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KBA Metal Decorating
AUTOMATION MAKES THE DIFFERENCE
ASIA CANTECH 2013 / SURABAYA
KBA Metal Decorating
1. KBA-Group
2. Automation Examples - „PRINTING UNIT“
3. Customers Benefits
4. Outlook METPACK 2014
KBA Metal Decorating
1. KBA-Group – KBA-MetalPrint GmbH
2. Automation Examples - „PRINTING UNIT“
3. Customers Benefits
4. Outlook METPACK 2014
KBA Metal Decorating
KBA-Group
Koenig & Bauer AG
© KBA-MetalPrint Page:5
Highlights of Koenig & Bauer AG -
parent company of KBA MetalPrint :
• Factories in Germany, Austria, Czech
Republic, Switzlerland
• Sales of some €1.2bn generated by
just under 6,000 employees
• Technological trendsetter
• No.1 in newspaper presses
• No. 1 in large-format sheetfed offset
(no. 2 overall)
• No.1 in packaging offset, security and
metal decorating presses
• Strong position in green technology
6
Koenig & Bauer AG
Commercial Web
Newspaper Printing Press - KBA Commander CT
Highlights:
• up to 90.000 cph
• 4-C print on both sides in one deck
• web width max 2.100mm - cutted, folded in one line
• Automatic Plate Change
• separate drives for cylinders and inking units for
reduced make ready time Newspaper Web
Products Web -
200 years ago The Times in London became the first newspaper in history to be printed by a
machine – Koenig’s double-cylinder press
© KBA-MetalPrint Page:6
Commercial Presses for Printing of Magazines, Brochures, etc…
7
Koenig & Bauer AG
Commercial Web Digital Inkjet Web Newspaper Web
KBA C16 – C80
Highlights:
• up to 50.000 cph
• max web width 2.280mm
• designed for short runs and fast job change
• print of bulk mail, inserts and covers for
catalogues etc…
KBA RotaJET 76 – Digital Printing
Highlights:
• up to 3.000 4Color DIN A4 pages per minute
• Piezo Ink Jet Technology
• 4 colors on both sides without turning bar
• designed for shortest job runs
© KBA-MetalPrint Page:7
Products Sheetfed for printing of magazines, packaging, cards, …
8
Koenig & Bauer AG
Security Printing
Disk printing Air Purification
Card Printing Packaging and Commercial Sheet-fed Printing
Rapida 106 – 205 - Highlights:
• offset printing on paper or board
• up to 12 decks - 4 + 4 printing, coating and
drying in one line
• perfecting drum to print on both sheet sides
• sheet thickness: 0,04 – 0,7 mm
• make-ready saving by highest automation
• up to 18.000 sph
Genius 52 - Highlights:
• offset printing on non-absorbing substrates
(PET,PVC, PS ….)up to 50.000 cph
• 5-colour printing in one deck
• very compact design
• 8000 sph with size 360x520mm
© KBA-MetalPrint Page:8
Special Applications
9
Koenig & Bauer AG
Disk printing Air Purification
Security Printing of identity papers, fiscal
stamps, bank notes
Alpha Jet - Highlights:
• Markings include barcodes, best-before dates,
data matrix codes and customized texts and
graphics
• apply on various substrates
Laser Systems:
• small caracter coding application
• marking with pin point sharp texts
• marking on metals and plastics
• laser labeller for coding of packagings, pallets
etc…
© KBA-MetalPrint Page:9
KBA Metal Decorating
KBA-MetalPrint
Company History KBA-MetalPrint
© KBA-MetalPrint Page:11
• 1876 Mailänder Druckmaschinenfabrik
• 1924 Carrier Lufttechnische Gesellschaft LTG
• 1974 Bauer & Kunzi GmbH
• 1994 Aquisition of Mailänder by LTG - LTG Mailänder GmbH
• 2003 Aquisition of Bauer & Kunzi GmbH by Koenig&Bauer AG
• 2006 Aquisition of LTG Mailänder GmbH by Koenig&Bauer AG
• 2006 KBA-MetalPrint GmbH has been founded as 100%
subsidiary of Koenig & Bauer AG
MORE THAN 100 YEARS EXPERIENCE IN METAL DECORATING
KBA-MP offers with
the MetalCoat 480
the fastet make-
ready coating
machine
KBA-MP offers with
the MetalStar the
highest quality and
fastet make-ready
metal printing
machine
KBA-MP offers with
their High Econ TNV
the lowest energy
consumption of all
thermal drying
systems in metal
decorating
KBA-MP was the
first manufacturer
in the world with a
overhead stacker
and indeed as a 1-
,2- or 3-stacker
KBA-MP offers with
their brand LTG the
recognized best
dryer in metal
decorating
KBA-MetalPrint – Line Supplier in Metal Sheet Decoration
© KBA-MetalPrint
Company Data KBA-MetalPrint
• Located in Stuttgart / Germany
• Sales 2012 EUR 80 million
• Sales 2013 prospect EUR 90 million
• Export ratio > 85%
• R & D 3% of sales
• Employees 280
• Production area in Stuttgart 24000 sqm
© KBA-MetalPrint Page:13
KBA-MetalPrint Business Areas
© KBA-MetalPrint Page:14
System supplier in metal sheet decoration for food cans, general packaging cans, crown corks, alu caps, twist off caps
with an installed machine base of
• 2500 Wicket ovens for sheets
• 1250 Coaters
• 850 Mailänder printing decks
• 550 MetalStar printing decks
Product Range - Printing
• MetalStar PR Multi-Colour Printing Machines
• Mailänder Traditional Printing Machines
© KBA-MetalPrint Page:15
Printing Line Configurations
Conventional Line
© KBA-MetalPrint Page:16
Printing Line Configurations
UV Line
© KBA-MetalPrint Page:17
Product Range - Coating
• MetalCoat 470 Coating Machine
• MetalCoat 480 Coating Machine
© KBA-MetalPrint Page:18
Product Range – Drying Ovens
• LTG DB 3000
for flat metal sheets
• Beltstar
• PinStar
for 2-pc cans
• IBO
• OBO
• Dry-Off
• Individual concepts and
