“From the very beginning, we felt that we had an ideal partner at our side with Koenig & Bauer. That applies both to the press technology and to the services offered by the manufacturer,” says Deviz managing director Andrey Shadrin. The press is scheduled to come back on stream in St. Petersburg in autumn 2017. Thomas Potzkai, head of service at KBA-Digital & Web, has no worries in this respect: “We have already demonstrated on numerous occasions in the past that we are well equipped to realise such press locations quickly, professionally and to the full satisfaction of our customers.” The Compacta 518 was originally installed at the Belgian printing house T´Hooft.
Established print company continues to grow
Deviz has enjoyed continuous and healthy growth ever since its founding more than 20 years ago. In the meantime, the company boasts a 15,000 m2 print centre accommodating several presses, including a 24-page KBA Compacta S80 for retail products. A broad product portfolio for the newspaper, magazine and advertising sectors has earned Deviz an excellent reputation across Russia, the Baltic states and Northern Europe. Andrey Shadrin: “Our objective has always been to develop innovative and tailored products for our customers. The Compacta 518 is to serve above all the growing advertising market in Estonia, Latvia, Lithuania and Finland.”
40-page press for an interesting market niche
The high-performance 40-page Compacta 518 is engineered for a cylinder circumference of 1240 mm and a web width of 1075 mm. It thus covers an interesting market niche between 32- and 48-page products. The press features a Patras M reel-loading system, Pastomat RC reelstand, four printing units with automatic blanket washing, a flexible superstructure and the variable-format KBA V5 folder. The loading of job and presetting data, as well as production monitoring and evaluation, is handled by the management system KBA LogoTronic.
KBA-Metronic: Intelligent marking solutions
Digital communication between man, machine and product is a central issue for the marking specialists at KBA-Metronic. In the age of the smart factory, the camera-readable coding of products is a precondition for automated processes – from detection in packaging lines to traceability in logistics and trade. Increasing individualisation and mandatory product information require powerful and flexible marking solutions.
Metronic marking systems with the code-M software module allow, among other things, the centralised administration of print jobs, the monitoring of entire marking lines and the integration of camera control systems. With the code-M data module, data from databases can be inserted into printed texts. Printing systems and fields are detected automatically, and the form of the imprints is user-definable. With the code-M data and code-M editor modules, many users can create sophisticated text layouts themselves. The job preparation department can carry out layout adjustments, and the marketing department can quickly implement advertising campaigns with action codes.
For the first time, KBA-Metronic will also be presenting the betaJET xenio. The tried and tested DOD inkjet system is highly versatile. KBA-Metronic regards the marking of products and packaging as an integrated process, and cooperates closely with users and mechanical engineers on new developments. The product portfolio with thermal, inkjet, laser and combined printer units covers current market requirements.
KBA-Sheetfed: Folding box printing, conventional and digital
KBA-Sheetfed, the market leader in sheet-fed offset presses for cardboard printing, is also present on the joint stand. In virtual presentations, KBA-Sheetfed will show the digital sheet-fed press KBA VariJET 106 – Powered by Xerox for folding box printing. The KBA VariJET combines conventional printing and finishing technologies with digital inkjet printing. This hybrid press supports regional and campaign-specific versions of packages, value added and infotainment packages as well as database-aided sales campaigns. KBA will also be providing information about its flatbed and rotary stamping units.
KBA-Flexotecnica: Migration-free printing on flexible packaging
For its new-generation CI flexo presses for flexible packaging materials, KBA-Flexotecnica focuses on migration-free printing with water-based inks, e.g. for food packaging. The new laminating machine EVOLAM, which allows the use of solvent-free adhesives, will also be presented.
KBA-Kammann: Direct digital printing on glass bodies is coming in
Digital inkjet printing is also gaining ground in the direct decoration of premium hollow bodies made of glass, plastic and metal. KBA-Kammann, the international market leader in screen, hot embossing and digital printing systems for decorating hollow glass bodies, will be showing this at the interpack. The flexible Kammann systems allow the optimum configuration of applications to meet the diverse requirements of the various target markets and customers.
Large-format sheetfed offset presses in unit design had already been manufactured at the Radebeul factory since 1968. It was then drupa 1995 which marked the transition from the dependable workhorses of the previous Varimat series to the extensively automated, high-performance Rapidas. Newly engineered from the ground up, the large-format Rapida series immediately claimed pole position in this format class. From the mid-1990s onwards, they successively displaced presses based on the out-dated five-cylinder system with their fast makeready times, superior substrate flexibility and application-specific configurations. The availability of highly automated technologies geared to significantly accelerated job changeovers heralded a renaissance for large-format sheetfed offset, not only in traditional fields such as book and packaging printing, but also in the commercial and publication segments.
