Koenig & Bauer AG

KBA Continent

KBA Newspaper Technology

Premier shaftless tower press

for 2/1 newspaper production

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The name reflects the aim: the KBA Continent is a sophisticated, user-friendly tower press targeting the global market and engineered for the production of top-quality colour newspapers and semi-commercials. A single-width press for four pages broadsheet or eight pages tabloid, the Continent is based on its hugely popular one-across/two-around stablemate, the Comet. It boasts technology that is second to none in this performance class, as evidenced by a string of awards and the admission of a Continent user in the Middle East to WAN-IFRA’s elite Colour Quality Club.

Technological excellence in every detailFirst-rate 2/1 web press

Basic concept

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The H-type printing units can be stackedto form a four-high tower for 4/4 blanket-to-blanket with one web or 2/2 with twowebs. It is also possible to start off with‘incomplete’ towers for 4/1 or 4/2 and toprogress to a full colour capability instages. DriveTronic shaftless drives and amodular construction with distributedcontrols support customised configurationsto suit individual production specificationsby allowing ‘missing’ couples to be addedeasily – and inexpensively – at any time.

The Continent has an above-average maximum web width of 1,000mm(39.37in) and the standard 533 - 700mm(21 - 27.5in) cut-off range customary in the international market. A maximum output of 75,000 copies per hour, cutting-edge console technology and a solid,ergonomic design for maximum ease ofhandling place the Continent at the verytop of its class.

An extensive choice of optional equipment including dryers for full-coloursemi-commercials and a facility for printing webs of different widths makethe KBA Continent an attractive proposition for printers seeking a highdegree of production flexibility. TheContinent can be configured as a floor-mounted or two-floor version to suitpresshall architecture.

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Printing units

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H-type printing unit1 Ink duct2 Duct roller3 Film roller4 Ink transfer roller5 Distribution cylinder6 Forme rollers7 Spray bar8 Chrome roller9 Dampening roller

10 Plate dampener11 Plate cylinder12 Blanket cylinder13 Roller washing unit

The off-bearer H-type units on the Continent deliver a superb print quality, are freely accessible, easy to operate and need very little maintenance.

Immaculate imageH-type printing units

The robust, box-type side-frames eliminate vibration, even at high pressspeeds, and are engineered for a longservice life. A patented configuration ofzero-play multiring bearings ensures that the precision-engineered plate andblanket cylinders run smoothly. The platecylinders are of corrosion-resistant refinedsteel, the blanket cylinders have a specialabrasion-free, anti-corrosion coating. Themain drives for the individual printingcouples can double as auxiliary drives forplate mounting, pre-inking and washing,which saves time and eases operation.

Customised colour capabilityThe four-high tower version (two stackedH-type units) guarantees total flexibilityin colour impositions. The Continent canprint 4-over-4 on one web or 2-over-2 ontwo webs, with the option of additionalweb leads according to requirements. Straightforward webbing-up reduces downtimes during edition changes andenhances press reliability. If just the

upper printing couples in an H-type unitare to be used for a specific print run, anoptional coupling is available that allowsthe web to be fed into the upper couplesthrough the lower, idle couples with nodiversion.

Quick and easy plate changeMaintenance-free lock-up slots and theergonomic arrangement of the plate cylinders in the Continent promote quickand easy, register-true plate mountingwithout the need for tools. The slots arecontinuous so double-spread plates canbe mounted. Circumferential and sidelay registration is remotely adjustable fromthe console.

Minigap on blanket cylinderProven minigaps and metal blankets guarantee an outstanding print qualitywhile reducing maintenance and blanket-changing times. Provision is made forblanket-washing units.

Rigorous safety standardsThe numerous safety features in the printing units conform to the most rigorous standards to protect both thepress crew and machine aggregates.

Examples of possible web leads

Four-high tower of H-type printing units

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The printing units are designed for ergonomic operation

The Continent incorporates proven film inking units with undershot ink knives for abrilliant full-colour print, plus low-maintenance three-roller spray dampeners.

User-friendlyFilm inking units and spray dampeners

Easy operationThe main components of the inking unitare the bleed-free segmented ink knives.The ink keys are adjusted remotely fromthe console, though manual adjustmentdirectly at the ink duct is also possible.

The electrically driven duct roller and thesuperpolyamide-coated film roller transferthe ink film to the roller system. Theduct-roller speed adapts to press speed byfollowing a curve stored in the computer.As an option the oscillating distributioncylinder can be connected to a temperaturecontrol unit.

