KBA COMPACTA 215

KBA COMPACTA 215

People & Print

Innovative 16pp commercial web press for easy handling and superb economy

Compacta_215_final.qxd 27.11.2007 13:25 Uhr Seite 1

Vision and realityFit for the future

KBA COMPACTA 215 Commercial web offset Highlights

f you want to be fit for the future, you must look beyond the present

and seize opportunities which, not solong ago, did not even exist.

This brochure on the KBA Compacta 215presents a concept for high-quality,economical web offset presses – a technology which KBA was the first tolaunch worldwide.

The Compacta 215 represents a hugestep forward in commercial web offsetand redefines the parameters forperformance, quality and economy inthe 16-page sector.

I On the following pages you can discoverhow, with the new Compacta 215, youcan improve your calculations byslashing per-thousand-copy costs andsatisfy the manifold demands of yourcustomers by enhancing your productionversatility and delivering a superb printquality.

New developments in press engineeringsuch as individual shaftless drives,decentralised intelligent controls,paper-saving minigaps on plate andblanket cylinders, and the automaticallyconvertible KBA F3 gripper folder, makethe Compacta 215 one of the mostadvanced 16-page web offset presses onthe market in its medium-output class.


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Highlights in brief

• Shaftless drives – a world first in commercial printing

• Minigap to cut paper consumption and enhance format flexibility

• Automatically convertible F3 gripper folder for high-speed set-ups

• Decentralised, intelligent control technology at component level

• Digital networking via KBA Logotronic• Beltless high-performance reelstand

KBA Pastostar RC with integrated paperlogistics via KBA Patras

• Film inking units with exceptionally high degree of regularity

• Dampening unit designed for alcohol-free printing

• Printing pressure adjustable for different paper thicknesses without blanket packing

• Multi-ring bearings for excellent print quality

• Cantilevered turner bars, formers etc. for easy access and accurate fold settings

• Automatic plate changing


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Kosten pro 1.000 Exemplare in DM

Kost

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ro 1

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0 E

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M

2.800

2.400

2.000

1.600

1.200

Deckungsbeitrag pro Jahr in DMin Abhängigkeit von der Auflage

Decku

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rag in 1

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50.000 100.000 150.000 200.000 250.000 300.000 350.000 400.000Auflage

50.000 100.000 150.000 200.000 250.000 300.000 350.000 400.000Auflage Compacta 215

(50.000 Ex/h;Minigap; 620 mmAbschnittlänge)

Compacta 215(50.000 Ex/h;Minigap; 620 mmAbschnittlänge)

(Modellrechnung beruhend auf Plandaten und optimalen Produktionsbedingungen: 70 g-Papier; Besetzung mit 4 Druckern; Arbeitszeit 24 h / Tag; 5 Tage / Woche; 50 Wochen / Jahr)

vergleichbare 16-Seiten Rotation(50.000 Ex/h; Konv. Spannkanal630 mm Abschnittlänge;automatischer Plattenwechsel)

vergleichbare 16-Seiten Rotation(50.000 Ex/h; Konv. Spannkanal630 mm Abschnittlänge;automatischer Plattenwechsel)

RunCompacta 215 (50,000 cph; minigap; 620 mm /24.5 in cut-off)

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51

50,5

1.400

1.200

1.000

800

600

Prof

it c

ontr

ibut

ion

in 1

,000

€

Annual profit contribution in €(run-dependent)

Cost per 1,000 copies in €

Compacta 215(50,000 cph;minigap; 620 mm / 24.5 in cut-off)

Comparable 16pp press(50,000 cph; conv. blanket gap;630 mm / 24.75 in cut-off;automatic plate changing)

RunComparable 16pp press(50,000 cph; conv. blanket gap;630 mm / 24.75 in cut-off;automatic plate changing)

Model calculation based on cost assumptions and optimum production conditions: 70 gsm (45 lb) paper, 4 printers, working hours 24 h/day, 5 days/wk and 50 wks/yr

Cost

per

1,0

00 c

opie

s in

€


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Paper costs 8.5% (white and colour waste)

Ink costs 10.2%

Personnel costs 6.6%

Cost of servicingloans 4.1%

Gas, electricity, and service costs 2.3%

I with the same speed, conventionalblanket gap and automatic platechanging. Of course, we also supplyautomatic plate changing with thispress.

Even for a run of 50,000 the cost perthousand copies with the Compacta215 and minigap is significantly lower– and savings increase proportionatelyfor longer runs.

n commercial web offset, the decisive criterion for competitiveness

is the cost per 1,000 copies. Alongsideset-up times and print output, the biggestcost factor is paper, which accounts forsome 70 % of total production costs.

