Donnelley Upgrades in Warsaw, Indiana with KBA Rotogravure Press
Press release from the issuing company
Publication rotogravure is currently enjoying a global upswing with enormous investments in state-of-the-art technology. R.R. Donnelley & Sons Company, the world´s second largest printing group, has once again opted for gravure know-how from Koenig & Bauer AG (KBA) and is adding a TR8B rotogravure press to its fleet in Warsaw, 150 km (93 miles) south east of Chicago.
The new one-level press is designed for web widths of up to 3.18 m (125 in) and consists of one reel stand, eight rotogravure printing units, an asymmetrical turner-bar superstructure engineered for up to 12 ribbons and two variable folders positioned back-to-back, each with three deliveries. This configuration supports production with 4 and 6 pages around the circumference with a cut-off from 300 mm to 500 mm (11¾ to 19¾ in). Up to 144 pages can be printed per impression at a speed of 57,000cyl rph (almost 16mps/ 3150fpm).
Individual Drives and Fast Changeovers
Only the eight printing units are connected via a longitudinal shaft. All other components - including draw roller groups - are linked via a virtual shaft and driven by AC servo motors with KBA Drivetronic control. Better access to folders is achieved with smaller individual drives which eliminate space-consuming mechanical shafts etc. and hence the folding cylinders and delivery each have separate drives.
Other features of the press - which cut version changes to within 10 minutes - include splash-guard-free inking units, an automatic impression roller cleaning system and an automatic forme cylinder loading system with double-decker trolleys. And the new-design dryer with optimized web travel ensures particularly gentle web drying.
World´s Largest Gravure
The history of R.R. Donnelley dates back to 1864 when Richard Robert Donnelley established a small family printing plant in Chicago. In less than one hundred years R.R. Donnelley mushroomed from a local company to a global player. The company posts yearly turnover in excess of US$ 5.8 billion and boasts 52 manufacturing plants in 19 countries with 34,000 employees serving customers spread over four continents. The Warsaw division employs 1,500 staff at two separate locations stretching over 120,000 m (12 hectares), each with its own printing and post-press fleet. It is the world´s largest center for gravure printing.
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