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Integrated Print Quality Control Systems
High intensity white LED
PQA-S V54,096 pixels
0.25 mm/pixel
Ink splashes, scumming, water splashes, oil splashes, hickeys and color variations etc.
Subject to sensitivity setting
Retains the most recent 100 jobs. 1,000 records/jobMonthly defect history data (monthly for a year)
1,000 jobs/month, 1,000 records job
Option
Option
1,024 pixels1.0 mm/pixel
High-frequency ignition fluorescent lamp
Ink splashes, scumming, water splashes, oil splashes, hickeys and color variations etc.
Subject to sensitivity setting
Retains the most recent 100 jobs. 500 records/jobMonthly defect history data (monthly for a year)
300 jobs/month, 500 records/job
-
-
PQA-S SG2,048 pixels0.5 mm/pixel
Maximum printing speed
-
Plain paper
-
Standard-
CameraResolution*1
Light sourceMax. inspection speedTarget defects
Target substrates
Defect history (XML file)
Color control*2
Automatic registration*2
PQA-W
*1 Acutal value depends on press model.*2 Must be selected when ordering.
26"~ 44"
3.0 mm (H) x 3.0 mm (W)
Anywhere on sheet (However, not within 10 mm of gripper edge)
Automatic measurement of registered locationsBetween colors and front/back printing position
ISO12647-2 [PSO], GRACoL,Japan Color
Standard equipment (switchable per job)
Spectrophotometer
L*a*b*, ∆E etc.20"~ 44"
3.2 mm (H) x 3.0 mm (W)
Within 38 mm of sheet edge
Handheld instrument
ISO12647-2 [PSO], GRACoL
Option
26"~ 44", Enthrone seriesUp to 6 colors
(single-sided presses other than Enthrone)Manual
3.5 mm (H) x 4.0 mm (W)5 mm (height) recommended
Gripper from sheet lead edge: 10–40 mmTail edge: 2.5–40 mm
Manual (removable measurement head type)-
ISO12647-2 [PSO], GRACoL,Japan Color
Standard equipment (switchable)
Densitometer
-20"~ 40"
Up to 6 colors (up to 4 colors for perfectors and SP machines)
Automatic3.2 mm (H) x 3.0 mm (W)
Within 38 mm of sheet edge
Handheld (option)
-
Option
ModelSensor headDensity control functionsColor control functionsCompatible modelsNumber of colors
Positioning on color barPatch size (minimum)
Color bar position
Spot measurement
Automatic registration
Defect history
Polarizing filter
Density, dot gain, trapping, contrast, hue error, grayness etc.
Up to 11 colors (up to 8 colors for perfectors and SP machines)
Automatic
PDC-SX PDC-SII PDC-SG PDC-LITE II
Model
Note:Copyright © 2016 Komori Corporation all rights reserved. All specifications stated herein are current as of March, 2016. Maximum printing speed may differ from specification herein. Komori reserves the right to change specifications on machines without notice and without obligation to modify equipment previously manufactured. Because of changes in design, specification, or optional attachments and accessories, the machine actually delivered may differ in appearance and performance from that shown in this brochure. The trademarks and logos of Komori Corporation or others used on this brochure are the property of Komori Corporation or their respective owners. Nothing contained in this brochure grants by implication, waiver, estoppel or otherwise, any right to use any trademark displayed on the brochure without the written permission of Komori Corporation or the respective owner.
KOMORI Print Management Solutions: Specifications
PQA Series Specifications
PDC Series Specifications
PMS en JPN 12P M21 4 Mar.2016 02K MP
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OUTLINE
The Ultimate Answer to Short Runs and Quick Turnarounds
DigitalOnDemand through Coordination with Digital Technologies
The relationship between digital and IT technologies in the printing industry is growing
deeper and convenience is becoming ever more important. Komori’s new solutions have
offset printing as the core working in concert with digital printing and postpress.
20Matching Concept
KHS-AI (Advanced Interface)
KOMORI CMS Solutions
Start production printing within 20 sheets of print start-up
20Matching Concept and Color Management
20Matching is a Komori technology that transcends the standard perceptions of the offset
printing industry by matching standard colors within 20 sheets of print start-up. Komori has
developed the new Komori CMS Solutions to work together with the KHS-AI integrated control
system, a core Komori 20Matching technology. Komori CMS Solutions consist of three tools that
only a specialist press manufacturer like Komori could create. The first is K-PressNavi operator
support software for the stabilization of offset printing. The second is K-ColorChecker print
quality analysis software. And the third is K-ColorSimulator high-level color matching software,
which makes CMS proof setting tasks, that were complex and difficult up to now, extremely easy
for today’s workforce.
