copyright 2008 komori corporation. all rights reserved. print forum 2011 komori with...
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Copyright 2008 KOMORI Corporation. All Rights reserved.
Print Forum 2011Print Forum 2011
Komori with “OffsetOnDemand”Komori with “OffsetOnDemand”
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Todays topics
Komori IntroductionKHS-AIH-UVOffsetOnDemand
Komori IntroductionKHS-AIH-UVOffsetOnDemand
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Komori Introduction For more than 80 years, since 1923, the Komori Group has been producing
offset printing presses.
Employees : 2,471 persons
Main products: Sheet-fed Web-fed Komori Chambon Currency and Security Printing Presses
Komori CZ Office
For more than 80 years, since 1923, the Komori Group has been producing offset printing presses.
Employees : 2,471 persons
Main products: Sheet-fed Web-fed Komori Chambon Currency and Security Printing Presses
Komori CZ Office
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Innovative
Latest Technology to improve profitability and respect the environment
KHS-AI + H-UV = OffsetOnDemand
Latest Technology to improve profitability and respect the environment
KHS-AI + H-UV = OffsetOnDemand
Copyright 2008 KOMORI Corporation. All Rights reserved.
KHS-AIKHS-AI
Latest Technology to improve profitability and respect the environmentLatest Technology to improve profitability and respect the environment
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KHS-AI
Today's issues in the press room Standardize printing procedure Digitize print quality control Reduce waste Reduce lost time between jobs
KHS-AI Concept Standardize the colour matching operation No waste sheets used for color matching Reduce make-ready sheets to 20-30 sheets Get standard density within 20 sheets Limit density change on the run
Today's issues in the press room Standardize printing procedure Digitize print quality control Reduce waste Reduce lost time between jobs
KHS-AI Concept Standardize the colour matching operation No waste sheets used for color matching Reduce make-ready sheets to 20-30 sheets Get standard density within 20 sheets Limit density change on the run
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KHS-AI
Fast Print start - Instant colour and register Pre-Inking - Auto learning Smart Feedback – Density change without paper Register Preset - Auto learning Air Preset - Self learning Smart Sequence – Automatic job change
Fast Print start - Instant colour and register Pre-Inking - Auto learning Smart Feedback – Density change without paper Register Preset - Auto learning Air Preset - Self learning Smart Sequence – Automatic job change
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KHS-AI
The Intelligent Way to Increase Profitability
Productivity with unparalleled performance Lasting performance over press lifetime Automatic Intelligence for smarter production Future proof applicationCost savings on:
Paper Time Inks Chemicals Electricity
Lower cost of production than any similar machineFast return on investment
The Intelligent Way to Increase Profitability
Productivity with unparalleled performance Lasting performance over press lifetime Automatic Intelligence for smarter production Future proof applicationCost savings on:
Paper Time Inks Chemicals Electricity
Lower cost of production than any similar machineFast return on investment
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KHS-AI - Cost Advantages
KHS-AI reduces start-up paper waste by about 80% KHS-AI saves 30 tons of paper a year per machine KHS-AI intelligent pre-setting reduces lost production time KHS AI increases productivity, reduces chemical waste KHS-AI saves electricity KHS-AI reduces ink consumption by 30 to 35 % KHS-AI is a Komori Patent, there is no equal in the industry
KHS-AI reduces start-up paper waste by about 80% KHS-AI saves 30 tons of paper a year per machine KHS-AI intelligent pre-setting reduces lost production time KHS AI increases productivity, reduces chemical waste KHS-AI saves electricity KHS-AI reduces ink consumption by 30 to 35 % KHS-AI is a Komori Patent, there is no equal in the industry
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KHS-AI - Pre-Inking The self-learning function creates an automatic compensation curve
corresponding to the changes in conditions. The self-learning function creates an automatic compensation curve
corresponding to the changes in conditions.
Pre-Inking 2
Basic Ink film formed Ink profile added
% of image
Ke
y
Op
en
ing
% of image
Ke
y
Op
en
ing
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The compensation curve will change automatically after pushing the update button. Inking, register, press pre-setting are more accurate as conditions change.
The compensation curve will change automatically after pushing the update button. Inking, register, press pre-setting are more accurate as conditions change.