This is why the KBA Compacta 215 hasbeen engineered to cut paper waste,while at the same time reducingmakeready times with its high level ofautomation.

A minigap on plate and blanket cylindersnarrows the non-print margin to just 6mm (0.25 in), while the pinless gripperfolder eliminates the pin trim. This

means you can print A4 products on acylinder with a circumference of 620 mm(24.5 in) instead of the previously standard 630 mm (24.75 in).

At the maximum production speed of50,000 cph in triple-shift operation,your savings from reduced paperconsumption can total some $ 180,000per year.

For an average run size of 200,000,again in triple-shift operation, yourannual profit contribution from aCompacta 215 with minigap – even withmanual plate changing – would be 12%higher than from a commercial press

Improve returnsCut costs

Paper costs 68.4% (production)

Distribution of total costs in %

KBA COMPACTA 215 Commercial Web Offset Economy


AThe standard features of the KBA Pastostar RCinclude motor-adjustable reel arms to handlereels of different widths

KBA Patras A delivers the prepared reels to thereelstands automatically

problem-free supply of paper to the press is essential for a trouble-free

print run. To this end, KBA offers thefloor-recessed reel-transport system KBAPatras and the reelstand KBA PastostarRC – in a choice of automation levels tomeet individual requirements.

KBA PATRASKBA Patras is a flexible, high-performancereel-transport system ranging from amanual version to a fully automatedsystem. Its modular design facilitatesoptimum adaptation to your productionrequirements and available space. KBAPatras is a robust system which requiresonly a minimum of maintenance. Itrepresents excellent value for moneyand will help to streamline paperlogistics for reduced wastage andimpressive cost savings.

The manual versions offer economicalsolutions for small and medium webinstallations. At the highest automationlevel, the reel is conveyed from the reelstore to the feed tracks by AGVs.Weighing units can also be integratedinto the system.

KBA Patras is compatible with other reel-transport systems and manual versionscan be upgraded with automation at alater date.

The automatic splice preparation stationKBA Easy Splice can be installed centrallyto serve a number of reelstandssimultaneously.

Supplying the paper'just in time'


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KBA COMPACTA 215 Commercial web offset Paper Logistics

The display in the side frame presents importantoperating data and enables production parametersto be entered at the reelstand

KBA PASTOSTAR RCThe high-performance reelstand KBAPastostar RC is fully compatible withthe modular system of the KBACompacta 215.

Easy-to-read data screens on theconsole monitor indicate the currentoperational status, while automationrelieves your press crew of mundanetasks. A new reel is spliced onto theexpiring one at full production speed.The reel change is initiated when theexpiring reel reaches a prespecifieddiameter based on paper thickness andweb speed. The beltless drive systemmakes splice preparation especiallyeasy.

The standard split arms are infinitelyadjustable by motor. This ability tohandle reels of different widths affordsmuch greater flexibility when switchingfrom one product to another.

Automatic webbing-up The web-up chain available as an optionfor the KBA Compacta 215 cuts changeovertimes and eases operation.

The web is suspended from a chainguide at the reelstand on the drive sideof the press. It is then drawn throughthe infeed unit, printing units, dryerand chill roll stand up to the slitter inthe folder superstructure in just threeminutes.


KBA COMPACTA 215 Commercial web offset Printing unit

he primary objectives in developing the printing units for the KBA

Compacta 215 were easy operation,reduced maintenance, the best possibleprint quality and the ability to print awide range of stock thicknesses.

Pre-loaded multi-ring bearings with zeroplay eliminate the need for bearer ringswith this press. Extensive practicalexperience has shown that the printquality obtained is superb. The absenceof bearer rings brings the added bonusof reducing maintenance time and costs.

A further advantage of the bearer-freesystem, as far as user-friendliness andefficiency is concerned, is that there isno need to pack the blanket cylinderswhen printing stock of different thicknesses. The upper blanket cylindercan be set relative to the lower onewithout changing the printing pressureon the upper plate cylinder.

Each individual printing unit is driven byan AC servo motor, which is also used asdrive motor for plate changing and othermakeready tasks. This shaftless drivesystem makes operation very much easier.

The replacement of drive gears, clutchesetc. by an 'electronic' shaft also reducespotential sources of abrasion.

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Printing units with future-oriented individual drives


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...and with excellent qualityThe printing unit can handle stocks of differentthicknesses without the need to pack the blanketcylinder...

Four-ring eccentric bearing Adjusting printing pressure to print stocks ofdifferent thicknesses

Flexible and user-friendlyOn-the-dot colour


KBA COMPACTA 215 Commercial web offset Printing unit

The semi-automatic version of the systemalready cuts makeready time considerably

T he KBA Compacta 215 incorporates film inking units with 14 rollers

(17 splitting points). This guaranteesan optimum quality even when printingdemanding formes with an unfavourableimage layout. The quality of ink laydownis demonstrated by the exceptionally highdegree of regularity.

