Heidelberg Unveils New Star 3000 Generation
Monday, December 11, 2006
12/08/2006 -- With the 3000 series, Heidelberg is unveiling a new generation of peripherals. Four new models will be launched onto the market in the next few months, helping print shops achieve even greater production speeds, shorter make-ready times, and less waste. Real savings can be made in particular for high-quality jobs or special applications, with enhanced ease of operation and eco-friendly production. A unique feature is the networking of peripherals with the standardized CANopen databus system (CAN stands for Controller Area Network). Heidelberg is the world's only supplier that develops its own peripherals in-house and systematically uses CANopen technology. JDF and Prinect network prepress, press, and postpress, while CANopen connects the peripherals to the press. With the new CombiStar 3000, Heidelberg employs the CANopen network to continuously check the status of the press, enabling the inking unit temperature control to be regulated more accurately. CANopen also simplifies operation of Star peripherals, with all settings being made at the touch of a button via the central Prinect CP2000 Center press control system. The preset functions enable peripheral presettings to be saved with the job and accessed quickly for a repeat job. CANopen means the Heidelberg Remote Service can now also access peripherals. All new Star units are initially being offered for the Speedmaster XL 105 and, in some cases, for the Speedmaster SM/CD 102. By drupa 2008, all cabinet-operated presses will feature the Star 3000 generation, replacing the current 2000 generation. Stable print process and less energy consumption with the CombiStar 3000 and CombiStar 3000 high end units The CombiStar 3000 is a completely revised system for dampening solution processing and inking unit temperature control. With the new high-end version of the Combistar 3000, Heidelberg has for the first time successfully used press data via CANopen to stabilize the inking unit temperature and thus produce even greater consistency in terms of ink density. CANopen functions like a closed loop that constantly reconciles the data between the press and the peripheral device. Waste sheets caused by stopping and restarting the press are reduced as the CombiStar 3000 reacts immediately to changing situations. This ensures consistent ink density and a stable print process while also enhancing productivity. The new CombiStar 3000 high-end unit also features two-stage dampening solution filtration, a digital metering pump, trend analysis to assess relevant process parameters, and numerous innovative energy saving functions. At cold to normal outdoor temperatures, the inking unit temperature control is operated from the recooler upstream of the printroom. This is very energy-efficient. A cooling unit is only activated at higher temperatures. Overall, up to 8,000 Euro can be saved each year with reductions in energy consumption of approx. 3,000 Euro, filtration savings of 2,500 Euro, precise alcohol metering bringing savings of approx. 2,000 Euro, and precise metering of dampening solution additives yielding savings of over 500 Euro. The CombiStar 3000 high end unit is suitable for conventional and UV printing, especially for reduced-alcohol, and eco-friendly printing. AirStar 3000 air supply cabinet consumes up to 50 percent less energy, generates 45 percent less heat, and requires up to 50 percent less space New blower technology means the AirStar 3000 is around 50 percent smaller and consumes up to 50 percent less energy than its predecessor. This can result in annual savings of up to 8,000 Euro for a Speedmaster XL 105-6+LX in three-shift operation. The new frequency-controlled turbo radial blowers are used only on Heidelberg presses and produce 45 percent less heat, making the blast air on the press much cooler. This simplifies the print process and prevents smudging and scumming. The redundant design results in maximum reliability in production. If one blower fails, a second or third one assumes its role and the press can continue operation. Furthermore, the new blowers are extremely quiet. Greater production speed for dual-coating presses using the DryStar 3000 LYL dryer The benefits of DryStar 3000 technology can now also be exploited in the new drying units of the Speedmaster XL 105 dual-coating press. With the aid of a patented round nozzle field, much more hot air is applied to the entire dryer surface than with conventional systems. Even coatings that are difficult to dry, such as blister coatings, can be covered at a speed that is 20 to 25 percent faster. Heidelberg launched the DryStar 3000 at drupa 2004 as the first Star product of the new generation. With over 500 installations, the DryStar Combination coating dryer has proved to be a great success. Many customers confirm that a Speedmaster CD 102 Preset Plus fitted with a DryStar 3000 Combination can be run 20 to 25 percent faster than other makes of press when working with coatings that are difficult to dry and also produces extremely glossy results. Doubling the quantity of air and reducing the distance between the DryStar dryer and the sheet are both key factors. The round nozzles of the DryStar 3000 also have the advantage that air is distributed to all sides and not just on two sides, as is the case with a conventional hot-air blade. This stabilizes sheet travel and prevents air finding its way under the rear edge of the sheet. The flat sheet position in turn means the IR radiation strikes the substrate at a right angle and has greater impact. DryStar 3000 UV ensures stable UV drying with shorter make-ready times The DryStar 3000 UV features a blue shimmering URS reflector (URS = UV reflector system). The reflector has over sixty optical layers, which reliably reflect the UV component of the emitted light. In contrast, the warm infra-red component is absorbed by the reflector and the heat is routed outside via coolant ducts. This ensures that neither the press nor the printing stock is heated excessively. This is particularly important for printing on plastic films. The dryers for the delivery and the interdeck dryers are not identical but are designed for their special position and requirements. This focuses the beam and accelerates hardening of the UV inks. The surface of the new URS reflectors is so cold that ink splashes and powder do not burn into the coating even after months of operation. Regular cleaning with alcohol is sufficient to keep productivity and press speed consistently high over a long period. Even after just a few weeks of operation, the difference is noticeable between these reflectors and cheap, scratch-sensitive aluminum reflectors that quickly dull. The DryStar 3000 UV is now fitted with cordless lamps that can be changed within a minute without using any tools. For hardening opaque white, Heidelberg offers lamps with special additives that can lead to an increase in production speed of up to 20 percent depending on the ink type. With the new DryStar 3000 UV, these opaque white systems can for the first time be used without the need for a special, expensive reflector. All DryStar 3000 UV dryers are designed as a slide-in/fold system. The sheet guide plate and impression cylinder can be accessed within seconds and cleaning and maintenance are simplified. The fully automatic plug-connection between the press and the dryer module is a unique feature. Instead of having to manually disconnect supplies of air, electricity, compressed air, and water, the operator on the DryStar 3000 UV only has to pull the dryer cassette from the press. All connections are contacted fully automatically, with even the water supply point opening or closing by itself. No tools or other work are necessary. The new UV dryers are all approved by the German Institution for Statutory Insurance in the Printing and Paper Industry. If the InstantStart software license is installed, they can be operated without any safety-related waiting times before and after washing, which further boosts productivity by up to 25 percent.