The washing system for the inking rollers,which is located at the distribution cylinder,is thrown on and off pneumatically andcan be removed and inserted without theaid of tools. The ink forme rollers are alsothrown on and off pneumatically and canbe set with the finest precision.

High-speed ink changes and cleaningInks can be changed quickly and easilyusing a set of tools that includes a wiperblade and an ink duct which can also beused to store ink. The ink ducts are thrownon and off pneumatically for cleaning.Inking units which can be disengagedand integrated in an automatic ink pumping system are available as anoption.

Three-roller spray dampenerThe fount solution is transferred to thedampener via a contactless, easy-accessspray bar. The two individually controlledspray nozzles per broadsheet page (fouracross the web) ensure a precise meteringof fount solution at all press speeds.Individual corrections can be made

remotely from the console. The contact-free transfer of fount solution eliminatescontamination and reduces maintenance.A dampening feed unit is installed foreach press section to filter, prepare and cool the solution. Shutters limitdampening application on narrower webs.

Three-roller spray dampener1 Spray bar with 4 nozzles2 Dampening roller3 Chrome roller4 Plate dampener5 Plate cylinder

Swivelling ink ducts facilitate ink changes

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Inking and dampening units

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A problem-free web run and a uniform web tension were the engineering objectives specified for the Continent to ensure consistent, reliable operation and low waste levels.

Correct web tension KBA Basko

Infeed unit and web leads

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Web infeedThe web is fed in via a running belt thatguides it from the reelstand to the RTF.The continuous belt system feeds the webin fast, is reliable, easy to operate andrequires a minimum of maintenance. Eachbelt can be used for two different webleads. An optional chain web-up system is available to feed the web through thedryer for semi-commercial production.

Safe web runLow-mass, smooth-running idler rollerspromote a problem-free web run duringchanges in press speed. The rollers thatcome into contact with the freshly printedweb are shot-blasted and hard chromium-plated. Photoelectric sensors monitor theweb right up to the delivery fan and trigger the appropriate safety measures in the event of a web break. Adjustableregistration units in the plate cylinder,plus web aligners between the H-typeunits in a four-high tower, compensatefor fan-out.

Infeed unitsThe infeed units in front of the printingunits are each controlled by a reliable,rapid-response measuring roller and drivenby an AC motor acting directly on the drawroller. To reduce slip the web is pressedagainst the draw roller by trolleys.

KBA BaskoOur web-tension control system, Basko,furnishes the press operator with aneffective tool for presetting, monitoringand maintaining the correct web tension.The standard tension is set at the reelstand and console and the actual tension throughout the press is indicatedon the console screen as an easy-to-readdisplay, allowing rapid intervention by theoperator. There is a measuring pointbetween each infeed unit and subsequentprinting unit. The adjustable infeed unitsin front of the printing units, and thedraw rollers in the superstructure, allowthe operator to set the optimum tensionfor each web individually prior to the production run.

Basko web-tension control system1 Basic tension, can be set at the reelstand and console 2 Infeed unit with AC drive 3 Measuring point 4 Severer 5 Photoelectric sensor 6 AC motor for the draw roller in the superstructure

7 AC motor for the ribbon-gathering roller and RTF 8 AC motor for the draw rollers beneath the former9 Variable-speed gearing for the main draw rollers

in the folder10 Diameter enlarger for the pin cylinder

Left: A uniform web tension promotes a high print quality and low waste rate

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Superstructure

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The Continent is normally configured withone former in the folder superstructure.To accommodate individual productionrequirements we also offer the option of two or three balloon formers, a skipslitter, section stitcher, length and/orcross perforator, length gluing unit etc

The compact yet sturdy superstructure on the Continent is freely accessible for makeready tasks and is easy to operate. A wide array of optional features affords exceptional flexibility.

Product flexibilityCustomised superstructure configurations

Simple operationThe arrangement of the draw rollers andidling rollers – one for each web – helpsminimise makeready times. The web isaligned by electrically driven draw rollersand a motorised cut-off register adjustmentunit. Draw-roller advance and the registerposition are infinitely adjustable from the console. The specified values are displayed as a graph on the screen, withprogram-controlled repositioning of thecut-off register during changes in speed.

Raft of optionsThe configuration of the rollers and turnerbars in the superstructure supports a variety of ribbon insertions.

