Innovations in Printing - Solutions for short and long run jobs

KBA Metal Decorating Innovations in Printing - Solutions for short and long run jobs Gerhard Grossmann, Area Sales Director

General situation - Demands 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! 30%? 70%? 70%? 30%? 50%? 50%? Short runs Fast make-ready times What is your ratio? Long runs Highest output KBA MetalPrint October 2015 Seite:2

General situation - Demands 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 Memory of set-up data Changeover process start during old job is running 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 KBA MetalPrint October 2015 Seite:3

Short runs 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 1 2 3 KBA MetalPrint October 2015 Seite:4

Fast plate change FAPC 1 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 2 3 4 5 6 KBA MetalPrint October 2015 Seite:5

Fast plate change DriveTronic SPC 1 DriveTronic SPC / simultaneous plate change system No intermediate drive elements such as gears and clutches Whole mechanical assemblies have been eliminated New USP Clip shows Rapida 106 Plate changing parallel to other make ready processes possible All units in ~ 1:15 min KBA MetalPrint October 2015 Seite:6

Fast plate change - Advantages 1 Plate change time on a MetalStar 3 (4-Color) KBA MetalPrint October 2015 Seite:7

Short runs 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 1 2 3 KBA MetalPrint October 2015 Seite:8

Printing unit washing device 2 Overview of Blanket & impression cylinder washing device CleanTronic (Option) - One fixed washing bar CleanTronic (Option) - One mobile washing bar CleanTronic Synchro (Option) 2 independent washing bars USP KBA MetalPrint October 2015 Seite:9

Make ready comparison 2 Simultaneous make ready processes Highest automation with DriveTronic SPC and CleanTronic Synchro + 69 % more productivity as the leading and best MetalStar before KBA MetalPrint October 2015 Seite:10

Short runs 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 1 2 3 KBA MetalPrint October 2015 Seite:11

New ErgoTronic console 3 New modern Windows operating system 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 KBA MetalPrint October 2015 Seite:12

Job Access 3 One button job change over program Washing 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 KBA MetalPrint October 2015 Seite:13

Quick register solutions ACR / Plate ident New 3 ACR Plate ident Pre-registration Register correction already before the first print Make ready and waste savings Automatic measuring spot detection Automatic register control of all 3 register directions Plausibility checks Job / Plates Plates / Printing units Plates / Color separations Language versions KBA MetalPrint October 2015 Seite:14

Long runs 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 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 1 2 3 KBA MetalPrint October 2015 Seite:15

DriveTronic feeder head 1 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 KBA MetalPrint October 2015 Seite:16

Infeed 1 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. 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 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 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 1 2 3 KBA MetalPrint October 2015 Seite:18

Infeed Old Inking systems, technology out of the 60 s 2 Modern Inking systems like KBA and fast running paper printing maschines Faster reaction time by zone setting changes 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 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 New 2 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) 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 Make ready Printing time No. jobs sum total sum Short run job old 2c multi grip Long run job old 2c multi grip 111 min 111 min 24 min 204 min 14 6 30,8 h 31,5 h 62,3 h ~ 8 shifts 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 h 20,1 h ~ 3 shifts 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 h 15,5 h ~ 2 shifts KBA MetalPrint October 2015 Seite:22

MetalStar 3 Summary 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-MetalPrint Stuttgart Seite:23

KBA Metal Decorating Thank you very much for your attention KBA-MetalPrint GmbH www.kba-metalprint.de