ASIA CANTECH 2013 / SURABAYA

Transcription

1 KBA Metal Decorating ASIA CANTECH 2013 / SURABAYA AUTOMATION MAKES THE DIFFERENCE

2 1. KBA-Group 2. Automation Examples - PRINTING UNIT 3. Customers Benefits 4. Outlook METPACK 2014 KBA Metal Decorating

3 1. KBA-Group KBA-MetalPrint GmbH 2. Automation Examples - PRINTING UNIT 3. Customers Benefits 4. Outlook METPACK 2014 KBA Metal Decorating

4 KBA-Group KBA Metal Decorating

5 Koenig & Bauer AG Highlights of Koenig & Bauer AG - parent company of KBA MetalPrint : Factories in Germany, Austria, Czech Republic, Switzlerland Sales of some 1.2bn generated by just under 6,000 employees Technological trendsetter No.1 in newspaper presses No. 1 in large-format sheetfed offset (no. 2 overall) No.1 in packaging offset, security and metal decorating presses Strong position in green technology KBA-MetalPrint Page:5

6 Koenig & Bauer AG Products Web years ago The Times in London became the first newspaper in history to be printed by a machine Koenig s double-cylinder press Newspaper Printing Press - KBA Commander CT Highlights: up to cph 4-C print on both sides in one deck web width max 2.100mm - cutted, folded in one line Automatic Plate Change separate drives for cylinders and inking units for Commercial Web reduced make ready time Newspaper Web KBA-MetalPrint Page:6 6

7 Koenig & Bauer AG Commercial Presses for Printing of Magazines, Brochures, etc KBA C16 C80 Highlights: up to cph max web width 2.280mm designed for short runs and fast job change print of bulk mail, inserts and covers for catalogues etc KBA RotaJET 76 Digital Printing Highlights: up to Color DIN A4 pages per minute Piezo Ink Jet Technology 4 colors on both sides without turning bar designed for shortest job runs Commercial Web Digital Inkjet Web Newspaper Web KBA-MetalPrint Page:7 7

8 Koenig & Bauer AG Products Sheetfed for printing of magazines, packaging, cards, Rapida Highlights: offset printing on paper or board up to 12 decks printing, coating and drying in one line Packaging and Commercial Sheet-fed Printing Card Printing perfecting drum to print on both sheet sides sheet thickness: 0,04 0,7 mm make-ready saving by highest automation up to sph Genius 52 - Highlights: Disk offset printing printing on non-absorbing substrates Air Purification (PET,PVC, PS.)up to cph 5-colour printing in one deck very compact design 8000 sph with size 360x520mm Security Printing KBA-MetalPrint Page:8 8

9 Koenig & Bauer AG Special Applications Alpha Jet - Highlights: Markings include barcodes, best-before dates, data matrix codes and customized texts and graphics apply on various substrates Laser Systems: small caracter coding application marking with pin point sharp texts marking on metals and plastics laser labeller for coding of packagings, pallets Disk printing etc Air Purification Security Printing of identity papers, fiscal stamps, bank notes KBA-MetalPrint Page:9 9

10 KBA-MetalPrint KBA Metal Decorating

11 Company History KBA-MetalPrint MORE THAN 100 YEARS EXPERIENCE IN METAL DECORATING 1876 Mailänder Druckmaschinenfabrik 1924 Carrier Lufttechnische Gesellschaft LTG 1974 Bauer & Kunzi GmbH 1994 Aquisition of Mailänder by LTG - LTG Mailänder GmbH 2003 Aquisition of Bauer & Kunzi GmbH by Koenig&Bauer AG 2006 Aquisition of LTG Mailänder GmbH by Koenig&Bauer AG 2006 KBA-MetalPrint GmbH has been founded as 100% subsidiary of Koenig & Bauer AG KBA-MetalPrint Page:11

12 KBA-MetalPrint Line Supplier in Metal Sheet Decoration KBA-MP was the first manufacturer in the world with a overhead stacker and indeed as a 1-,2- or 3-stacker KBA-MP offers with their brand LTG the recognized best dryer in metal decorating KBA-MP offers with their High Econ TNV the lowest energy consumption of all thermal drying systems in metal decorating KBA-MP offers with the MetalCoat 480 the fastet makeready coating machine KBA-MP offers with the MetalStar the highest quality and fastet make-ready metal printing machine KBA-MetalPrint

13 Company Data KBA-MetalPrint Located in Stuttgart / Germany Sales 2012 EUR 80 million Sales 2013 prospect EUR 90 million Export ratio > 85% R & D 3% of sales Employees 280 Production area in Stuttgart sqm KBA-MetalPrint Page:13