For even greater production flexibility thesuperstructure on the Continent can beequipped with optional turner bars (withor without bay windows), an insertiondeck etc.

Folder superstructureThe electrically driven RTF that gathersthe individual ribbons has trolleys withpneumatic thrown-on/off plus a slitter fortabloids. The air-blown 71° former createsa precise length fold before the ribbonsenter the folder. RTF advance can beremotely adjusted and controlled from theconsole. The folding rollers can be setseparately on both sides to the specifiedcopy thickness. Their angle of inclinationcan also be adjusted in order to avoidcreasing the copies.

Left: The web running into the folder via the former, viewed from the dedicated AC drives for the draw rollers in the superstructure

Right: View of the superstructure on a Continent

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The Continent is available with a choice of two state-of-the-art folders: the standardKF 3B or the more highly automated KF 3. Both have a 2:3.3 cylinder ratio, the samedimensions and compatible interfaces, and both can deliver a maximum of 64 pagesbroadsheet or 128 pages tabloid.

Accuracy and dependabilityKF 3B and KF 3 jaw folders

The two folders incorporate extensivesafety features and are engineered fordurability. Maintenance- and user-friendly,they are extremely reliable and deliver arazor-sharp fold. They are also fullyembedded in the DriveTronic shaftlessdrive system and have dedicated ACdrives that can double as auxiliary drivesfor makeready and maintenance tasks.

KF 3B jaw folderThe speed and advance of the main drawrollers in the KF 3B can be controlledeither directly at the folder or from theconsole, and are integrated in theContinent’s shaftless drive and presettingsystem. Jaw gap, overfold and underfoldcan all be adjusted centrally at the folderduring makeready. The diameter of the pincylinder is infinitely adjustable to pagecount at the folder during the productionrun. Copy spacing in the delivery streamis also adjustable. If the web jams, anelectronic copy control in the paddlewheel actuates the severing knife, whichtogether with an electronic overload protection device in the drive motorbrings the press to an immediate halt. To ensure a smooth machine run, thefolding-cylinder assembly and the deliveryare located in the same rigid cast-ironsubstructure.

KF 3 jaw folderThe KF 3 folder is extensively automatedfor faster conversion of production-relevant functions. The diameter of thepin cylinder can be infinitely adjustedpneumatically at the folder or the consoleto accommodate the specified copy thickness. Over- and underfold adjustmentscan be carried out remotely at the consolewhile the press is running. An electroniccopy control with counter is locatedbetween the jaw cylinder and the deliverywheel.

Optional extras for greater flexibilityFor even greater flexibility the KF 3 foldercan be fitted with various optional features, eg a quarterfold facility as achopper fold, a second parallel cross fold,cross and length perforators, ribbon andsection stitchers and gluing and/or softening units.

KBA KF 3B jaw folder (with extras)1 Former2 Driven draw rollers3 Length perforator (optional)4 Cross perforator (optional)5 Draw-roller motor6 AC drive7 Section stitcher (optional)8 2:3:3 cylinder assembly9 Quarterfold (optional)

The KF 3B jaw folder combines rugged technology and intelligent automation with value for money

Right: The high-performance KF 3 folder is highly automated yet easy to access

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Folder

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Reel logistics

Just-in-time reel supplyEfficient logistics

Like all KBA web presses the Continent can be embedded in a KBA Patras reel-logisticssystem. The standard reelstand is a Pastoline.

KBA Patras reel-logistics systemThe KBA Patras paper transport system(see separate brochure) is module-basedto support a wide range of versions, egwith transfer table, rails and reel truck, sothat it can be customised to accommodateindividual production specifications andplant architecture.

KBA Pastoline reelstandThe Pastoline automated reelstand has ACdrives, an electric braking system, splitarms and an operator-friendly design. Itis built for web speeds of up to 13mps(2,560fpm). The arms on the standardversion can handle a variety of webwidths in increments of 1mm (0.04in) upto a maximum of 1,000mm (39.37in), amaximum web width of 1,270mm (50in)and a maximum reel weight of 1.3 tonnes(2,866lbs). Pastoline reelstands are fullyintegrated in the console system andexceptionally easy to operate. Optionalextras, eg lateral alignment of the outerreel edges to the expiring web, are available for semi-commercial production.