upgrades for existing can
lines independent of
manufacturer
• DrumStar
for drums manufacturing
© KBA-MetalPrint Page:19
Product Range - CleanAir
• Regenerative Thermal Oxidizers
• TNV
© KBA-MetalPrint Page:20
KBA Metal Decorating
1. KBA-Group – KBA-MetalPrint GmbH
2. Automation Examples - „PRINTING UNIT“
3. Customers Benefits
4. Outlook METPACK 2014
KBA Metal Decorating
Automation Examples - „PRINTING UNIT“
Inking Unit
Milestones „Inking technology“
Many Machines in the market: Inking unit type „Storage system“
• Design of the 60‘s and 70‘s
• Design with the large diameter storage
roller results in slow reaction time by
zone setting changes and more waste
sheets
• High ink application with last form rollers
• Danger for stripes and ghosting effects
• More sensitive for ink/water balance
problems because of bad ratio:
thin ink film on first form rollers and
direct influence of dampening water
Note: In Metal-Decorating plenty of
these storage inkers are still in use and
sold until today
© KBA-MetalPrint Page:23
Milestones „Inking technology“
MetalStar: Inking unit type „Multi roller system“
• Newest design for inking units
• Faster reaction time by zone setting
changes
• Better ink/water balance
• Lower ghosting and stripe addiction due
to fettling effect of 3th. + 4th. form roller
• Approx. 99% of all new printing presses
are based on multi roller systems except
traditional Metal Decorating Machines
Since approx. 40 years, Multi-roller
Inking units are the state-of-the-art
solution for all modern sheet-fed
suppliers like KBA, Heidelberg,
manroland, Komori a.s.o.
© KBA-MetalPrint Page:24
Milestones „Inking technology“
In 1967 KBA (Planeta) developed an immediate interruption of ink delivery
• At press stop the ink profile on rollers will be destroyed
by movement of ozillators
• This is the reason for increased waste sheets and time
• Nearly 50 years ago KBA developed a device to avoid
this effect
• Together with the press stop, key rollers are lifting up
from the ozillators and interrupt immediatly the ink
delivery
On all modern printing machines like KBA presses, such a
device is standard.
Only in Metal-Decorating, some other presses without
this helpful device are still available!
© KBA-MetalPrint Page:25
Inking Unit (option)
Inking unit temperature control
• Guarantees process stability and high
printing quality due to the cooling of all
three oscillators
© KBA-MetalPrint Page:26
Milestones „Inking technology“
For shorter make ready and higher printing quality modern presses like MetalStar include:
• Wear free ink metering ink blades with hard metal tips
• Single-train ink supply to the front form roller
• Segmented and side effect free inkzone settings
• Flexurally rigid, ceramic-coated ink duct roller
• Specially coated ink ducts for faster and easier cleaning
• Disengaging of unused inking units
• Ink cooling system / Inking unit temperature control
• Motorized adjustment of oscillation timing (stepless
during production)
• Ink run-in programs
• Differential drive for dampening form roller (switchable during production)
© KBA-MetalPrint Page:27
MetalStar / Ink repelling foil
KBA Σ Duration Without Σ Duration
Duration for 1,000 ink
duct cleanings
5 min. x 1,000
60
= 83,34 h 7 min. x 1,000
60
= 116,67 h
10 20 30 40 t [h]
KBA
Competitor
29 % savings
50 60 70 80 90 100 110 120
© KBA-MetalPrint Page:28
KBA Metal Decorating
Automation Examples - „PRINTING UNIT“
Combimatic
CombiMatic (standard)
• Automatic roller washing
CombiMatic (Cloth-System)
• Automatic plate cylinder washing
• Automatic blanket cylinder washing
• Automatic impressions cylinder washing
© KBA-MetalPrint Page:30
KBA Metal Decorating
Automation Examples - „PRINTING UNIT“
Plate Change
Plate Change Systems
FAPC – Fully Automatic Plate Change
(option)
SAPC – Semi Automatic Plate Change
(standard)
• Automated plate change
• Pneumatic opening and closing of the plate cylinder
guard
• Automatic rotation to the change positions
• Automatic clamping and tensioning of the plate clamps
• 40 sec. per unit
• Change process includes register zeroing
• Plate change completed in 3 cycles
• Parallel changing in several printing units
• Fast and optimised change process with change
time of 3-4 minutes, including register zeroing
• Divided rear plate clamps
• All units in 3-4 minutes, it doesn’t matter how
many
© KBA-MetalPrint Page:32
FAPC (Fully Automatic Plate Change)
• Simultaneous change in 3 cycles
• Plate change completed in less than
4 minutes
© KBA-MetalPrint Page:33
Duration Plate Change for 1,000 plate changes
2222 FAPC Σ Duration Without Σ Duration
Duration Plate Change
3,5 min. x 1,000
60
= 58,33 h 1 min. x 6 units 1,000
60
= 100,00 h
20 40 60 80 t [h]
KBA FAPC
Others
+ 42 %
100
© KBA-MetalPrint Page:34
KBA Metal Decorating
Automation Examples - „PRINTING UNIT“
Press and Ink Control Devices
• Printing unit configuration at the console
(activate/deactivate,operating modes)
• Sheet travel configuration at the console
(sheet guiding / sheetformat / settings)
• Ink/dampening control at the console
(CIP3 / memory / ink profile settings)
• Configuration of washing systems and programs
(rollers / blanket/ imp. cyl. / plate)
• Configuration of auxiliaries
(dampening solution / temperature control / ...)