Large-format sheetfed offset from Saxony since 1968
Irrespective of the new competition which has emerged in this format class over the past ten years, KBA-Sheetfed remains the clear number one with a market share of 60% of new large-format installations. In total, more than 3,000 large-format presses have been supplied by the Radebeul factory, including 1,500 Rapidas. KBA-Sheetfed currently offers the large-format Rapida in four series: Rapida 145, Rapida 164, Rapida 185 and Rapida 205, which together cover formats from 106 x 145 cm to 150 x 205 cm.
Presses becoming longer and longer
The large-format Rapidas have also been setting new standards with regard to the press configurations realised for customers. The longest large-format press in the world to date, a 42-metre long Rapida 145 with a total of 14 printing and finishing units was recently supplied to a European packaging printer. The first printing unit is followed by a coater and two intermediate dryer units, then an automatically convertible perfecting unit, another six printing units, two further coaters either side of two more intermediate dryer units, and finally a three-section extended delivery. Thanks to the comprehensive automation, with automated pile logistics, simultaneous plate and coating forme changing, CleanTronic Synchro for parallel washing processes and full inline colour control, even such press lines are easy to handle.
At home in international packaging and book printing
Large-format Rapidas are at home in packaging, book and commercial printing companies throughout Europe, the Americas, Asia, Australia and in a few individual cases also Africa. In the packaging segment, in particular, the share of long presses with 10, 11, 12 or even 13 printing, coating and drying units has risen significantly, not least due to a constantly growing trend towards inline finishing in folding carton production. In the coming year, such presses are to be delivered to customers in the USA, Sweden, Spain, Mexico, Brazil and Chile, among other countries. Where a large-format Rapida typically comprised five printing and finishing units at the turn of the century, the average length of a press has today risen to seven units.
With the Rapida 205, KBA-Sheetfed also manufactures the press with the largest sheet format on the market – 3 m2 of print on a single sheet. Around 50 of these superlarge-format presses have been supplied since they were first launched in 2003. They are used above all in display and poster printing, but occasionally also in folding carton production where particularly large outer packaging is involved. The second press model in this format class is the slightly smaller Rapida 185, which has already been installed in a double-coater configuration with 12 units and a total length of 38.5 metres.
Alongside cardboard, microflute corrugated and plastic films, large-format Rapidas around the world print a diversity of commercial jobs, books, magazines and catalogues. The list of such installations shows not only straight presses with four or five colours and inline coating, but also long perfectors with eight printing units for 4-over-4 production. Slightly modified Rapida printing units are furthermore the basis for metal decorating presses from KBA-MetalPrint.
Unique technical features
To be able to defend a leading position on the market in the longer term, it is imperative for a manufacturer to offer users unique technical and process-enhancing features. In the case of the Rapidas, this means consistent implementation of the DriveTronic dedicated drive technology at the feeder, the infeed (DriveTronic SIS) and in the printing and coating units. Practice-oriented automation is another aspect which must not be neglected. Both yield significant benefits in terms of makeready times, ergonomic operation and efficiency. On packaging presses for industrial-scale operations, options such as anilox roller sleeves, which can be changed in a flash by a single operator, are fast becoming a standard choice.
Facilities to disengage unused inking units have been standard on large-format Rapidas for decades. Pallet-free logistics systems for substrates from 220 g/m2, reel-to-sheet feeders, cold foil modules and a double-pile delivery are further unique equipment options. Automation solutions such as CleanTronic Synchro (parallel washing processes), sheet inspection systems and inline colour control in numerous variants, including Instrument Flight for control based on grey balance, take workload off the press crew, shorten makeready times and reduce waste.
With top speeds of 18,000 sheets/h (Rapida 145) and 16,500 sheets/h (Rapida 164), the large-format Rapidas can output up to 30,000 m2 of print in a single hour. That corresponds to the entire production and storage floor space of many a large packaging company.
A new KBA Rapida 145 has already been taken into service, and further large-format Rapidas were relocated to Erlensee from the old print centre in Hanau. Before reinstallation, however, they were treated to a thorough overhaul and a number of state-of-the-art retrofits. All three presses are integrated into automatic logistics systems, which handle substrate transport along the whole chain from initial delivery through to post-press finishing and conversion.