Top: The Patras reel-handling system supports logistical flexibility

Right: The Pastoline reelstand is reliable, cost-effectiveand can handle a range of reel widths

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Automation

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Intelligent automationModular systemCutting-edge console technology, distributed controls at subassembly level and a hostof optional automation modules allow the Continent to be custom-configured to suitindividual specifications.

Three-level hierarchy• Subassembly level with distributed

controls• Console level with operating and

data systems• Process level with production

management system (optional)

Distributed controlsThe reelstands, printing units, folders andother subassemblies are controlled viadistributed processing stations linked toeach other and to the console by high-powered data bus systems. Control panelsdirectly at the printing units and folders,and a mobile, plug-in control station for all offset functions make for easieroperation.

Console levelThe production run is controlled via automated press functions initiated, controlled and monitored from ergonomically designed, height-adjustable consoles featuring process-oriented graphical user interfaces andclear, colour data screens.

Left: The print run is monitored and controlled from high-tech consoles

With the Continent the page(s) on whichchanges are to be made can be selecteddirectly by using presetting data (product-oriented job preparation and press opera-tion). As an alternative, production canbe press-oriented, ie the subassemblyrequiring adjustment is selected via the function keyboard with the aid ofinformative colour graphic screens.Depending on the press configuration the main data screens are augmented byauxiliary screens for additional aggregates.

With the relevant modules a large volumeof production data for repeat jobs can bestored at the console without the needfor an additional production schedulingand presetting system.

Link-up to production management systemThe console system can, as an option, belinked to a production scheduling andpress presetting system and/or expandedto include additional modules, eg formaintenance, statistics etc. Digital datafor presetting the ink keys can be downloaded online from pre-press via aRIP interface. In addition, data can beexchanged directly with other companydepartments such as administrationand/or sales.

Remote maintenance and diagnosticsAn optional remote diagnostics PC withVPN router furnishes a direct link to theKBA service department.

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Suitable for semi-commercialsHeatset package

Heatset and/or coldset

The Continent is a popular choice for semi-commercial (heatset) production on improvedstock and delivers a high-quality print, especially on matt-coated, SC and LWC stock, at a very favourable cost per copy.

High level of cost efficiencyMore and more printers are specifyingthermal air dryers and the associatedheatset facilities so that they can printsupplements and other semi-commercialssuch as ad inserts, flyers etc alongsidetheir standard newspaper titles. This is a field in which we have a wealth ofexperience – and a large installed base.

Heatset packageDepending on the job to be printed thespecial version recommended for printingquality semi-commercials can include thefollowing features:• reinforced inking units• ink temperature control• porcupine roller with web catcher• hot-air dryer• chill roller stand • silicone unit• sidelay control• stitchers• gluing units

• length and cross perforators • quarterfold and/or second parallel

cross fold etc.

Two essentials for a good print qualityare, of course, an efficient pre-press andthe use of high-grade consumables (ink,paper etc).

Top: Chill-roller stand after the heatset dryer

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Modifications may be made with no prior notice. No part of this publication may be reproduced in any way without the permission of Koenig & Bauer AG. Illustrations maydepict special features not included in the basic press price.

Technical data

KBA Pastoline reelstandMaximum reel diameter: 1,270 mm (50 in)Maximum splicing speed: 13 mps (2,560 fpm)

KBA Patras reel logisticsWith choice of automation levels

KBA KF 3B and KF 3 folders2:3:3 cylinder ratioMaximum output: 64 broadsheet or 128 tabloid pages

KBA ContinentAt a glance

SpecificationsStandard formats:Maximum web width: 870/1,000 mm (34.25/39.37 in)Cylinder circumferences: 533 - 700 mm (21 - 27.5 in)Maximum output: 75,000 cph(depending on format and equipment)

Printing units:• H-type, partial or complete, 2 - 4 couples• Stacked H-type, maximum 8 couples• Film inking units with undershot ink knives • 3-roller spray dampening units

Shaftless drives:KBA DriveTronic with dedicated AC drives

Option:Semi-commercial package with thermal air dryer

Koenig & Bauer AG

The KBA Continent fromKoenig & Bauer AG

For further information please contact our sales department at:Koenig & Bauer AGWürzburg FacilityPostfach 60 6097010 Würzburg, GermanyFriedrich-Koenig-Str. 497080 Würzburg, GermanyTel: (+49) 931 909-0Fax: (+49) 931 909-4101kba-wuerzburg@kba.comwww.kba.com10/2010-e. Printed in Germany

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