ASIA CANTECH 2013 / SURABAYAasia-can.com/wp-content/uploads/10-KBA-Metal... · Newspaper Printing...

KBA Metal Decorating

AUTOMATION MAKES THE DIFFERENCE

ASIA CANTECH 2013 / SURABAYA

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1. KBA-Group

2. Automation Examples - „PRINTING UNIT“

3. Customers Benefits

4. Outlook METPACK 2014


1. KBA-Group – KBA-MetalPrint GmbH





KBA-Group

Koenig & Bauer AG

© KBA-MetalPrint Page:5

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

6

Koenig & Bauer AG

Commercial Web

Newspaper Printing Press - KBA Commander CT

Highlights:

• up to 90.000 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

reduced make ready time Newspaper Web

Products Web -

200 years ago The Times in London became the first newspaper in history to be printed by a

machine – Koenig’s double-cylinder press


Commercial Presses for Printing of Magazines, Brochures, etc…

7

Koenig & Bauer AG

Commercial Web Digital Inkjet Web Newspaper Web

KBA C16 – C80

Highlights:

• up to 50.000 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 3.000 4Color DIN A4 pages per minute

• Piezo Ink Jet Technology

• 4 colors on both sides without turning bar

• designed for shortest job runs


Products Sheetfed for printing of magazines, packaging, cards, …

8

Koenig & Bauer AG

Security Printing

Disk printing Air Purification

Card Printing Packaging and Commercial Sheet-fed Printing

Rapida 106 – 205 - Highlights:

• offset printing on paper or board

• up to 12 decks - 4 + 4 printing, coating and

drying in one line

• perfecting drum to print on both sheet sides

• sheet thickness: 0,04 – 0,7 mm

• make-ready saving by highest automation

• up to 18.000 sph

Genius 52 - Highlights:

• offset printing on non-absorbing substrates

(PET,PVC, PS ….)up to 50.000 cph

• 5-colour printing in one deck

• very compact design

• 8000 sph with size 360x520mm


Special Applications

9

Koenig & Bauer AG

Disk printing Air Purification

Security Printing of identity papers, fiscal

stamps, bank notes

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

etc…



KBA-MetalPrint

Company History KBA-MetalPrint


• 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

MORE THAN 100 YEARS EXPERIENCE IN METAL DECORATING

KBA-MP offers with

the MetalCoat 480

the fastet make-

ready coating

machine

KBA-MP offers with

the MetalStar the

highest quality and

fastet make-ready

metal printing

machine

KBA-MP offers with

their High Econ TNV

the lowest energy

consumption of all

thermal drying

systems in metal

decorating

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-MetalPrint – Line Supplier in Metal Sheet Decoration

© KBA-MetalPrint

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 24000 sqm


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

• 850 Mailänder printing decks

• 550 MetalStar printing decks

Product Range - Printing

• MetalStar PR Multi-Colour Printing Machines

• Mailänder Traditional Printing Machines


Printing Line Configurations

Conventional Line


Printing Line Configurations

UV Line


Product Range - Coating

• MetalCoat 470 Coating Machine

• MetalCoat 480 Coating Machine


Product Range – Drying Ovens

• LTG DB 3000

for flat metal sheets

• Beltstar

• PinStar

for 2-pc cans

• IBO

• OBO

• Dry-Off

• Individual concepts and

upgrades for existing can

lines independent of

manufacturer

• DrumStar

for drums manufacturing


Product Range - CleanAir

• Regenerative Thermal Oxidizers

• TNV



Automation Examples - „PRINTING UNIT“

Inking Unit

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



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.



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!


Inking Unit (option)

Inking unit temperature control

• Guarantees process stability and high

printing quality due to the cooling of all

three oscillators



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)


MetalStar / Ink repelling foil

KBA Σ Duration Without Σ Duration

Duration for 1,000 ink

duct cleanings

5 min. x 1,000

60

= 83,34 h 7 min. x 1,000

60

= 116,67 h

10 20 30 40 t [h]

KBA

Competitor

29 % savings

50 60 70 80 90 100 110 120




Combimatic

CombiMatic (standard)

• Automatic roller washing

CombiMatic (Cloth-System)

• Automatic plate cylinder washing

• Automatic blanket cylinder washing

• Automatic impressions cylinder washing




Plate Change

Plate Change Systems

FAPC – Fully Automatic Plate Change

(option)

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

• 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


FAPC (Fully Automatic Plate Change)

• Simultaneous change in 3 cycles

• Plate change completed in less than

4 minutes


C:/Users/ve/Documents/Präsentationen/Metalstar PR Einzelfilme/pgm/2-6_plate_change.wmv

Duration Plate Change for 1,000 plate changes

2222 FAPC Σ Duration Without Σ Duration

Duration Plate Change

3,5 min. x 1,000

60

= 58,33 h 1 min. x 6 units 1,000

60

= 100,00 h

20 40 60 80 t [h]

KBA FAPC

Others

+ 42 %

100




Press and Ink Control Devices

• 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

ErgoTronic


ErgoTronic

Remote register setting

• Lateral

• Circumferential

• Diagonal

Remote distributor start setting


ErgoTronic

Automatic sheet size setting Remote Control of printing pressure


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.


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


C:/Users/ve/Documents/Präsentationen/Metalstar PR Einzelfilme/pgm/3-7_acrc.wmv

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


Format changing silmutan (1 min.) P + H

Impression cylinder washing (4 min.*) A

Changing pile feeder/stacker (3 min. simultan) P + H

Plate changing (4 min.) P

Blanket washing (4 min.) A

2. Print (4 min.) P

3. Print (4 min.) P

1. Print (4 min.) P

3 Min. 1

3. Print

.

Minutes

14 2 4 6 8 10 12 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48

Ink run-in (1 min.) P

Make-Ready-Diagram MetalStar PR-6 UV

4 Min. 4 Min. 4 Min. 1 ** Makeready time

= 22 - 30 min. per 4–6 C job,

depending of quality of first

sheet and number of

adjustment processes

2. Print

* 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.

5 Min.

A Inking roller washing (5 min.)

6 Min.

P + H Cleaning Ink chamber, refilling (6 min.)

1. Print


• 22 days, 3 shilfts with 500-550 hrs production time

• 1.200.000 – 1.800.000 sheets

• 600 – 700 printjobs

• 4-6 colours

• Including ink fountain and roller cleaning

Results of modern Printing machines

Average of a normal production month – reality!

Every 30 to 40 minutes a new job


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 will show on Metpack 2014:



KBA-MetalPrint GmbH

www.kba-metalprint.de

Thank you very much for your attention

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