OffsetOnDemand
OffsetOnDemand is Komori's system to facilitate short runs and quick turnarounds by shortening
makeready time, cutting paper waste and reducing the printing process to the absolute
minimum while maintaining the high print quality and productivity of offset printing. The core
of Komori's revolutionary new OffsetOnDemand printing system is the fusion of the KHS-AI
integrated control system, the award-winning H-UV and the new leading edge Color Management
System. The result — OffsetOnDemand is the ultimate short run and quick turnaround solution
for today's highly competitive printing marketplace.
H-UV: Innovative Powderless UV Drying System
H-UV is the core technology of OffsetOnDemand. This is a revolutionary UV curing system that
enables instant curing using a H-UV lamp developed with Komori know-how and high-sensitivity
UV inks. H-UV enables immediate curing with just one lamp for each printed side of the sheet
and offers ecological and economic benefits as well as high quality and reliability.
KOMORI Products that Support OffsetOnDemandKOMORI Print Management Solutions
For OffsetOnDemand to enable short runs and quick turnarounds, the combination of PDC Series products and PQA
Series products that support digital control of print quality and high-level print quality control drives print process
optimization and dramatically raises productivity.
Series
Series
Optimization of Printing Tasks by Komori Products
Changeover/test printing
Series
Checking print quality
Series
Maintaining print quality
Printing tasks
For integrated control
For maintaining print quality
Series
Series Series
Series
For checking print quality
Integrated control system for Komori products that reduces paper waste, shortens makeready times, manages data and links various systems.
Checks standard print quality by digitizing colors and register.
Maintains print quality by inspecting quality and controlling colors.
H-UV Innovative Curing SystemInnovative System for Instant Curing
54
High Precision Preset Function(Self-Learning Function)Paper waste at print start-up is reduced to an
absolute minimum, makeready time is shortened,
and resources are substantially saved by
automatically analyzing and calibrating preset
data and optimizing color matching according to
changes in the machine, the printing
environment and printing materials.
Komori Offset Printing Press
Komori Web Offset Press
Automatic calibration using update results
Printing materials
Changes in environment
Paper gradePaper sizeFold specification
Air PresetsCentral management of all air control units in
the sheetfed press. Very effective in stabilizing
sheet feeding and delivery by making presets
that match the sheet size and thickness as well
as paper grade and grain.
Printing Task Optimization withKHS-AI as the CorePrinting task optimization can be advanced and
printing productivity can be greatly enhanced by
combining KHS-AI with PDC Series, for print quality
digitization, and PQA Series, for high-level print
quality control.
AI-Link(Integrated Control System for Web Offset Presses)Automatic control of fine adjustments at print
startup in addition to KHS-AI preset functions.
AI-Link provides integrated control of
peripheral devices in addition to control of all
units from the splicer to the folder.
These control synergies offer unprecedented
reduction of paper waste and extremely short
makereadies.
Self-DiagnosticsIn addition to managing the operating record, this
function provides graphs of trend data to assist in
understanding the press status. It also informs the
operator of press maintenance conditions. By
providing a self-diagnostic to prevent the
occurrence of problems, the system also helps to
minimize press down time.
KHS-AI (Advanced Interface)
Integrated Control for Shorter Makereadies, Less Paper Waste and Reduced Machine Down TimeKHS is an innovative productivity enhancement system developed to reduce job changeover time and paper waste
to an absolute minimum. The system uses job data from the MIS-linked K-Station and preset data from PCC, which is
linked to the CTP workflow. Plates output by a CTP system and preset data calculated from CIP4/PPF data enable
first-pull register accuracy and color matching. KHS-AI with self-learning is a further evolution of this KHS system.
Preset data is optimized by a self-learning function attuned to changes in the machine, the printing environment
and the printing materials.
On sheetfed presses, air and register adjustment preset functions — corresponding to the paper size, thickness,
grade and grain — ensure stable sheet feeding and delivery. On web offset presses, all tasks, including changes in
the fold specification, are automatically controlled, substantially reducing makeready time and paper waste. In
addition, the system manages job control, operation history and maintenance data and includes a self-diagnostic
function for troubleshooting.
A cylinder airCentral airAir above sheet release
Upper fan
5 air blows above pile
Suction drum
Decurler
Delivery air guide
Transfer cylinder air guide
Impression cylinderupper air
Sucker blowSucker vacuumSide lay
Suction boardFeedboardAir side layDriven front register lay
*Preset locations differ according to press specifications.