% of image
Key
Op
enin
g
Update
KHS-AI - Pre-Inking
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KHS-AI - Job Change Control
1. De-inking rollers
1-a.(Ink roller cleaning)
2. Blanket Cleaning
2-a.(Impression cylinder cleaning)
3 . Plate Changing
4 . Pre-Inking
5 . High speed start up
6. Run 30 sheets and wait for OK
All these procedures can be handled automatically by…
KHS-AI "Smart Sequence"
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High Speed Start-up High Speed Start-up at 12,000 sph Time to reach 30th copy Sheets required for Stable Density Sheets required Stable Register
High Speed Start-up at 12,000 sph Time to reach 30th copy Sheets required for Stable Density Sheets required Stable Register
Approx. 40% SavingApprox. 40% Saving
Approx. 60% SavingApprox. 60% Saving
Approx. 60% SavingApprox. 60% Saving
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KHS-AI - Cost Reduction Effect on an LS 29
What If you could reduce just 100 sheets waste per job ?…
Case 1 : 1 day operation, complete 30 jobs…100 Sheets of 135 gsm paper = 5.5kg x 30jobs x $1.50per kg = $247 cost saving per day
Case 2 : 25 days operation per month $247 x 25 working days = $6,175 cost saving per month
Case 3: 5 years operation using KHS-AI$6,175 x 60 months = $370,500 in 5 years
+ Power savings (about $300 per month) x 60 = $18,000 in 5 years
Total Saving over 5 Years in Paper and Power = about $388,000
+ Ink & Chemicals savings over 5 years (± $7,000)
KHS-AI can easily save you $395,500 in 5 years
What If you could reduce just 100 sheets waste per job ?…
Case 1 : 1 day operation, complete 30 jobs…100 Sheets of 135 gsm paper = 5.5kg x 30jobs x $1.50per kg = $247 cost saving per day
Case 2 : 25 days operation per month $247 x 25 working days = $6,175 cost saving per month
Case 3: 5 years operation using KHS-AI$6,175 x 60 months = $370,500 in 5 years
+ Power savings (about $300 per month) x 60 = $18,000 in 5 years
Total Saving over 5 Years in Paper and Power = about $388,000
+ Ink & Chemicals savings over 5 years (± $7,000)
KHS-AI can easily save you $395,500 in 5 years
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Komori Technology improves the environment and your profitability at the same time
1 tree produces 3 tons of dry wood (2.5 tons of paper) 3 tons of wood makes 37,500 sheets of 40" size coated paper In 1 year a 40" press uses 533 trees (avg. 20million sheets) Average total waste paper is 5% (26 trees) Average start-up waste on a standard press is 200 sheets When we use KHS-AI we can save 160 sheets per start-up Even at only 10 jobs per day you will save 400,000 sheets
(25 tons of paper) or ten trees per year when you use KHS-AI
1 tree produces 3 tons of dry wood (2.5 tons of paper) 3 tons of wood makes 37,500 sheets of 40" size coated paper In 1 year a 40" press uses 533 trees (avg. 20million sheets) Average total waste paper is 5% (26 trees) Average start-up waste on a standard press is 200 sheets When we use KHS-AI we can save 160 sheets per start-up Even at only 10 jobs per day you will save 400,000 sheets
(25 tons of paper) or ten trees per year when you use KHS-AI
Copyright 2008 KOMORI Corporation. All Rights reserved.
