More performance and automation in large format

With the enhanced Rapida 145 KBA-Sheetfed will probably be the only exhibitor presenting a high-tech large-format press at drupa. The six-colour press with coater and automated pile logistics on display will be equipped with a raft of new highlights aimed at automating the printing process further and making this even more effective. Its higher maximum speed of 18,000sph (Rapida 164: 16,500sph) and new double-pile delivery are striking features. The first large-format presses with double-pile delivery are already in operation. This option is now also available in medium format for the Rapida 106.

Increased productivity through a waste-free delivery pile

The new double-pile delivery contributes to optimising production at packaging companies with high throughput. A waste-free delivery pile which stands next to a smaller pile of waste can be sent straight to a die-cutter or laminating machine to be converted. Productivity is increased as manually sorting through a pile for waste is now no longer necessary.

Both piles can be embedded in substrate logistics. Waste can be ejected at full speed, i.e. at 18,000sph (Rapida 145) and 20,000sph (Rapida 106). What is more, start-up and run-up waste is removed automatically. Further applications are planned in the future. In addition, double-pile delivery makes nonstop pile change at maximum speed safer. Production with two piles is possible in both manual and automatic mode.

Automatic paper stretch compensation

Colour imposition, dampening and the number of colours influence the substrate and can lead to variations in print length. Stretching the printing plate along the axis and radius of the cylinder (up to 0.2mm) on Rapida jumbos remotely via the console (ErgoTronic PlateStretch) can compensate for the print length. Manual intervention is not necessary. The result is improved print quality and less waste.

Perfect print quality at a glance

There have also been advances in inline colour control with QualiTronic ColorControl. Green and red lights show the operator at the ErgoTronic console’s monitor whether the colour densities are within specified tolerances. A sound signals deviations and prompts immediate corrections. A feeder stop can be done to avoid waste if an error cannot be rectified quickly enough.

QualiTronic PDF for automatic quality control

Another new product to be unveiled at drupa in large format is QualiTronic PDF inline sheet inspection as part of automatic quality control during printing. It compares a freshly printed sheet with the contents of a PDF file from pre-press. After approving the reference sheet, production monitoring creates a virtual reference as soon as the OK sheet counter starts. A camera with a resolution of around 300dpi detects the smallest errors up to 90µm, even at maximum press speed. The inspection parameters can be adjusted during printing. The operator can find detailed information on possible sheet errors on the ErgoTronic console’s wallscreen. Certificates and reports provide detailed information on the print quality.

QualiTronic PDF Pile View is an additional tool for subsequent error analysis following production or in the case of complaints. The precise control of the entire job eliminates waste and prevents the customer from delivering faulty sheets.

Logistics alternative with higher automation

As the market leader in board printing technology, KBA-Sheetfed has a wealth of experience in substrate logistics. As part of PileTronic the new system boasts above-floor assembly and a low installation height. It does away with interfering with the hall floor or a building’s foundations. 

The piles are transported via LOX bands and servo motors smoothly and precisely to the press. A clear and simple user interface makes operation easier. Plug & Play components are also used.

The pile turner has an individually controlled programme for preparing the pile. Vibration duration, air supply, pile position or mechanical strain on the substrate can be set according to material. The system extracts the top three to five waste sheets automatically during pile preparation.

Transparent energy consumption

Press performance, the resulting energy consumption and individual components, such as the dryer, can be tracked at the console in real time. KBA LogoTronic Professional logs and stores the energy consumed according to job. 

VisuEnergy is KBA’s solution for analysing all energy consumers in a printing house. These can then serve as input variables for a company’s energy management system.