Prime components of the inking units are the Colortronic ink fountains withintegral electronics. The metering elements have carbide tips, while thefountain rollers are ceramic-coated. Thereis a total absence of bleed in the zones,ink application is 100% uniform – evenduring long runs – and repetitiveaccuracy is extremely high. The distancebetween ink keys is 32 mm (1.25 in).

The first forme roller oscillates in orderto eliminate ghosting on difficultprinting formes. An automatic ink supplyis available as an option.

Dampening unit for alcohol-freeprintingThe dampening unit on the Compacta215 facilitates both direct and indirectdampening. In the case of indirectdampening, the dampening forme roller(no. 10) is in contact with the ink distributing roller (no. 5), whereas thecontact to the distributing roller is brokenduring direct dampening. The dampeningforme roller (no. 10) oscillates whendampening directly in order to eliminatewater streaks and ghosting.

Semi-automatic plate changing can also be upgradedto the fully automatic system at a later date.


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Printing unit with film inking unit

Semi- and fully automatic platechanging cuts this time even further.There are no time-consuming clutchingsequences and the plate cylinders canbe positioned accurately ready for theplate change. A fully automatic changeof all 8 plates on a press with 4 printingunits takes approx. 2 minutes.

Tailored automationPlate change made easy

Autoplater for fast job changes The targets set when developing theC215 were short makereadies, operator-friendly handling and the greatestpossible economic efficiency.

For a manual plate change (which canbe carried out with the web still in thepress), the cylinder can be positionedby pushbutton to be ready for the platechange. The plate is held by a quick-release clamp. The individual drivesystem allows the plates on the printingunits to be changed either individuallyor simultaneously. A complete change of plates on a press with four printingunits takes 2 personnel approx. 8 minutes.

1 Ink fountain2 Ink fountain roller3 Film roller4 Ink transfer rollers5 Ink distributing roller6 Ink forme rollers7 Ink forme roller

(oscillating)8 Dampening fountain9 Dampening fountain roller

10 Dampening transfer roller11 Dampening forme roller

(oscillating)12 Plate cylinder13 Blanket cylinder14 Web


KBA COMPACTA 215 Commercial web offset Minigap

Costs Down, Quality UpPractice-oriented minigap technology

Blanket cylinder

Blanket plate

BlanketTrailing edge

Leadingedge

Carrier plate

Blan

ket

plat

e w

idth

Max

. w

eb w

idth Tensioning bar

Clamp

A One major advantage of KBA’s minigapin comparison to sleeves is that thespecial clamping system allows thetrailing edge of the plate to movedeeper into the gap during production.This compensates for the differences inlength caused by the blanket fullingand changes in blanket temperature,and thus eliminates the risk of thecarrier plate breaking. The gap remainingafter the blanket plate has been mountedallows the blanket to relax.

s with the high-performance KBA Compactas 217 and 318, the plate

and blanket cylinders on the Compacta215 boast KBA’s minigap technologywhich has already proven its effectiveness at maximum speeds incontinuous operation. The minigapnarrows the non-print margin to just 6 mm (0.25 in). This can bring bigsavings in paper and therefore in production costs.

Blanket plates comprise a printing blanket vulcanised onto a metal carrier Minigap technology saves paper

Instead of the conventional type ofblanket, the minigap system operateswith a blanket plate. The blanket isvulcanised onto a metal carrier platewhich is bent at each end. The acute-angled edge is inserted in the leadingcylinder gap, the obtuse angle in thetrailing gap. The blanket is clamped byturning the tensioning bar. Retensioningis not necessary.


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200

mm1 m

1 m

Blanket plates

t = 1.61 mm1 m

1 m

A further advantage is that blanketplates take up a mere fraction of thestorage space required by sleeves andare also easier to handle. The blanketplates can be changed in just twominutes, as opposed to ten minutes forconventional blankets. All proprietaryblanket washing systems can be used.

An added bonus is that the minigapallows a wider range of formats to beprinted because the print-free margin ismuch narrower, and promotes a smoothpress run because cylinder bounce isvirtually eliminated.

620Blanket plates1 m3

620sleeves25 m3

Sleeves

Data based on storage of 10 blanket plates orsleeves per week for approx. 62 weeks.

Space also costs money! Comparison of the storagespace requirements for blanket plates and for sleeves

Behaviour of the blanket in the printing zone

Blanket bulge Web

Blanket bulge

Blanket bulge


L ong runs with frequent imprint changes are a major trend in

commercial printing today, especially formailings. In response, KBA has redefinedthe approach to imprinter technologies,incorporating new features only nowpossible thanks to individual drives.