Komori H-UVKomori H-UV
Brand newBrand new
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Drying systems used in offset printing
Sheet-fed machines Oxydation: Ink is dried by atmospheric oxygen. IR: Uses expensive IR heat to accelerate oxydation drying Classic UV: Mercury UV light causes photo-polymerisation to cure the ink LED-UV: Special LED-UV light causes photo-polymerisation to cure the ink
Sheet-fed machines Oxydation: Ink is dried by atmospheric oxygen. IR: Uses expensive IR heat to accelerate oxydation drying Classic UV: Mercury UV light causes photo-polymerisation to cure the ink LED-UV: Special LED-UV light causes photo-polymerisation to cure the ink
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Oxydation drying – good points and bad points
Good points Most common system, easily understood. Cost it is low compared to other drying systems
Bad points Lost time waiting for drying. Factory floor space needed for drying paper. Reverse side scratching if drying is not complete. Need to use troublesome spray powder. Need to use small stacks on difficult materials/jobs
Good points Most common system, easily understood. Cost it is low compared to other drying systems
Bad points Lost time waiting for drying. Factory floor space needed for drying paper. Reverse side scratching if drying is not complete. Need to use troublesome spray powder. Need to use small stacks on difficult materials/jobs
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UV Drying - good points and bad points
Good points Instant drying No need for floor space for drying paper. Easy to turn over and print reverse side No spray powder so clean press environment Small stacks not necessary
Bad points Installation cost and running cost are high Because heat and ozone occurs, rust-proofing and ducting is needed Odour and taint problems can happen
Good points Instant drying No need for floor space for drying paper. Easy to turn over and print reverse side No spray powder so clean press environment Small stacks not necessary
Bad points Installation cost and running cost are high Because heat and ozone occurs, rust-proofing and ducting is needed Odour and taint problems can happen
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Principle of UV curing system
Classic UV lamp Ultraviolet rays between 200-600nm are output. 254nm wavelength generates ozone, Wave length above 400nm generates heat. Classic UV ink Using a photo initiator with 220nm-580nm reactivity
LED lamp Wave lengths of 365nm, 385nm and 395nm are possible. Manufacturers currently prefer 385nm and 395nm LED-UV ink Current photo initiator wavelength 385nm
Classic UV lamp Ultraviolet rays between 200-600nm are output. 254nm wavelength generates ozone, Wave length above 400nm generates heat. Classic UV ink Using a photo initiator with 220nm-580nm reactivity
LED lamp Wave lengths of 365nm, 385nm and 395nm are possible. Manufacturers currently prefer 385nm and 395nm LED-UV ink Current photo initiator wavelength 385nm
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UV light emitted by Classic UV
Ultraviolet
Infra-red
High energy Low energy
10nm
Electromagnetic wave and x-ray
400nm 780nm
Visible Light
1mm
Radio wave
Copyright - eye graphics
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Wavelength nm
UV
Pow
er
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Classic UV
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Merits of LED-UV LED life at least 15 times more than classic UV lamp
Classic UV lamp nominal 1,000 hours, LED 15,000 hours
LED power consumption approx. 20% of classic UV
Heat generation is low, machine stays cool Plastic and other difficult substrates have no register problems
Instantaneous on/off Classic UV start-up 1 minute, cool down 4 minutes
LED life at least 15 times more than classic UV lamp Classic UV lamp nominal 1,000 hours, LED 15,000 hours
LED power consumption approx. 20% of classic UV
Heat generation is low, machine stays cool Plastic and other difficult substrates have no register problems
Instantaneous on/off Classic UV start-up 1 minute, cool down 4 minutes
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UV light emitted by LED-UV
254nm
Ozone occurrence wave length
Heat generation
As for wave length eye graphics make
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120
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90
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Wavelength - nm
ou
tpu
t %
Classic UV
LED-UV
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LED-UV tests in Tsukuba
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Problems of LED-UV
Distance between lamp and substrate +/- 20mm Lamp housing less than 15mm causes problems with carton. Must be positioned over a cylinder to be close enough.
UV coating not yet available LED wavelength (385nm) causes coatings to “yellow”
LED lamp cost very high (+/- $200,000 for 1 lamp on 29”) LED lamp life is long, but exchange cost is high ($100,000?).
Distance between lamp and substrate +/- 20mm Lamp housing less than 15mm causes problems with carton. Must be positioned over a cylinder to be close enough.
UV coating not yet available LED wavelength (385nm) causes coatings to “yellow”
LED lamp cost very high (+/- $200,000 for 1 lamp on 29”) LED lamp life is long, but exchange cost is high ($100,000?).
