innovations in printing -solutions for short and long...
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KBA Metal Decorating
Gerhard Grossmann, Area Sales Director
Innovations in Printing - Solutions for short and long run jobs
General situation - Demands
© KBA • MetalPrint October 2015 Seite:2
Don‘t buy printing machines for only one discipline like long or
short runs – you have always mixed situations in your plant – you
need both!
Long runs
Highest output
50%? 50%?
70%? 30%?
30%? 70%?
Short runs
Fast make-ready times
What is your ratio?
Different requirements at short or long runs requires different
solutions
Long runs
Highest output
•High printing speed
•Feeder for high speed and sensors for high safety
•Ink/Water stability
•Color stability during printing and stops
•Fast pallet changing
•Solution for waste sheet handling
•Memory for printing condition
•Fast blanket wash-up
Short runs
Fastest make-ready times
•Fast plate change
•Parallel changeover processes
•Fast wash-up of blanket, rollers,
impression cylinder, Ink fountain
•Intelligent operating software
•Memory of set-up data
•Changeover process start during old job
is running
General situation - Demands
© KBA • MetalPrint October 2015 Seite:3
Different requirements at short or long runs requires different
solutions
Short runs
Fastest make-ready times
•Fast plate change
•Parallel changeover processes
•Fast wash-up of blanket, rollers,
impression cyl., Ink fountain
•Intelligent operating software
•Storage of set-up figures
•Changeover process start
during old job is running
Short runs
1
2
3
© KBA • MetalPrint October 2015 Seite:4
Fast plate change – FAPC
FAPC - Fully Automatic Plate Change / New overlay process for time savings
Change time: All units in 3 min. including register zeroing
Only at KBA – Full automatic plate change in 3 cycles � 3 x 1min = 3 min total
New
1
1 2 3 4 5 61 2 3 4 5 61 2 3 4 5 6
© KBA • MetalPrint October 2015 Seite:5
Fast plate change – DriveTronic SPC
DriveTronic SPC / simultaneous plate change system
• No intermediate drive elements such as gears and clutches
• Whole mechanical assemblies have been eliminated
USPNew
• Plate changing parallel to other make ready processes possible
• All units in ~ 1:15 min
Clip
show
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ap
ida 1
06
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© KBA • MetalPrint October 2015 Seite:6
Fast plate change - Advantages
Plate change time on a MetalStar 3 (4-Color)
1
© KBA • MetalPrint October 2015 Seite:7
Different requirements at short or long runs requires different
solutions
Short runs
Fastest make-ready times
•Fast plate change
•Parallel changeover processes
•Fast wash-up of blanket,
rollers, impression cylinder,
Ink fountain
•Intelligent operating software
•Storage of set-up figures
•Changeover process start during
old job is running
Short runs
1
2
3
© KBA • MetalPrint October 2015 Seite:8
Printing unit washing device
Overview of Blanket & impression cylinder washing device
CleanTronic (Option)
- One fixed washing bar
CleanTronic Synchro (Option)
2 independent washing bars
CleanTronic (Option)
- One mobile washing bar
USP
2
© KBA • MetalPrint October 2015 Seite:9
Make ready comparison
Simultaneous make ready processes
•Highest automation with DriveTronic SPC and CleanTronic Synchro
+ 69 % more productivity as the leading and best MetalStar before
2
© KBA • MetalPrint October 2015 Seite:10
Different requirements at short or long runs requires different
solutions
Short runs
Fastest make-ready times
•Fast plate change
•Parallel changeover processes
•Fast wash-up of blanket, rollers,
impression cyl., Ink fountain
•Intelligent operating software
•Storage of set-up data
•Changeover process start
during old job is running
Short runs
1
2
3
© KBA • MetalPrint October 2015 Seite:11
New ErgoTronic console
• Touchscreen operation
• Graphic user guidance
• Wallscreen (optional)
• Remote register
• Ink and dampening remote control
• Job-based saving of all
relevant press parameters
• Remote maintenance via Internet
• CIP3 interface
• Job change over program
• Ink run-in program
New modern Windows® operating system
3
© KBA • MetalPrint October 2015 Seite:12
Job Access
One button job change over programWashing device
•program select
Printing units
•plate change
•engage/disengage
•ink run up program
Substrate
•format/thickness
•front & side lay
All data settings can be done during the current production
3
© KBA • MetalPrint October 2015 Seite:13
Quick register solutions ACR / Plate ident New
• Automatic measuring spot
detection
• Automatic register control of all 3
register directions
Pre-registration• Register correction already before the
first print
• Make ready and waste savings
Plausibility checks• Job / Plates
• Plates / Printing units
• Plates / Color separations
• Language versions
ACR Plate ident
3
© KBA • MetalPrint October 2015 Seite:14
Long runs
Highest output
•High printing speed
•Feeder for high speed and sensors for high
safety
•Fast pallet changing
•Ink/Water stability
•Color stability during printing and stops
•Solution for waste sheet handling
•Storage for printing condition
•Fast blanket wash-up
Different requirements at short or long runs requires different
solutions
Long runs
1
2
3
© KBA • MetalPrint October 2015 Seite:15
DriveTronic feeder head
The next generation of the KBA-MP High-
Performance feeder head - Designed for up to
10,000 sheets per hour
•Minimum setting options required (Universal setting
for the majority of substrates)
•Simple operation, Low-maintenance
•Stepless, continuous pile lift ensures a constant
height for sheet feeding
•Quick change pallet system available with change
times close to zero without machine stop
•control of the machine via touch display with a clearly
arranged navigation
1
© KBA • MetalPrint October 2015 Seite:16
Infeed
New KunziMatic Registering System
Patented vacuum powered system for
precise registering of tin and
aluminium sheets to the front and side
marks at highest printing speeds
New SIS – Side lay free infeed system
Patented side lay free infeed system for
gerating more time for accurate registering
the tin plates.