Conventional imprinters permit flyingimprint changes on only one side of theweb, for example address changes orvariable price markings.

The newest imprinter solutions, whichKBA already pioneered well ahead of its

Variable imprinter technology

Seize new opportunities

Imprinter functions

black black cyan magenta yellow


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KBA COMPACTA 215 Commercial web offset Imprinter

Modern imprinter technology enables simpleimprint changes on both sides of the web

rivals, are built around additional"normal" printing units. The individualdrives enable two separate printing unitsto be activated and deactivated alternately and thus facilitate simpleflying imprint changes at full productionspeed. In contrast to conventionalimprinters, the changes can here be initiated simultaneously for both sides of the web, e.g. to produce differentlanguage versions of a brochure. It goeswithout saying that the "imprinter"units can also be used as fully-equippedprinting units for production with spotcolours, etc., bringing a further boostto production flexibility.


Superstructure 2 webs for parallel productionF3 with 2 x 8/16pp module

T

Superstructure 2 webs with all modulesF3 with 2 x 8/16pp module

Superstructure 1 web with turner bars F3 with 2 x 8pp module

Superstructure 2 webs, straight-on productionF3 with 2 x 8/16pp module

Superstructure 1 web 'straight-on'

he superstructure is engineered for aweb width of 1,000 mm (39.5 in) and

owes a lot to Frankenthal’s gravure know-how. For example, all essential elementssuch as turner bars, former and RTF arecantilevered for easy access.

Exploiting synergiesGravure superstructure know-how


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KBA COMPACTA 215 Commercial web offset Superstructure

Ribbon travel has been kept to a minimum, and web-up times cut bynearly one-third. The key draw units inthe superstructure (main draw roller,former roller etc.) are driven directly by 3-phase AC motors. The modulardesign and individual drives allow thesuperstructure to be adapted easily todifferent types of production, e.g. drawand slitting unit with subsequent turnerbars, second web, cross leads to aparallel press, auxiliary former, perforating unit, length gluing unit and plough fold.

The slitters operate like scissors and,because they are cantilevered, can bechanged in less than five minutes. Atrimming system trims the web on bothsides. The trimmed strip is severed by adriven knife and drawn away by suction.

The cantilevered turner bars are adjustablein their pivot direction via a simplescrew. They are available in a choice ofwidths and can be interchanged accordingto production requirements. New design developments, furthermore,cut the air consumption significantlyand save valuable energy. The bars at the same time remain free ofcontamination and guarantee a morestable passage of the ribbons. Linearregister rollers afford optimum controlof the cut-off register.

The entire former section can be shiftedin the direction of web run, and theangle of the former nose is adjustable.Even the rollers beneath the former areadjustable in all directions via universaljoints, ensuring a perfect former fold.Before the web reaches the turner bars,it is chilled to room temperature via thechill-roller stand. The first chill roller isalso a measuring roller for registering

web tension. With its large angle ofwrap, the three-roller system achievesan optimum chill effect with a lowamount of chill water. This helps tosave energy.


Production flexibility, the shortest possible changeovers, high folding

accuracy, low maintenance and absolutereliability – these were the targets setin developing the folder for the KBACompacta 215.

To exploit the minigap’s full potential forsaving paper, a pinless gripper folder isa must, and this is where developmentengineering has benefited from Frankenthal’s substantial lead in foldertechnology and expertise over ourcompetitors. Gripper folders have beenbuilt in Frankenthal for several decades,primarily for gravure presses operatingdaily at web speeds of up to 16 mps or3,150 fpm.

The standard version of the KBA F3gripper folder has a first cross fold,double parallel fold, delta fold (with orwithout subsequent quarterfold), timedlength perforation, and cross perforationdepth-adjustable on the run.

Folder conversion for different types ofproduction is 100% automatic from theconsole and takes between two and sixminutes, depending on the particularfold.

Positioning the 2 x 8pp module beneaththe folder allows 2 x 8 poster pages(closed at the head) or, for a two-webinstallation, 2 x 16 poster pages to beprinted. In addition, a cut-off cassettewith its own electric drive can beintegrated for the production of 2 x 4, 2 x 8, or 4 x 4 pages.


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KBA COMPACTA 215 Commercial web offset Folder

A gripper folder has several advantagesover a pin folder above and beyond thepotential savings in paper. It produces a high-quality product which is oftensaleable without trimming. The grippercylinder runs a little in advance therebycreating slight web tension before thecross fold so that an extremely accuratefold is achieved.