14 KBA-MetalPrint Business Areas System supplier in metal sheet decoration for food cans, general packaging cans, crown corks, alu caps, twist off caps with an installed machine base of 2500 Wicket ovens for sheets 1250 Coaters Mailänder printing decks MetalStar printing decks KBA-MetalPrint Page:14

15 Product Range - Printing MetalStar PR Multi-Colour Printing Machines Mailänder Traditional Printing Machines KBA-MetalPrint Page:15

16 Printing Line Configurations Conventional Line KBA-MetalPrint Page:16

17 Printing Line Configurations UV Line KBA-MetalPrint Page:17

18 Product Range - Coating MetalCoat 470 Coating Machine MetalCoat 480 Coating Machine KBA-MetalPrint Page:18

19 Product Range Drying Ovens LTG DB 3000 for flat metal sheets Beltstar PinStar for 2-pc cans DrumStar for drums manufacturing IBO OBO Dry-Off Individual concepts and upgrades for existing can lines independent of manufacturer KBA-MetalPrint Page:19

20 Product Range - CleanAir Regenerative Thermal Oxidizers TNV KBA-MetalPrint Page:20

21 1. KBA-Group KBA-MetalPrint GmbH 2. Automation Examples - PRINTING UNIT 3. Customers Benefits 4. Outlook METPACK 2014 KBA Metal Decorating

22 Automation Examples - PRINTING UNIT Inking Unit KBA Metal Decorating

23 Milestones Inking technology Many Machines in the market: Inking unit type Storage system Design of the 60 s and 70 s Design with the large diameter storage roller results in slow reaction time by zone setting changes and more waste sheets High ink application with last form rollers Danger for stripes and ghosting effects More sensitive for ink/water balance problems because of bad ratio: thin ink film on first form rollers and direct influence of dampening water Note: In Metal-Decorating plenty of these storage inkers are still in use and sold until today KBA-MetalPrint Page:23

24 Milestones Inking technology MetalStar: Inking unit type Multi roller system Newest design for inking units 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 Since approx. 40 years, Multi-roller Inking units are the state-of-the-art solution for all modern sheet-fed suppliers like KBA, Heidelberg, manroland, Komori a.s.o. KBA-MetalPrint Page:24

25 Milestones Inking technology In 1967 KBA (Planeta) developed an immediate interruption of ink delivery At press stop the ink profile on rollers will be destroyed by movement of ozillators This is the reason for increased waste sheets and time Nearly 50 years ago KBA developed a device to avoid this effect Together with the press stop, key rollers are lifting up from the ozillators and interrupt immediatly the ink delivery On all modern printing machines like KBA presses, such a device is standard. Only in Metal-Decorating, some other presses without this helpful device are still available! KBA-MetalPrint Page:25

26 Inking Unit (option) Inking unit temperature control Guarantees process stability and high printing quality due to the cooling of all three oscillators KBA-MetalPrint Page:26

27 Milestones Inking technology For shorter make ready and higher printing quality modern presses like MetalStar include: Wear free ink metering ink blades with hard metal tips Single-train ink supply to the front form roller Segmented and side effect free inkzone settings Flexurally rigid, ceramic-coated ink duct roller Specially coated ink ducts for faster and easier cleaning Disengaging of unused inking units Ink cooling system / Inking unit temperature control Motorized adjustment of oscillation timing (stepless during production) Ink run-in programs Differential drive for dampening form roller (switchable during production) KBA-MetalPrint Page:27

28 MetalStar / Ink repelling foil Duration for 1,000 ink duct cleanings KBA Σ Duration Without Σ Duration 5 min. x 1, = 83,34 h 7 min. x 1, = 116,67 h Competitor KBA t [h] 29 % savings KBA-MetalPrint Page:28

29 Automation Examples - PRINTING UNIT Combimatic KBA Metal Decorating

30 CombiMatic (standard) Automatic roller washing CombiMatic (Cloth-System) Automatic plate cylinder washing Automatic blanket cylinder washing Automatic impressions cylinder washing KBA-MetalPrint Page:30

