Newest ink density measurement reduces the operation and material expenditures for the reliable COLORMAN presses
Thursday, November 17, 2016
"Hauptsach gudd gess" – the main thing is good food; a very common phrase in Saarland. The Saarbrücker Zeitung newspaper is another important part of the local way of life. It constantly invests in new technology and is therefore always up to date with its reliable COLORMAN. Two ten year old COLORMAN presses have now received an upgrade with IDCµ, the new ink density control for newspaper printing.
InlineDensity Control with micro marks (IDCµ) absolutely proved its worth at its very first installation site in the Bamberg print house. This is where Saarbrücker Zeitung informed itself and discussed its requirements with manroland web systems and the Munich based Grapho Metronic ink control experts. As a result the team of Saarbrücker Zeitung’s print manager Gerhard Leibrock became the second printing company to invest in IDCµ. “The customer was convinced that he was being offered the newest, most functional and fitting system when he made the decision to purchase”, manroland web systems project manager Werner Nuber explains.
Operating effort lowered significantly
Efficient production and quality assurance: These were the prospects for the print house’s first installation of an ink density measurement system. After the first practical experiences Gerhard Leibrock is convinced: “IDCµ will significantly reduce operation and material expenditures. The fact that IDCµ takes charge of ink feeding completely automatically means that even a small operating team is capable of producing securely.” Leibrock also appreciates the accompanying improvement of the print quality and documentation: “It lets us achieve absolutely efficient production processes.” The cooperation between Klaus Zöhler, Saarbrücker Zeitung production manager, and Peter Hartman, print instructor at manroland web systems, was also efficient and very professional, before as well as after taking the ink density control was put into operation. This accounted for the significant reduction of start-up waste right from the beginning. The waste reduction was made possible through improved presets, resulting from very homogenous ink profiles in the production run. This is just one example why the argument “all-in-one” was decisive for the decision. IDCµ as a product from the printing press manufacturer raises high expectations and offers great opportunities. Saarbrücker Zeitung has after all only one single contact partner, manroland web systems. Interface related losses are unlikely and the support in case of possible disruptions is already covered with the existing TelePresence service contract. New features like an upcoming dampening control can be easily integrated into the workflow.
Werner Nuber has been providing support for Saarbrücker Zeitung for years, wear related interventions for the two COLORMAN presses are needed most. However, more extensive retrofits are also carried out on a regular basis, for example integrating additional turning bar levels or the automation of splicers. “A relationship characterised by openness and mutual esteem developed itself during this cooperation”, Nuber observes and adds: “With the installation of IDCµ Saarbrücker Zeitung goes one step further in optimally automating a ten year old existing press”.
IDCµ is part of an extensive modernisation, which also includes retrofitting the control console computer and a mobile MobilPad control station upgrade. An existing cut-off register control system was replaced, and ribbons can now be easily regulated with InlineCutoff Control.
Real density measurement with micro marks
How does IDCµ work in the 64-page COLORMAN? The IDCµ regulates four webs in Saarbrücken. Two cameras are used for each of the four paper webs to control the ink density and dampening feed on the front and reverse side. The moveable cameras periodically perform density measurements with printed micro marks. The value measured at each ink zone position is compared with the given set value and corrected in case of deviations. “IDCμ therefore achieves outstanding control accuracy within close tolerances”, Nuber knows and makes the unique technology responsible for the high measurement stability: “The IDC cameras measure identical micro marks along the whole width of the web with a familiar structure. They do not interpret changing images and values like they do in “image measurement”.
In order to let IDCµ display its efficiency completely the ink density control has been fully integrated into the PECOM-X workflow. When printing new and repeat jobs all IDCμ presets are configured automatically by the Printnetwork PressManager (PPM). Individual density specifications differing from the standard can subsequently be adjusted directly via the mobile control system (MobilPad). The PressQuality reporting module evaluates the ink density measurement – IDCµ is a self-learning system after all.