An additional advantage is that grippersare less prone to abrasion and requireless maintenance than pins. A jam inthe folder, for example, would destroy

Proven gripper technologyTechnology lead for the customer

Gripper technology saves paper

pins but does not damage grippers.Because the F3 folder has individualdrives, there is no need for complexgear trains, electromagnetic clutchesetc., which eliminates further potentialsources of abrasion.

Systems not required for the currentrun can be left stationary, reducingenergy consumption and abrasion stillfurther, and extending service andmaintenance intervals. During monitoringwork, the individual drives allow thecylinder group to be positioned to themillimetre for the gripper or folding knife.

One particularly useful productionfeature is that the circumferentialsetting of the electrically driven spiderwheel can be adjusted on the run tosuit different copy weights, thus improving the delivery quality of thecopy stream.


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A host of further technical refinementsease your crew workload and

increase folder productivity and reliability.

For example, a new severing unitensures that the in-running ribboncannot jam back at the severing knifeand damage the draw roller.

The stop in the quarterfold can be cleanedof trimmings during production.

It is possible to configure the folderwithout the double parallel and deltafolds if your product structure is suchthat these are not required. All extensionmodules are naturally also available forthis version.

F3 with extension module, 2 x 8pp or 2 x 16pp

Folder F3


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KBA COMPACTA 215 Commercial web offset Folder

F3 with extension module, 2 x 8pp or 2 x 16pp and cut-off cassette

F3 with cut-off cassette

Intelligent modular technologyMatching individual needs

1 Former (standard width)1a Former (half-width)2 Former fold rollers3 Driven draw rollers4 Severer5 Length perforator6 Cross perforator7 Driven draw rollers8 Knife cylinder9 Individual main motor

10 Gripper/folding-knife cylinder11 Folding-jaw and -knife cylinder12 Folding-jaw cylinder13 Quarterfold14 Folding knife15 Folding rollers16 Spider wheel17 Sheet exit (lateral)18 Tape roller19 Spider wheel20 Sheet exit (cross fold delivery)21 2 x 8pp module22 Extension module, cut-off cassette

(to 1/2 circumference)23 Driven draw rollers24 Knife and grooved cylinder25 Sheet exit


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B 1/2

B 1/2

1/4

1/4

Production optionsPerfect products in every variation

1/4

bW2/3

1/3

W1/3

W1/3

1/4 C

Standard

a

W1/1

1/2 1/2 W

1/2 C

1/3 W

1/2 C

1/2 C

1/4 W

1/2 C

1/4 W

1/4 W

1/2 C

1/6 W

2 x 16 pages A51/4 C = 1551/4 W = 250 max./165 min.

1/2 W 1/4 C

1/4 W1/4 W

Former foldFormer fold First cross fold Former fold1 First cross fold 2 Quarter fold 3 Double parallel fold

W1/2

W1/2

1/6 1/6 W

1/2 C

1/4 C

24 pages1/4 C = 1551/3 W = 333 max./165 min.

1/3 W 1/4 C

32 (2 x 16) pages A5(Two-up) 1/4 C = 1551/2 W = 500 max./210 min.

Auxiliary equipment

16 pages A41/2 C = 3101/4 W = 250 max./105 min.

e

c

dW1/3W1/3

1/2 C

32 pages A51/4 C = 1551/4 W = 250 max./165 min.

48 pages1/4 C = 1551/6 W = 166 max./165 min.

Auxiliary equipment

1/4 W

1/2 C

1/8 W1/4 W

1/6 W 1/4 C

Auxiliary equipment


Circumference C = 620 mm (24.41in)Web width W = 1,000 mm (39.37in)(max.)

420 mm (16.54in) (min.)

W1/2

W1/2

Auxiliary equipment

8 pages A31/2 C = 3101/2 W = 500 max./210 min.

12 pages1/2 C = 3101/3 W = 333 max./165 min.

24 pages1/2 C = 3101/6 W = 166 max./105 min.

16 pages A41/2 C = 3101/4 W= 250 max./165 min.

32 pages1/2 C = 3101/8 W = 125 max./105 min.

24 pages1/2 C = 3101/6 W = 166 max./165 min.

Web leads Standard folds


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1/3 C

1/2 W

1/3 C

1/4 W1/2 C

1/3 W1/2 C

1/2 C

KBA COMPACTA 215 Commercial web offset Production options

In conjunction with the different web leads in thesuperstructure, the KBA F3 folder allows the pro-duction of virtually all products currently on themarket, as the following overview shows:


1/6 W

1/3 C

1/8 W

1/2 W

1/2 C

1/4 W

C1/4 W 1/4 W

1/2 C

1/3 W

1/4 W


n.

1/4 W 1/4 C

1/4 W1/3 C

1/3 C

1/8 W

1/3 C

Former fold Former fold Former foldDouble parallel fold Former fold Delta fold First cross fold4 Quarter fold 5 Delta fold 6 Quarter fold 7 Quarter fold 8 Former fold

1/6 W

1/4 U1/4 C

n.