31 Automation Examples - PRINTING UNIT Plate Change KBA Metal Decorating

32 Plate Change Systems SAPC Semi Automatic Plate Change (standard) Automated plate change Pneumatic opening and closing of the plate cylinder guard Automatic rotation to the change positions Automatic clamping and tensioning of the plate clamps 40 sec. per unit FAPC Fully Automatic Plate Change (option) Change process includes register zeroing Plate change completed in 3 cycles Parallel changing in several printing units Fast and optimised change process with change time of 3-4 minutes, including register zeroing Divided rear plate clamps All units in 3-4 minutes, it doesn t matter how many KBA-MetalPrint Page:32

33 FAPC (Fully Automatic Plate Change) Simultaneous change in 3 cycles Plate change completed in less than 4 minutes KBA-MetalPrint Page:33

34 Duration Plate Change for 1,000 plate changes 2222 FAPC Σ Duration Without Σ Duration Duration Plate Change 3,5 min. x 1, = 58,33 h 1 min. x 6 units 1, = 100,00 h Others KBA FAPC t [h] + 42 % KBA-MetalPrint Page:34

35 Automation Examples - PRINTING UNIT Press and Ink Control Devices KBA Metal Decorating

36 ErgoTronic Printing unit configuration at the console (activate/deactivate,operating modes) Sheet travel configuration at the console (sheet guiding / sheetformat / settings) Ink/dampening control at the console (CIP3 / memory / ink profile settings) Configuration of washing systems and programs (rollers / blanket/ imp. cyl. / plate) Configuration of auxiliaries (dampening solution / temperature control /...) Advance job preparation at the console or via LogoTronic KBA-MetalPrint Page:36

37 ErgoTronic Remote distributor start setting Remote register setting Lateral Circumferential Diagonal KBA-MetalPrint Page:37

38 ErgoTronic Automatic sheet size setting Remote Control of printing pressure KBA-MetalPrint Page:38

39 DensiTronic Professional Density- and Spectral measuremt and Control with Dynamic ink control DensiTronic Professional - is an automatic colour measuring system. Its motorised measuring head is able to scan control strips at any position on the printed sheet. KBA-MetalPrint Page:39

40 ACR-Control (Automatic Camera Register) 2 measuring fileds on the sheet up to 5 resp. 7 colours Automatic measuring field detection Automatic register control of all 3 register directions KBA-MetalPrint Page:40

41 Process automation with LogoTronic CIP3 / CIP4 CIP3 PPF Cip3 Link Interface for processing of CIP3 PPF data from prepress to the machine console CIP4 JDF LogoTronic Professional CIP4 JDF Production management & shop floor data collection (SFDC) LogoTronic Professional are offered with an CIP4 JDF interface for data exchange with MIS (order-, resource- and shop floor data) => Postcalculation / Jobcosting LogoTronic Professional for networked printing houses with complete CIP4 JDF workflow KBA-MetalPrint Page:41

42 1. KBA-Group KBA-MetalPrint GmbH 2. Automation Examples - PRINTING UNIT 3. Customers Benefits 4. Outlook METPACK 2014 KBA Metal Decorating

43 Make-Ready-Diagram MetalStar PR-6 UV A Inking roller washing (5 min.) P Plate changing (4 min.) A Blanket washing (4 min.) P Ink run-in (1 min.) A Impression cylinder washing (4 min.*). P 1. Print (4 min.) P + H Cleaning Ink chamber, refilling (6 min.) P 2. Print (4 min.) P + H Changing pile feeder/stacker (3 min. simultan) P 3. Print (4 min.) P + H Format changing silmutan (1 min.) 5 Min. 6 Min. 4 Min. 4 Min. 4 Min. 1 3 Min Print 2. Print 3. Print ** Makeready time = min. per 4 6 C job, depending of quality of first sheet and number of adjustment processes Minutes * average washing time, as not to be washed every job ** The value given are usage based averages that may vary depending on press features, process settings, operating conditions, quality specifications. KBA-MetalPrint Page:43

44 Results of modern Printing machines Average of a normal production month reality! 22 days, 3 shilfts with hrs production time sheets printjobs 4-6 colours Including ink fountain and roller cleaning Every 30 to 40 minutes a new job KBA-MetalPrint Page:44

45 1. KBA-Group KBA-MetalPrint GmbH 2. Automation Examples - PRINTING UNIT 3. Customers Benefits 4. Outlook METPACK 2014 KBA Metal Decorating

46 KBA-MetalPrint will show on Metpack 2014: New press developments: Only presses with modern multi roller inking unit design like mentioned With modern features like declutchable inking units, Ink run in programs a.s.o. The new Mailänder 280 and. much more on Metpack 2014 KBA-MetalPrint Page:46

47 KBA Metal Decorating Thank you very much for your attention KBA-MetalPrint GmbH