Innovations in Printing -Solutions for short and long …asia-can.com/wp-content/uploads/7.-KBA-MetalPrint.pdf · Innovations in Printing -Solutions for short and long run jobs

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



solutions

Short runs





impression cyl., Ink fountain


•Storage of set-up figures

•Changeover process start

during old job is running

Short runs

1

2

3


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


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

1


Fast plate change - Advantages

Plate change time on a MetalStar 3 (4-Color)

1



solutions

Short runs




•Fast wash-up of blanket,

rollers, impression cylinder,

Ink fountain


•Storage of set-up figures

•Changeover process start during

old job is running

Short runs

1

2

3


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


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



solutions

Short runs





impression cyl., Ink fountain


•Storage of set-up data

•Changeover process start

during old job is running

Short runs

1

2

3


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


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


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


Long runs

Highest output


•Feeder for high speed and sensors for high

safety





•Storage for printing condition



solutions

Long runs

1

2

3


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


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


Long runs

Highest output


•Feeder for high speed and sensors for high safety





•Storage for printing condition



solutions

Long runs

1

2

3


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


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


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


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


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

KBA Metal Decorating

KBA-MetalPrint GmbH

www.kba-metalprint.de

Thank you very much for your attention

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Innovations in Printing -Solutions for short and long …asia-can.com/wp-content/uploads/7.-KBA-MetalPrint.pdf · Innovations in Printing -Solutions for short and long run jobs