Two fast Rapida 106 presses with LED-UV at Tosho Printing

Japan used to be a trendsetter when it came to LED-UV curing in sheetfed offset making it all the more noteworthy that one of the country’s largest printing companies has fired up two KBA Rapida 106 presses both with future-focused LED-UV curing technology. This once again highlights the trailblazing role of KBA-Sheetfed Solutions regarding the implementation of new processes.

Tosho Printing, a subsidiary of the global Toppan group, has installed a highly automated four-colour and a five-colour high-end Rapida 106. The two new Rapidas have raised the bar with regards to productivity within the company. They are equipped with a camera system for monitoring sheet travel, DriveTronic SPC dedicated drives at the plate cylinders, CleanTronic Impact combined blanket, impression cylinder and roller washing units, Emission Extraction System (EES), ErgoTronic ACR auto-register, QualiTronic ColorControl for quality control and inspection, optimum control strip height for improved paper format utilisation, DataMatrix-Select and the LogoTronic Professional production management system.

High production output and short lead times

The management of Tosho Printing knew that their new Rapidas would produce more per hour than their other machines and just one month after installation the two presses met the company’s ambitious targets. Even Tosho’s executives, who would have preferred to invest in Japanese technology, now trust in KBA presses from Germany. Despite high press speeds of 18,000sph, the press operators can relax during production thanks to the high level of automation. The sheets that are cured with LED-UV can be sent straight to post-press reducing lead times, minimising short-term storage requirements and enhancing overall productivity.

Tetsuo Ouchi, corporate officer production control at Tosho Printing, describes the situation as follows: “Japanese press manufacturers will have to work even harder. We hope that they will also develop the solutions already offered by KBA.” Nevertheless, he expects significantly more than the contractually agreed delivery and efficient service from KBA. “It’s all about working together as partners, even when it comes to developing new print products.” The company recently tested FlyingJobChange. It permits the even more efficient production of 1/1-colour Mangas on a four-colour perfector. While units 1 and 3 are printing, units 2 and 4 are set up or vice versa.  

Strong when it comes to newspapers and commercials

Founded in 1911, Tosho Printing now operates 30 sheetfed offset presses and other newspaper and commercial presses at five sites. Yomiuri, Japan’s largest daily, and others are produced at the firm’s three newspaper operations. The other two specialise in commercial products, books and magazines. The same is true of the plant in Kawagoe-shi on the edge of Tokyo that operates the two new Rapidas. 1,700 employees work at the company.