• Advance job preparation at the console or via
LogoTronic
ErgoTronic
© KBA-MetalPrint Page:36
ErgoTronic
Remote register setting
• Lateral
• Circumferential
• Diagonal
Remote distributor start setting
© KBA-MetalPrint Page:37
ErgoTronic
Automatic sheet size setting Remote Control of printing pressure
© KBA-MetalPrint Page:38
DensiTronic Professional
Density- and Spectral measuremt and Control with Dynamic ink control
• DensiTronic Professional -
is an automatic colour
measuring system. Its
motorised measuring head is
able to scan control strips at
any position on the printed
sheet.
© KBA-MetalPrint Page:39
ACR-Control (Automatic Camera Register)
• 2 measuring fileds on the sheet up to 5
resp. 7 colours
• Automatic measuring field detection
• Automatic register control of all 3
register directions
© KBA-MetalPrint Page:40
Process automation with LogoTronic – CIP3 / CIP4
CIP3 PPF Cip3 Link
• Interface for processing of CIP3 PPF data
from prepress to the machine console
CIP4 JDF LogoTronic Professional
• CIP4 JDF Production management & shop floor data collection (SFDC)
• LogoTronic Professional are offered with an CIP4 JDF interface for data exchange
with MIS (order-, resource- and shop floor data)
=> Postcalculation / Jobcosting
• LogoTronic Professional for networked printing houses with complete CIP4 JDF
workflow
© KBA-MetalPrint Page:41
KBA Metal Decorating
1. KBA-Group – KBA-MetalPrint GmbH
2. Automation Examples - „PRINTING UNIT“
3. Customers Benefits
4. Outlook METPACK 2014
Format changing silmutan (1 min.) P + H
Impression cylinder washing (4 min.*) A
Changing pile feeder/stacker (3 min. simultan) P + H
Plate changing (4 min.) P
Blanket washing (4 min.) A
2. Print (4 min.) P
3. Print (4 min.) P
1. Print (4 min.) P
3 Min. 1
3. Print
.
Minutes
14 2 4 6 8 10 12 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48
Ink run-in (1 min.) P
Make-Ready-Diagram MetalStar PR-6 UV
4 Min. 4 Min. 4 Min. 1 ** Makeready time
= 22 - 30 min. per 4–6 C job,
depending of quality of first
sheet and number of
adjustment processes
2. Print
* average washing time, as not to be washed every job
** The value given are usage based averages that may vary depending on press features, process settings, operating conditions, quality specifications.
5 Min.
A Inking roller washing (5 min.)
6 Min.
P + H Cleaning Ink chamber, refilling (6 min.)
1. Print
© KBA-MetalPrint Page:43
• 22 days, 3 shilfts with 500-550 hrs production time
• 1.200.000 – 1.800.000 sheets
• 600 – 700 printjobs
• 4-6 colours
• Including ink fountain and roller cleaning
Results of modern Printing machines
Average of a normal production month – reality!
Every 30 to 40 minutes a new job
© KBA-MetalPrint Page:44
KBA Metal Decorating
1. KBA-Group – KBA-MetalPrint GmbH
2. Automation Examples - „PRINTING UNIT“
3. Customers Benefits
4. Outlook METPACK 2014
New press developments:
• Only presses with modern multi roller inking unit design like
mentioned
• With modern features like declutchable inking units, Ink run in
programs a.s.o.
The new Mailänder 280
• and….
• much more on Metpack 2014
KBA-MetalPrint will show on Metpack 2014:
© KBA-MetalPrint Page:46
KBA Metal Decorating
KBA-MetalPrint GmbH
www.kba-metalprint.de
Thank you very much for your attention
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