The new six-colour Rapida 145 with inline coating unit is engineered for production speeds up to 17,000 sheets per hour. Comprehensive automation lays the foundation for efficient packaging production. Inline quality management is another extremely important aspect. With QualiTronic ColorControl, ink densities are measured and controlled sheet after sheet over the whole length of a run.
Looking ahead to further years of reliable service
The first of the relocated Rapidas came back on stream at the new facility last autumn. With its new grippers and retrofitted logistics components, it is set for many more years of reliable service. After recommissioning, work began on the overhaul of the second large-format Rapida. The whole relocation project was then completed at the beginning of 2017.
Number one in folding cartons
KBA-Sheetfed is the long-established market leader for large-format folding carton production. From multinational packaging groups to regional family-run businesses, users appreciate the enormous substrate flexibility and productivity of the large-format Rapidas, the particular readiness with which KBA addresses requests for application-oriented press configurations, and the company’s superior know-how in the field of inline finishing. Economic efficiency is today a key focus for developments in the packaging branch. In this respect, unique technical features such as universal gripper systems, the sidelay-free infeed DriveTronic SIS or individual logistics solutions have contributed decisively to the high reputation of sheetfed offset technology manufactured in Radebeul.
The new Rapida 75 PRO, a six-colour coater press with extended delivery, was commissioned in mid-June 2016. It is ideally equipped for the printing of pharmaceuticals packaging in short runs. The decisive features include 225 mm raised foundations to enable higher piles, an enlarged sheet format of 605 x 750 mm, central format setting, fully automatic FAPC plate changers, CleanTronic Synchro for parallel washing processes, QualiTronic ColorControl for inline colour measurement, and extensive preset capabilities.
Rapida 75 PRO replaces two presses
After just eight months on stream, figures prove that the investment in the Rapida 75 PRO has certainly paid off: The dramatically shortened makeready times – now just five minutes compared to 15-20 minutes with the predecessor press – have boosted productivity by around 30 per cent. Thanks to the larger sheet format, furthermore, almost twice as many blanks can be accommodated on each sheet. QualiTronic ColorControl has also achieved significant reductions in waste. Especially where repeat jobs are the order of the day, inline colour control is a direct money earner. In addition to the original Rapida 75, Eberle Druck has in the meantime been able to decommission a second press – the Rapida 75 PRO sails through the jobs which used to run on both presses.Peak production speeds play a subordinate role. Rattpack plant manager Marco Resch, who is responsible for both the Dornbirn and Vienna locations, explains: “For print jobs with an average of 250 to 500 sheets, fast makeready is much more valuable than a high production speed.” The facility to disengage unused inking units, on the other hand, is one of the most frequently exploited strengths of the press. In pharmaceuticals packaging, up to 60 per cent of the inks used are spot colours. Where others rely on Euroscale colours, the Rapida 75 PRO at Eberle Druck is often set up to use several or even exclusively spot colours.
The new press has delighted not only plant manager Marco Resch and commercial manager Simon Spiegel, but also the operators in the printshop. The ErgoTronic console with TouchTronic control and a generous wallscreen, in combination with touchpanels at the feeder and delivery, ensures that all important information is made available instantly and in a readily understandable form. In addition, LogoTronic Professional provides a link between the Rapida 75 PRO and the company’s management information system: A mouse click is all it takes to load the next job from the list presented on the console.Within the Rattpack Group, Eberle is responsible for the production of folding cartons for pharmaceuticals packaging, patient information leaflets and other special products for the pharmaceuticals industry (medical device sets, ampoule packs, mini-booklets, etc.). As an express service centre, furthermore, the company takes pride in its exceptional flexibility and fast delivery times. With around 500 employees at eight locations in Austria and Germany, the group generates an annual turnover of approx. €90 million.
But there is one further objective which is no less worthy of consideration in the forefront of an investment decision: Increased operational safety. This aspect is in fact decisive for a company’s overall productivity. Sustained employee motivation depends on a healthy working environment. The elimination of potentially hazardous activities, such as work in unnatural postures, heavy lifting, repugnant odours or stressful operating procedures, can noticeably reduce or even avoid the occurrence of chronic illnesses and work accidents. At the end of the day, every employer should feel obliged to consider investments in the latest available technologies, in order to minimise the risk potential at every single workplace.