Web Press KHS-AI
Sheetfed KHS-AISmart FeedbackLinked to a PDC Series product, Smart Feedback
shortens color matching time and is very effective
in reducing paper waste by automating
everything up to formation of the ink film
thickness in the inker before printing and
providing conventional ink key opening feedback.
Density
Standard density
Target density
0 200 Number of copy100
Approximately 90 percent reduction of waste paper
Conventional FeedbackSmart FeedbackAutomatically replenishes
the necessary amount of ink before printing
Smart SequenceSmart Sequence is the ultimate short makeready
system, allowing the main makeready processes
from the end of one job to the start of the next
job to be started with just the touch of a button.
Virtually the entire makeready process is
accomplished automatically and seamlessly. This
reduces operator load and improves both print
quality and productivity.
1.Creation of job changeover data
5.Plate changing (Full-APC)
Smart Sequence start
7. Key presets
8. Web presets
9. Dryer heat-up
10. Pre-inking
6. Folder changeover
2.Ink removing
3.Blanket washing
4.Paper roll changing
2.Ink removing1.Finish
3.Blanket washing
4.Paper size and thickness
presets and air presets
6.Pre-inking and register presets
7. Test printing
8.Measurement by PDC-SII
9.Register adjustment
10. Production printing
5. Impression cylinder cleaning
plate changing (Full-APC)
Smart Sequence Operation Flowon Sheetfed Presses
ChillstandChillstand
Printingunit
Printingunit
SplicerSplicer
WebpathWebpath
FolderFolder
Komori-made
peripherals
Komori-made
peripheralsThird-partyperipheralsThird-partyperipherals
High QualityHigh ProductivityHigh Added Value
Short MakereadyCustomer Support
* Content of this catalog includes optional functions.
• Automatic register control• Dryer• Stacker-bundler
• Web guide• Cut-off• PQA-W
AI-LinkConcept schematic
PQA Series
PDC Series
LITHRONE Series+
KHS-AI
Pro
ductivity
Productivity enhancement by combinations of systems
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Print Density Control Series
Series
PDC Series devices are systems that digitize the colors on printed sheets – previously adjusted and controlled by the
operator. Densities, L*a*b* and dot gain can be measured and recorded by scanning the color bar on the printed
sheet. When there is a difference from the target density value, the measurement results are fed back to the press
and the ink key openings are automatically adjusted. For color matching at print start-up in particular, changeover
time can be considerably shortened and paper waste can be significantly reduced by using the PDC device with the
Smart Feedback function linked to KHS-AI. Compatible with ISO 12647-2, the international print standard, the PDC
system is indispensible. A variety of models are available for a range of press configurations and needs.
Standardized Printing with Shorter Changeovers and Less Paper Waste
Spectral Print Density Control SX Model
High-end multifunction model with automatic registration functionPDC-SX adds an automatic registration function to the color control function so that both color and register are measured in one process and the information is automatically fed back to the press. For the color control function, an automatic X-Y travel system is used so that measurement can be performed regardless of the position of the color bar to maximize the image area of the sheet. On a perfector, the bar can be located in the center of the sheet to cut waste. In addition, spot measurement of particularly important points on the image is possible. The automatic registration function works by using special register marks so that register is measured together with color in the same scan and any adjustments are automatically fed back to the press.
Spectral Print Density Control SII Model
Komori’s best seller, with more than 2,500 units in operationPDC-SII scans the color bar on printed sheets and measures densities, dot gain, colors, and color differences and then displays the results in an easy-to-understand format on the display. The system is equipped with a function that feeds back to the press the amount of adjustment necessary as calculated from the density values whenever a change in densities occurs during printing. Since PDC-SII is spectral, it is capable of measuring special colors. In addition, spot assessment of densities and colors anywhere on the sheet during the run is possible with the handheld measuring instrument. The system also provides a printout of measurement results and makes it easy to produce materials for a report.
Spectral Print Density Control SG Model
High Cost Performance Model for Color ManagementPDC-SG control color by measuring the color bar on printed sheets when density feedback to the press is based on density and Lab measurements. If spot measurements are required, the scanning head can be easily removed from the track and used as a handheld unit.
Scanning Density Control System
Density control with easy operation at a low investment pointPDC-LITEII is a CMYK process color density control system that can be equipped on Komori sheetfed presses up to 40 inches in size. Since PDC-LITEII provides digital control of densities with easy operation at a low investment point, it is the ideal system as the first step on the way to genuine digital control of print quality. Equipped with a function that feeds back to the press the amount of adjustment necessary as calculated from the density values whenever a change in densities occurs during printing.
