisers (RTOs)
on all web presses to eliminate emissions in line with
stringent international standards.
Alcohol-free Printing
Paarl Media has implemented an alcohol-free printing
process on all its heatset web offset presses, which
offers a healthier and more cost effective production
process with a high quality end result.
Green Inks
Volatile Alcohols are used in various inks and other
coatings as a solvent to control viscosity and drying
characteristics. Paarl Medias sheetfed presses run
on Mineral Oil and volatile organic compound (VOC)
free offset inks, based on vegetable oil. These provide
excellent stability and performance, even at the highest
press speeds.
Copper Skin Recycling
The used gravure copper skins from engraved cylinders
are recycled. Copper is also recovered from the excess
that builds up in the copper sulphate solution used in the
plating process.
Toluene Recovery
Toluene is a thinning agent used in gravure inks to ensure
low viscosity to allow the ink to be drawn easily into
the engraved cells in the cylinder and then transferred
onto the substrate. This also facilitates rapid drying
to prevent smudging as the volatile solvents quickly
evaporate in the hot dryers after each printing station.
At Paarl Media, up to 95% of the Toluene is recovered and
sold back to the ink manufacturers for reuse.
All waste paper is recycled with baling
facilities at all the major plants. Paarl
Media is the only printer in Africa with
closed loop paper and dust extraction
systems in their press halls and binderies
from Kongskilde and Hcker.
Sustainable paper
All paper is sourced from certifed suppliers, including local and international ranges of
environmentally friendly paper stock.
Effcient ink usage
Pump inking systems across all presses decrease wastage. Ink is delivered in bulk,
reducing transport requirements and impact on landflls.
Reducing your carbon footprint
Printing at one of Paarl Medias plants closest to you reduces delivery distances. Digital
workfow, including digital proofng, as well as a full in-house service from pre-press to
dispatch further limits your transport requirements.
Effcient production
Advanced automation throughout the production process lowers energy consumption,
materials used and waste generated.
More to print than ink
Paarl Media was the frst African printer to receive FSC (Forest Stewardship
Council) CoC (Chain of Custody) certifcation. This serves as an independent
international verifcation that the products printed can be traced back
from their point of origin to responsible well-managed forestry, controlled
and recycled sources.
New sheetfed presses include technology which reduces paper usage per
press by approximately 750 000 sheets per year equivalent to the
conservation of approximately 1040 trees per year per press.
The energy-effcient Kongskilde and HCKER system ensures 100% dust
free air is released into the environment.
Energy recovered during the regenerative thermal oxidisation process is
re-utilised in the drying section, thereby vastly reducing gas energy
consumption.
PAPER RECYCLING
46
COLD
PAPER
RECYCLE
The signifcance of celebrating a milestone is
that it offers a pause for refection.
It gives us the opportunity to look back on
the past, examine the lessons offered, and to
strengthen and consolidate the business practices
that worked well.
It presents the chance to steer a course into
the future, one that brings together our best
aspirations built on a solid knowledge base and
backed by the technology and skills invested to
this point.
And so it is, that we look to the 10 year celebration of Paarl Media through the lens of
the past, but with a frm view of the future of the company.
We are enthusiastic about the trajectory of growth that will enable us to provide an
even more comprehensive and wide reaching service for our clients throughout South
Africa.
It is with great anticipation that we wait to see how our investment in innovative
business solutions will be received initiatives such as Shoppers Friend, our ongoing
advancement of green print technology and the launch of our KwaZulu-Natal plant,
to name a few.
We are also eager to follow the progress of our bursary students, 26 of who will
graduate this year. Our R10 million Bursary Trust forms part of our ongoing commitment
to develop the talent pool and skills base of our youth.
We hope that as we charter new ground in printing - that you will be part of the
journey with us.
And that we can look forward to working together with you to create innovative
business products, forge longstanding relationships and shape a wonderful, greener
and exciting future.
STEERING THE
FUTURE
PAPER SP0NSORED BY UPM
The paper of UPM, the Helsinki-based forest products group, has been
awarded the European Union ECO Label - the EU Flower Certifcate for
its fne, magazine, bag and sack papers. This is the highest certifcation
for environment-friendly paper in Europe and includes UPM ECO paper,
which is made from 100% recycled paper at UPMs
PAPER SPONSOR
INK SPONSOR
INK SPONSORED BY COATES
Coates Brothers (South Africa) Limited
manufactures and sells printing inks, synthetic
resins and industrial surface coatings. It
imports and distributes products for the
printing and graphic arts industries.
PRINTING OF THIS PUBLICATION SPONSORED BY manroland
manroland AG is the worlds second largest printing systems
manufacturer and the worlds market leader in heatset web offset.
Manufacturing presses since 1845, they now have more than 100
branches, offces, sales and service partners to take care of over 200
countries worldwide.
PRINT SPONSOR
Western Cape Sales 27 21 550 2400
KwaZulu-Natal Sales 27 31 714 4700
Eastern Cape Sales 27 41 379 3970
Gauteng Sales 27 11 201 3400
www.paarlmedia.co.za
Paarl Media Group (Pty) Ltd
T 27 21 550 2500
T 27 21 870 3800
E info@paarlmedia.co.za
PO Box 37014, Chempet, 7442
10 Freedom Way, Milnerton, 7441
T 27 21 877 6200
E info.labels@paarllabels.co.za
PO Box 248, Paarl, 7620
22 Oosterland Street,
Dal Josafat, Paarl, 7646
T 27 21 870 3800
E academy@paarlmedia.co.za
PO Box 248, Paarl, 7620
15 Jan van Riebeeck Drive,
Paarl, 7646
T 27 11 201 3400
E sales@shoppersfriend.co.za
PO Box 1569, Kelvin, 2054
48 Milkyway, Linbro Park, 2196
T 27 11 713 9875
E info.coldset@paarlcoldset.co.za
PO Box 83594, South Hills, 2136
83 Heidelberg Road, Production
Park, Johannesburg, 2001
T 27 21 514 5500
E info.coldset@paarlcoldset.co.za
PO Box 417, Paarden Island, 7420
5 Lynx Road, Paarden Island, 7405
T 27 21 870 3600
E info.paarl@paarlmedia.co.za
PO Box 248, Paarl, 7620
15 Jan van Riebeeck Drive,
Paarl, 7646
T 27 21 550 2400
E info.cape@paarlmedia.co.za
PO Box 37014, Chempet, 7442
10 Freedom Way, Milnerton, 7441
T 27 11 201 3400
E info.gauteng@paarlmedia.co.za
PO Box 1569, Kelvin, 2054
48 Milkyway, Linbro Park, 2196
T 27 31 714 4700
E info.kzn@paarlmedia.co.za
PO Box 10624, Ashwood, 3605 52
Mahogany Road, Mahogany Ridge,
Westmead, 3610