Avoiding dust and odours
Equipment features to enable IPA reduction are an effective means to combat undesirable odours. That includes, for example, roller coatings for low-alcohol printing or production using an alcohol substitute (in both cases for conventional, UV and hybrid inks). EES (Emission Extraction System) serves a similar purpose in UV printing and finishing applications. It prevents unpleasant odours occurring around the delivery, and thus at the press operator’s main workplace, and at the same time extracts dust. In some special cases (e.g. UV printing) extraction in and around the inking units can also be expedient to minimise ink misting.
Making processes simpler and safer
Modern technologies often achieve great impact. One example of this is the DriveTronic SIS sidelay-free infeed on Rapida sheetfed offset presses: It dispenses with setting and maintenance tasks and relieves the operator of manual interventions in harmful postures. Injuries are excluded. The high level of automation, furthermore, eliminates sources of error.
A further example is the provision for essentially automated blanket changes: It takes around 65 to 70 pulls on a torque wrench to open the blanket clamps fully. And then the same again for closing. The task takes approx. 8 minutes. It is furthermore physically tiring and highly stressful for the operator’s joints. With this in mind, KBA-Sheetfed offers appropriately suitable cordless screwdrivers, which make the work much easier and reduce the time needed by a third.
A plate lift also saves the operator a lot of physically demanding work, especially in connection with long or raised presses. Large-format plates, in particular, can be rather difficult to handle and entail a risk of injury if not transported correctly. With a plate lift, it is a much simpler matter to lift the plates up to the gallery level. The press operator or assistant then only needs to insert them into the corresponding plate changer magazine.
The non-stop rollers at the delivery similarly enhance safety. Modern deliveries are already designed such that the press is automatically stopped if the operator or any foreign object violates the defined boundaries of the delivery. This safeguard is taken one step further on a Rapida press, where the non-stop rollers are activated as soon as the pile plate is lowered while the press is running. The operator is thus safely protected from the still passing gripper carriages. Once the press has come to a standstill, the rollers can be retracted at the press of a button.
Greater comfort with AniSleeve, AniloxLoader and SFC
KBA’s coating units are further examples of how previously manual processes can be automated and made safer. For example: Anilox roller exchange. AniloxLoader is the corresponding option for the medium-format Rapida 106. Up to three anilox rollers can be stored in the coater magazine. Anilox roller changing takes place automatically and parallel to other makeready processes. That saves time and relieves the operator of a great deal of heavy lifting.
The situation is similar in large format: With the AniSleeve system, the changing of anilox roller sleeves is child’s play and can be handled by a single person, despite the dimensions. Once the bearings are released at the sides, the sleeves can be pulled out and placed in a sleeve depot using a simple lifting system. A new sleeve with a different cell volume can then be pushed back into the coater – again with a minimum of effort. Large packaging printers use this automation option almost without exception.
On Rapida presses, coating forme changes are accomplished in a matter of seconds with SFC (Simultaneous Forme Change), doing away with time-consuming clamping, bolting and tensioning. That lightens the operator’s workload and enhances process security. Furthermore, coating forme changes can take place parallel to other makeready processes at the printing units.
When it comes to health and work safety in the printshop, there are possibilities to implement much more than is prescribed in the official regulations. It is up to the individual company to decide whether to make use of the available potential, in order to guarantee employees a safe and ergonomic workplace.
Extensive automation for greater efficiency
A KBA Rapida 75 had been in production at Eberle Druck since 2011. At that time, the press had to be purchased at short notice, and the company accepted a number of compromises with regard to the equipment features. It was not possible to place the press on raised foundations to allow higher piles, and a colour control option was also missing. Job changeover times, furthermore, were relatively long.
The company invested in the more extensively automated successor model Rapida 75 PRO immediately after the market launch. The six-colour press with inline coater and extended delivery is ideally equipped for the printing of pharmaceutical packaging in short runs: Sheet format enlarged to 605 x 750mm, 225mm raised foundations, central format setting, fully automatic FAPC plate changers, disengaging of unused inking units, CleanTronic Synchro for parallel washing and QualiTronic ColorControl for inline colour measurement.