Color Management• Color feedback by means of density and Lab
measurements*1
• Spot measurement of critical points
• Accommodates color bar in the center of the sheet
by means of automatic X-Y travel system (PDC-SX).
• Compatible with ISO 12647-2, G7 and JapanColor
reports
*1 Color feedback by Lab measurement available only with PDC-SX.
Automatic Register Adjustment Function (PDC-SX)
• Color register feedback control
• Front/back register feedback control
• Image position on paper feedback control
• High precision measurement with Komori’s
register marks
* Control point depends on press specifications.
CMS CompatibleK-ColorSimulator 2
Using K-ColorSimulator 2, Komori’s own CMS
software, high level color matching between the
offset press and a range of printers can be
achieved simply by measuring the K-Color chart in
the margin of the printed sheet using a PDC
device. With a proof consisting of a simulation of
the offset printing colors that is output ahead of
time, waste in the color matching work at printing
can be considerably reduced.
* K-ColorProfilerII (optional) is necessary to measure the K-Color chart when using PDC-SII.
Printingsample
Printingsample
Registerfeedback
Summary of Functions
PDC-SX
••
Automatic
•26" ~ 44"
PDC-SII
Spectrophotometer
••
Handheld
-
20" ~ 44"
PDC-SG
••
Manual*1
-
26"~44" (single-sided, up to 6 colors)Enthrone Series
PDC-LITE II
Densitometer
•-
Optional
-
20" ~ 40"(up to six colors)
Function/model
Sensor head
Density control function
Color control function
Spot measurement
Automatic registration
Compatible models
*1 Removable measurement head type.* For detailed specifications, see the back cover.
Output of simulation of offset printing colors from printer by means of K-ColorSimulator 2
Matching of colors from start-up offset printing using standard densities with colors of printer
PDC-SX
PDC-SII
PDF Comparator System (PDC-SX option)A file comparator system that uses sensors to read the printed image for comparison with the originating pdf or tiff file data has been developed and may be specified with PDC-SX. This allows the operator to check for missing or added characters in the initial printing stage, preventing production losses.
98
PQA Series systems ensure high-level print quality control by inspecting all sheets in-line on the press according to
the same assessment criteria, checking for defects such as scumming, ink splashes, water drops, oil and ink spots,
hickeys and color variations. Previously the operator was required to check for these items visually by regularly
sampling printed sheets. When a defect is detected in the inspection, the operator is notified by a horn and a
warning lamp and the tape inserter or rejecter in the delivery is automatically activated, reducing the amount of
paper waste in printing and preventing defective sheets from being sent to postpress with the production sheets.
The lineup includes models suitable to the full range of press configurations and needs.
High-level Print Quality Control through In-line Quality Inspection
Print Quality Assessment System Series
Series
Print Quality Assessment System for Web
After the installation of an inspection system, inspection criteria are tightened and
many false detections are reported. Since this increases the operator’s workload,
the system is lacking in serviceability. When tolerances are relaxed, a major incident
eventually occurs due to major defects being overlooked. Komori confronted such
issues of conventional inspection systems head-on. PQA-W Print Quality Assessment
System for Web is the result of the unstinting infusion of Komori’s most advanced
technologies. False detections due to curving or expansion/contraction of the web
are slashed unconditionally, and high-efficiency inspection is assured by the
adoption of cutting-edge technologies.
Print Quality Inspection FunctionThe system enables the loading of an accurate
initial reference image using a high-precision CCD
camera and lens by means of advanced light
source control technology. Any difference found
by comparing the initial reference image with the
image on the printed sheet using Komori’s own
inspection algorithm is detected as a defect.
The inspection history data, such as detected image
data and defective sheet count, is saved in a
database and can also be monitored over the
network.
Press Interlock FunctionThe inspection process is extremely simple.
At job changeover, the system is linked to the job
data from KHS-AI, and the job name and printing
paper information necessary for inspection is
automatically set. Simple, automated operation is
assured by Komori’s total integrated system,
including the automatic start of inspection by a
link to the production sheet counter of the press
when production printing starts.
PQA-S V5color control screen
Color Control/Automatic Register Adjustment FunctionsIn addition to print quality inspection, the lineup
includes models that offer color control and
automatic register adjustment.