1
One of the key advantages is that the feed
process in the front lays is not interrupted by a
sidelay process. Higher Speed – more
accurate registering and helpful for Scroll
© KBA • MetalPrint October 2015 Seite:17
Long runs
Highest output
•High printing speed
•Feeder for high speed and sensors for high safety
•Fast pallet changing
•Ink/Water stability
•Color stability during printing and stops
•Solution for waste sheet handling
•Storage for printing condition
•Fast blanket wash-up
Different requirements at short or long runs requires different
solutions
Long runs
1
2
3
© KBA • MetalPrint October 2015 Seite:18
Infeed
Old Inking systems, technology out
of the 60‘s
Modern Inking systems like KBA and
fast running paper printing maschines
2
• Design with the large diameter storage roller results in slow reaction time by zone setting changes and more waste sheets
• Danger for stripes and ghosting effects
• More sensitive for ink/water balance
• Faster reaction time by zone setting changes
• Better ink/water balance
• Lower ghosting and stripe addiction due to fettling effect of 3th. + 4th. form roller
• Approx. 99% of all new printing presses are based on multi roller systems except traditional Metal Decorating Machines
© KBA • MetalPrint October 2015 Seite:19
Inking unit
• Quick change ink duct foil or Nano surface available
• Faster-reacting inking unit
• Axial freedom of ink forme roller +/-7.5 mm
• Disengaging of unused inking units
(rollers stand still, savings of ink and drive energy)
• Ink train separation into 2 groups
• Vibrator frequency (1:3 / 1:6 / 1:12)
• Motorised adjustment of oscillation timing (stepless
during production)
• Ink run-in programs
• Differential drive for dampening form roller
(switchable during production)
New 2
© KBA • MetalPrint October 2015 Seite:20
Summary – Efficiency Sample Calculation
70% 30%
• MetalStar3-6, 6 Colours
• 20 jobs to do, 67,000 sheets
• Short run jobs � 70% = 14 jobs
• Long run jobs � 30% = 6 jobs
• Short run job 500 sheets, 4c + 2 spot colors, cleaning of
all cylinders and 2 printing units from job to job
Production speed: 5000 sph
• Long run job 10.000 sheets, 4c + 2 spot colors, cleaning
of all cylinders and 2 printing units from job to job
Production speed: 7400 sph
© KBA • MetalPrint October 2015 Seite:21
Summary – Efficiency Sample Calculation
• Short run job old 2c multi grip
• Long run job old 2c multi grip
Make ready Printing time No. jobs sum total sum
111 min
111 min
24 min
204 min
14
6
30,8 h
31,5 h62,3 h
• Short run job MetalStar 3
• Long run job MetalStar 3
18 min
18 min
6 min
81 min
14
6
5,6 h
9,9 h15,5 h
• Short run job MetalStar 2
• Long run job MetalStar 2
28 min
28 min
7 min
91 min
14
6
8,2 h
11,9 h20,1 h
~ 2 shifts
~ 3 shifts
~ 8 shifts
© KBA • MetalPrint October 2015 Seite:22
MetalStar 3 Summary
© KBA-MetalPrint • Stuttgart Seite:23
• The MetalStar 3 guaranteed a high printing quality at maximum speed
• And offers the widest range of possibilities to reduce make ready time
• Highly automized to reach the highest productivity
• The huge spread of individual configuration options allow the use of our machine in each
business model
• KBA-MetalPrint GmbH offers the best technology and a wide range of services
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