48 pages1/4 C = 1551/6 W = 166 max./105 min.

2 x 6 pages 1/2 C = 3101/3 W = 333 max./185 min.



36 pages1/3 C = 2071/6 W = 166 max./165 min.

2 x 12 pages1/3 C = 2071/4 W = 250 max./165 min.

1/3 C

1/4 W 1/4 W

1/6 W 1/3 C

32 pages A51/4 C = 1551/4 W = 250 max./105 min.

24 pages1/3 C = 2071/4 W = 250 max./105 min.

36 pages1/3 C = 2071/6 W = 166 max./105 min.

48 pages1/3 C = 2071/8 W = 125 max./105 min.

12 pages1/3 C = 2071/2 W = 500 max./210 min

18 pages1/3 C = 2071/3 W = 333 max./165 min.

n.

64 pages1/4 C = 1551/8 W= 125 max./105 min.

n.

24 pages1/3 C = 2071/4 W = 250 max./165 min.

Extension module 8/16pp Cut-off cassette


KBA COMPACTA 215 Commercial web offset Drive

KBA Drivetronic: Individual shaftless drives for the printingunits, draw elements and folder facilitate press operationwhile enhancing the versatility and economic efficiencyof the KBA Compacta 215

The drives are synchronised via an electronic(virtual) shaft

T he KBA Compacta 215 was the first commercial web offset press on the

world market to dispense completelywith a main shaft.

The infeed unit, printing units, chillrollers, draw units in the superstructureand the key modules of the KBA F3gripper folder are all driven directly viaAC positional servo motors. Mechanicalshafts have been replaced by a virtualshaft and a CLC card assumes thefunction of the main drive.

Called KBA Drivetronic, this revolutionarydrive technology, which has proven abig success in everyday operation onKBA’s newspaper and commercial weboffset presses, offers a host of advantagesbeyond the maintenance-free, energy-saving and fully enclosed 3-phase drives.

For example, auxiliary drives for set-upsare a thing of the past. Register isconsistently accurate. Print quality isbetter because there is no mechanicalshaft to generate vibration. The reductionin gearing cuts repair and maintenancework. And there is no mechanicalcircumferential register – its function isassumed by the individual drives. Thisall adds up to a smooth machine run,high-speed reactions during controlsequences and excellent print quality.

If you decide to extend your modules ata later date – e.g. in the superstructureand folder – nothing could be simpler.The individual subassemblies are pre-installed and tested before leaving thefactory, dramatically reducing erectionand commissioning times.

KBA DrivetronicPioneering dedicated

drives

Each printing unit is driven by a dedicatedAC positional servo motor


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approx. 36.00 m

appr

ox. 5

.70

m

4 + 4 printing units, 2 webs with all modules

2 presses in parallel configuration with cross leads

appr

ox.

4.50

m

appr

ox. 5

.70

m

appr

ox. 12

.00

m

approx. 31.00 m

approx. 37.30 m

Straight-on press

Single-web press with turner-bar deck, 2 x 8pp module and 5 printing units

KBA COMPACTA 215 Commercial web offset Configurations

components can be retrofitted in thesuperstructure as and when necessary,so that the press can be modified easilyto keep pace with changes in marketdemands.

Made to measureCustomised installations

The modular design of the KBA Compacta 215, with its flexible

individual drive technology plus numerous modules for the superstructure and KBA F3 gripper folder, offers you enormous flexibility in customising your press configurationsto meet individual production requirements.

The modular system also shortens andsimplifies project planning for newinstallations. And because the individualsubassemblies can be tested before leaving the factory, commissioningtimes are shorter, too.

The Compacta 215 is available in a widechoice of versions from a single-web,straight-on press with four printingunits and standard folder to a two-web,eight-unit press with two turner-bardecks with cross leads and F3 folderplus additional 2 x 16pp module. Most

Non-KBA equipment, e.g. dryers, siliconeunits, water-circulation units, etc., are fully integrated into the consolesystem.


All important commands are initiated from theuser-oriented control console

KBA OPERADialogue between man and machine

n the high-performance Compacta 215,the user-oriented control console

KBA Ergotronic, the automatic press-presetting system KBA Easytronic, theautomatic web tension control systemKBA Webtronic and the productionmanagement system KBA Logotronic are important elements of an integratedautomation concept. Through thenetworking of intelligent control technologies at unit level, theoperating crew maintains full controlover the whole press through-out allphases of production. With KBA OPERA(Open Ergonomic Automation System),KBA furnishes the modules which areindispensable to master today's increasingly complex press installationsand the instant dialogue between manand machine which these demand.