PQA-S V5
[Inspection/Color Control Model]
Print quality inspection + color control*1
[All-in-one model]
Print quality inspection + color control*1 +
automatic register adjustment
*1 Color patch system (located on gripper edge or in center)
In-line Print Quality Assessment System for Sheetfed
Advanced model meeting a wide range of needs
Includes automatic air control preset function based on sheet size, thickness, grade
and grain direction for stability at the inspection point. Komori software
compensates for individual problem sheets, further enhancing detection accuracy.
Specific areas of the sheet can be designated for different levels of inspection
sensitivity. Lineup includes Inspection/Color Control Model, providing print quality
inspection and color control, as well as All-in-One Model, providing print quality
inspection, color control and automatic register adjustment.
High Cost Performance Model for Color Control
Contributes to stable color and reduced paper waste by in-line measurement and
feedback to press. Simplicity of operation is achieved through coordination with
KHS-AI and other Komori systems.
Komori sheetfed offset press
Komori web offset press
Inspection results• Horn and indication lamp• Tape, marker• Delivery processes
PresetsJob information• Job name• Inspection permissible value setting• Paper information• Fold specification
Detection mode changed automatically according to press status• Start of production printing, blanket washing etc.
Sheet Numbering System/Automatic Mask Creation Software (PQA-S option)
The sheet numbering system that numbers each sheet on the feeder board and a
new system that accurately recognizes die-cutting data and facilitates quality
control in units of blanks has been developed and may be specified with PQA-S.
Also, PQA-S masking software that automatically creates the inspection area in
advance from the die-cutting data has been developed. This further strengthens
print quality control for packaging.
Sheet Numbering System
* Restrictions apply to models on which these systems can be installed and to combinations of models and functions.
Series
1110
As printing machines gain more functions and operations become more complex, the load on the operator
must be addressed. KID is an operation support system that puts together the information needed by the
operator and presents it at just the right time in an easy-to-understand format. KID makes it possible to
maximize the total performance of the press and achieve higher productivity. In addition, KID collects and
displays information from KHS-AI, PDC Series and PQA Series.
Support System with Optimized Information Presentation
Komori Info-Service Display
Press monitor
Display of printing image in actual dimensions
DoNet for Komori OnDemand
PCC converts digital data from prepress into a PQC-format ink profile for the
press. Using the preview image from CIP4/PPF data to calculate the area
ratio and presetting the ink keys with this accurate data has become
standard practice in the industry. PCC also converts PPF data and CMYK-TIFF
data into PQC ink key data for Komori presses.
PQC CIP Communicator
K-Station provides central control of multiple Komori presses and functions
as an interface to outside systems (such as the Management Information
System [MIS]). This facilitates sending/receiving production data by CIP4/JDF
and permits data management. K-Station receives the digital job ticket (*1)
from the MIS and passes it to KHS-AI. A digital job ticket (*2) is compiled
from KHS-AI data and sent as feedback to MIS.
Printing Task Control Software/JDF Interface
*1 Digital job ticket (Project name, job name, materials, image, estimated number of sheets, start and end times etc.)*2 Digital job ticket (Number of printed sheets, number of production sheets, number of waste sheets, operational status, start and end times etc.)
Building a Digital Workflow with the DoNet ConceptDoNet is a digital workflow concept centered on digital-ready, high-performance printing presses — the final output
device of printed items — based on the press manufacturer's viewpoint of supporting printing standardization. For
linkage with prepress and postpress equipment, Komori assures world-class JDF connectivity and conducts frequent
interoperability testing with systems from other manufacturers and vendors. This way Komori implements open
architecture thinking with the priority on users' operating environments.
Navigation system that supports standardization of printing
Print quality analysis software
Easy color matching software
Calculation of ink feed quantityTask standardization
Calculation of ink feed quantityTask standardization
Interface between internal and external systems
SeriesStandard print quality maintenance,
measurement and feedback
Series
Standard print quality inspection and control
Job information interfacePrint start-up by self-learning function
ICC profile creation software
Operation support system
VideoScope
* For detailed information, see the KOMORI CMS Solutions catalog.
To profit from ‘color,’ Komori’s Total Color Management based on real printing standardization
Easy color matching software
Simulation of offset printing with printer
Stabilization and standardization of printing
Navigation system that supports standardization of printingK-PressNavi is a completely new printing information tool that displays operating navigation to the press operator and supports standard printing operations in the printing plant.
Print quality analysis softwareK-ColorChecker is a color control tool that analyzes print quality and color matching from the PDC measurement results and automatically creates a report.
K-ColorSimulator 2 is the core system of the Komori CMS, providing simple high-level color matching between the offset press and various printers.
*
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