The Rapida 75 PRO has enabled makeready times to be shortened dramatically compared to the old Rapida 75 – from 15-20 minutes to just five minutes. Productivity has increased by 30 per cent. Thanks to the larger sheet format, considerably more packaging blanks can be accommodated on each sheet. In some cases, there is room for an entire new row of blanks. Waste has been reduced significantly, and print quality is extremely constant. In addition to the old Rapida 75, Eberle Druck has also been able to decommission a second press.v
In January of this year, a KBA Rapida 105 press went into production at the Dauir Printing House in Almaty, the former capital of Kazakhstan. The four-colour press is equipped for commercial printing and outputs up to 16,000 sheets per hour.
Dauir was founded back in 1932, then under the name Printing House No. 2. During the Soviet era, the company printed over 3,000 different newspaper titles and books in high-volume runs. The sheetfed department was already then a domain of “vista blue” presses from Saxony.
After the dissolution of the Soviet Union, the company was privatised. As chance would have it, Dauir – whose name translates as “our times” – was acquired by a group of investors headed by Svetlana Nazarbayeva, sister-in-law of the President of the Republic of Kazakhstan. The building was renovated from the ground up, and the machinery base was modernised. In fact, a new printing press or downstream finishing machine was purchased almost every year.
Today, Dauir counts a workforce of almost 600 employees, many of whom have studied at the Moscow Institute of Printing. The product portfolio centres around illustrated books, encyclopaedias and popular literature. For the past 12 years, textbooks for all levels of education – from pre-school to university – have also become standard products, together with a diversity of materials for the further training of teachers and lecturers.
A publishing subsidiary Kitap was founded in 2003, not least to better coordinate the publishing of school textbooks, as well as scientific literature from the fields of mathematics, physics, chemistry, biology and world history. Further activities embrace a wide range of poetry and fiction, alongside some 60 newspaper titles.
A year ago, in January 2016, KBA president Claus Bolza-Schünemann visited the company and prepared the ground for the latest investment. After a break of over 25 years, during which several printing presses were purchased from other German and Japanese manufacturers, the Dauir Printing House has now once more taken delivery of a press “Made in Saxony”.
The inkjet web press KBA RotaJET L, which was demonstrated in live production for the first time at drupa 2016 and recently ordered in the version RotaJET 130 by Finnish book printer Bookwell Digital Oy, stands at the focus of the presentations planned by KBA-Digital & Web Solutions for the forthcoming Hunkeler Innovation Days in Lucerne from 20th to 23rd February. The KBA experts will be available on Stand 24/25 to provide all pertinent information on the technology and possible fields of application of high-volume inkjet web printing. The RotaJET L series is offered in 1/1 and 4/4 configurations for web widths from 77 to 138 cm. The press can be tailored extremely flexibly to individual applications, and also allows for retrospective expansion in terms of width and number of colours.
The modular RotaJET L models are complemented by the RotaJET VL series for web widths up to 225 cm. Maximum flexibility, excellent print quality and ultimate productivity are the hallmarks of KBA’s RotaJET digital web presses. KBA currently builds the world’s widest inkjet web presses for the book printing, decor, publications, packaging and advertising segments. One of the greatest assets brought into play in press manufacture is a sheer boundless wealth of technical know-how relating to web control and substrate handling. The combination of precision engineering and modern inkjet head technologies also achieves excellent print results on complicated substrates, as KBA-Digital & Web demonstrated admirably at the last drupa.
Branch VIPs gather in Halle
More than 100 prominent guests attended the inauguration ceremony at the MZ print centre, among them Christian DuMont Schütte, chairman of the supervisory board of the DuMont media group in Cologne, his deputy Isabella Neven DuMont, CEO Dr. Christoph Bauer, CFO Stefan Hütwohl and COO Otto Christian Lindemann. In his address, Stefan Hütwohl emphasised that the investment in the new press from Koenig & Bauer was for DuMont not only a commitment to the group’s Halle location, but at the same time a demonstration of faith in the future of the printed newspaper.
It was almost a year ago to the day that contracts were signed for the new Commander CL, continuing a partnership which has thrived for more than 180 years between DuMont and Koenig & Bauer. “I would like to give special mention to the exceptional cooperation with Koenig & Bauer. The past months have shown us that our investment in the Commander CL was very definitely the right decision,” said Bernd Preuße, managing director of the print division DuMont Druck.
Modern newspaper press technology
The new four-high Commander CL is engineered to print up to 45,000 full-colour newspapers per hour, either with 32 pages in Rhine format or 64 pages tabloid. Almost 200,000 copies of the Mitteldeutsche Zeitung and a further 1.3 million copies of the advertisers Wochenspiegel and Super Sonntag will now be produced on the new Commander CL from Koenig & Bauer.