KBA ERGOTRONICThe new control console of the Compacta215 is a perfect symbiosis of functionalityand aesthetic design. All important production commands, including thosefor automatic conversion of the folder,are initiated from the console. Clearlyarranged data screens with plain-textdisplays promote accurate and rapidhandling via touchscreen controls.

Remote diagnostics and maintenanceKBA service staff can be contacted atany time via a 24-hour hotline for promptand effective assistance. Modem facilitiesalso enable the KBA customer servicedepartment to communicate directly withthe computer systems of the Compacta215, ensuring that any malfunctionscan be located and rectified with anabsolute minimum of delay.

O


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KBA COMPACTA 215 Commercial web offset OPERA

Intelligent automation concepts relieve the press crew

KBA COLORTRONICThe Colortronic desk is the press operator'scentral workplace and permits optimumhandling of the ink settings for the upperand lower printing couples. A presettingsystem for the ink keys is part of thestandard package. Broad LED strips provide an immediate indication of the

ink profiles set and facilitate fastcorrections when necessary.

KBA CIPLinkThe CIP3 converter CIPLink is an optionalcomponent of the KBA Logotronic systemfor calculation of the area coverage, andthus of the ink key openings, on thebasis of pre-press data. The CIP3 filescan be imported from floppy disk, fromCD-ROM or online via a local network.In this way, the relevant data from pre-press can be transferred directlyinto the press in digital form.

KBA EASYTRONICThe automatic press presetting systemKBA Easytronic raises the availability ofthe press and contributes to considerablesavings in wastage. It features, for example, automated web-threading,automatic web width conversion whensetting up a new job, run-out washing inaccordance with production demands,

and defined pre-inking. All superstructure and folder componentsare preset on the basis of the pre-pressdata. A single press of a button providesfor optimised starting, setting-up andstopping of the press, ensuring theshortest possible production times and an absolute minimum of wastage.


The goal for practically every print enterprise is to possess an unbroken

workflow from order receipt to productdispatch. Since so many differentmachines and programs are involved tocater for different product ranges, suchworkflows are scarcely available "off-the-shelf". Individual configurationsmust be tailor-made. This is also generally not a domain for "one-stop suppliers". KBA makes a dedicated contribution to networking and workflow with its management systemsLogotronic professional and Logotronicbasic, but at the same time workstogether closely with recognised suppliers of branch management soft-ware. The universal JDF format (JobDefinition Format) developed by the CIP4consortium, of which KBA is a member,permits data exchange with both

management information and prepresssystems. The JDF specificationtakes into account all process-relevantmodules. Data transfer, however, cannevertheless use the previously installedinterfaces.

Logotronic basicAll KBA Compacta presses are equippedas standard with the Logotronic basicversion of the system. This versionserves to transfer essential preset datato the press. Logotronic basic embracesthe optional modules CIPLink (CIP3/CIP4data transfer for press presetting) andlogging for paper and ink data. Theexisting company hardware (server) isused to implement the networking system.Presetting data for the ink keys and forthe duct roller settings are transferred.

Logotronic professionalTo support a digital exchange of job andpresetting data for the press, to permitimmediate monitoring and systematicevaluation of production data, and toestablish links to upstream PPS systemsor company EDP networks, the consolecan be further expanded by adding theopen production management systemLogotronic professional. The logging ofpress and production data facilitatesoperations management, with KBA Logotronic as a source of trulymeaningful statistics. Logotronic professional is the central element ofcommunication between KBA presses andthe corresponding print company MIS,whether via direct database access orvia JDF. The communication moduleJDFLink implements JDF dataexchange.


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KBA COMPACTA 215 Commercial web offset Workflow

Important information on current print productioncan be called up from any location

• Improved cost accounting on the basis of exact press and production data (no daily worksheets to be completed by hand)

• Clearer overview through facility to retrieve all job, presetting and press data

• Comprehensive and transparent information for management

PressWatchThe Logotronic component PressWatchprovides management with an overviewof all the jobs currently being run.Counter states, printing speeds, job dataand progress, press status messages and a whole array of other relevantinformation can be displayed in realtime.

SpeedWatchSpeedWatch creates a time/speed diagram, similarly in real time, withwhich all events and messages for aselected press can be depicted.Correspondingly authorised persons areable to access this information via theInternet or the company Intranet.

JDFLink with Logotronic professionalInterconnection of Logotronic professionalvia the universal interface JDFLinkoffers the following advantages:

• Unbroken automated workflow (job data can be passed directly from the branch

• Access to Logotronic professional fromall connected workstations

• Presetting and repeat data provide forshorter makeready times

• More effective production per shift• Less waste• Single data input brings greater

efficiency and reduces the risk of errors

KBA LOGOTRONICDigital workflow


or you, as a responsible entrepreneur,concern about the environmental

compatibility of new productionequipment, a sparing use of naturalresources and a conscious avoidance of waste are integral aspects of yourbusiness and are subject to increasingregulation by government.

Preserving the environment is part ofKBA's philosophy and as such is anchoredin our guiding principles.

The KBA Compacta 215 successfullycombines ecology with economy. Theminigap and gripper folders save valuablepaper and reduce waste. Maintenance-free, fully enclosed 3-phase drives withminimal wattless power consumptionreduce energy consumption, as doindividual drives which allow presscomponents to be switched off whennot needed.

Environmentally-friendly automaticblanket washing units cut the consumption of washing agents to aminimum. In addition, all relevant press parts can be cleaned with new-generation cleaning agents, e.g. thosebased on vegetable oils, which improvesworking conditions for your staff. The

dampening unit has been designed bothfor low-alcohol and alcohol-freeprinting to cut solvent emissions.Finally, the use of pure materials whenmanufacturing the press facilitatesrecycling at the end of its service life.

The Compacta 215 is a model exampleof how press ecology can benefit print-shop economy.

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KBA COMPACTA 215 Commercial web offset Environment

EcologyEffective environmental

management


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Technical dataMax. production speed 50,000 cph

Max. web speed 8.7 mps (1,712 fpm)

Cylinder circumference 546 - 700 mm (21.5 - 27.5 in) (details available upon request)

Min./max. web width 420/1,000 mm (16.5/39.5 in)

Standard stock weights 36-130 gsm (23-83.5 lbs), (with sheeter up to 200 gsm 128.5 lbs)

Circumference-related data Max. web speed Max. image areawith 546 mm (21.5 in) circumference 7.58 mps (1,492 fpm) 540 x 995 mm (21.25 x 39 in)

with 578 mm (22.75 in) circumference 8.03 mps (1,581 fpm) 572 x 995 mm (22.5 x 39 in)

with 590 mm (23.25 in) circumference 8.19 mps (1,612 fpm) 584 x 995 mm (23 x 39 in)

with 598.6 mm (23.5 in) circumference 8.31 mps (1,636 fpm) 592.5 x 995 mm (23.25 x 39 in)

with 620 mm (24.5 in) circumference 8.61 mps (1,695 fpm) 614 x 995 mm (24 x 39 in)

with 700 mm (27.5 in) circumference 8.75 mps (1,722 fpm) 694 x 995 mm (27.25 x 39 in)

Basic equipment .KBA reelstand.KBA infeed unit.Stretching roller.Printing units.Blanket-washing system. Ink-feed system.Dampening-water system.Web catcher.Dryer without/with afterburner.KBA chill roll stand.Superstructure.Silicone unit.Web-centre alignment. Ink-register control.Cut-off register control. Length gluing.Automatically convertible KBA F3folder – basic module

.Plate-punching machine

.Bending machine

KBA Opera (standard).KBA Opera (standard).Console (KBA Ergotronic) incl.electrical angle adjustment

.Remote adjustment of inking unit, dampening unit and register(KBA Colortronic)

.Shaftless drive (KBA Drivetronic)

.Production management system (KBA Logotronic): basic

.Data transfer via CIP3 possible

Optional extras.KBA Patras reel-transport system.Webbing-up unit. Imprinting unit.Automatic plate changer.Desk illumination.Height adjustment for desk.Remoistening unit.Cross lead for parallel press.Steel substructure for two-high press.Auxiliary former. F3 extension module for 2 x 8 or 2 x 16 pages

.Cut-off cassette for F3 folder

.Cutter and perforator

.Coater and gummer

.Plough fold

.Sheeter

.Compressed-air unit

.Chilling unit

KBA Opera (optional extras). Film and plate scanner (KBA Scantronic)

.Production management system(KBA Logotronic): professional

.Online data transmission(KBA CIPLink)

KBA COMPACTA 215 Commercial web offset Data

KBA COMPACTA 215At a glance


KBA COMPACTA 215 fromKoenig & Bauer AG

Texts or illustrations contained in thisbrochure may not be reproduced in anyform, either in part or in full, without theexpress permission of Koenig & Bauer AG.Illustrations may show optional specialequipment not included in the basic priceof the presses. Subject to technical ordesign modifications without prior notice.

Please direct enquiries to our salesdepartment at:Koenig & Bauer AGFrankenthal FacilityPostfach 1122 67225 Frankenthal, GermanyJohann-Klein-Str.167227 Frankenthal, GermanyTel: (+49) 6233 873-0Fax: (+49) 6233 873-3222www.kba-print.comE-mail: [email protected]/2007-e Printed in Germany

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