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A system which can cure LED-UVA system which can cure LED-UV ink using just one ozone-freeink using just one ozone-free UVUV lamplamp
LED
Black
LED
Cyan
LED
Mag
LED
Yell
Ozone less UV lamp
The Hybrid UV system proposed by Komori
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Hybrid UV performance tests in Tsukuba 4 lamps on, 16,000sph printing OK 3 lamps on, 16,000sph printing OK 2 lamps on, 16,000sph printing OK 1 lamps on, 16,000sph printing OK
1 lamp at 50% power, 16,000sph printing OK
4 lamps on, 16,000sph printing OK 3 lamps on, 16,000sph printing OK 2 lamps on, 16,000sph printing OK 1 lamps on, 16,000sph printing OK
1 lamp at 50% power, 16,000sph printing OK
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UV spectrum comparison of Komori Hyper UV
As for wave length eye graphics make
254nm
Ozone occurrence wave length
Calorification territory
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120
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90
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90
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0-4
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0-5
00
wavelength nm
UV
ou
tpu
t %
Classic UV
LED-UV
Hybrid UV
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Advantages of Komori Hyper UV system Reduced initial cost (opposite of LED-UV)
Less than half price of LED-UV
Reduced lifetime cost of UV lamp (opposite LED-UV) Lamp life is shorter than LED-UV lamp but exchange cost is cheap,
Power consumption same as LED-UV plus compact power source Hyper UV15.8kw (lamp 10.2kw and water cooling 4.6kw on 32”).
Heat generation is low Dryer area + 4-5°
Ozone free Ozone generation wavelength (254nm) is cut.
Easy to print carton board Distance between lamp and substrate same as classic UV
Environmentally friendly printing LED ink has no VOCs No need for heat blower Reduction of CO2 emission
Reduced initial cost (opposite of LED-UV) Less than half price of LED-UV
Reduced lifetime cost of UV lamp (opposite LED-UV) Lamp life is shorter than LED-UV lamp but exchange cost is cheap,
Power consumption same as LED-UV plus compact power source Hyper UV15.8kw (lamp 10.2kw and water cooling 4.6kw on 32”).
Heat generation is low Dryer area + 4-5°
Ozone free Ozone generation wavelength (254nm) is cut.
Easy to print carton board Distance between lamp and substrate same as classic UV
Environmentally friendly printing LED ink has no VOCs No need for heat blower Reduction of CO2 emission
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Development concept of Hyper UV Komori investigated the best solution to printers in both price and
technology wise at this stage, we would like to contribute benefit to printers
Installation and running cost is low, allowing UV development into commercial printing.
Cost advantages between lamp life and exchange cost.
Overcomes a major defects with LED-UV, UV coating, no scratching on carton.
Komori investigated the best solution to printers in both price and technology wise at this stage, we would like to contribute benefit to printers
Installation and running cost is low, allowing UV development into commercial printing.
Cost advantages between lamp life and exchange cost.
Overcomes a major defects with LED-UV, UV coating, no scratching on carton.
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LS-440 (conventional) Remarks
Number of operating days
288 days Per year
Actual operating time
11.5 hours 12 hour working
Average run 3,000 sheets Per job
Production quantity
12.8 jobs Per day
Sales price 4,000 Yen Per edition
Ink cost 10 Yen Per colour /1 s
20% image
Electric power 92kw
Lamp change expense
0 Yen
Annual profit 26,158,548 Yen
LS-440 (H-UV) Remarks
Number of operating days
288 days Per year
Actual operating time
11.5 hours 12 hour working
Average run 3,000 sheets Per job
Production quantity
16.6 jobs Per day
Sales price 4,000 Yen Per edition
Ink cost 28 Yen Per colour /1 s 20% image
Electric power 131kw
Lamp change expense
2.2 times change 1,500hr life
Annual profit 27,122,908 Yen 964,360 Gain
Considering a 30% productivity increase
H-UV Profitability - compared to Conventional printing
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LS-440 (conventional) Remarks
Number of operating days
288 days Per year
Actual operating time
11.5 hours 12 hour working
Average run 3,000 sheets
Production quantity
12.8 jobs Per day
Sales price 4,000 Yen Per edition
Ink generation 10 yen Per colour /1s
20% image
Electric power 92kw
Lamp consumption expense
0 Yen
Annual profit 26,158,548 Yen
LS-440 (H-UV) Remarks
Number of operating days
288 days Per year
Actual operating time
11.5 hours 12 hour working
Average run 3,000 sheets
Production quantity
15.3 jobs Per day
Sales price 4,400 Yen Per edition
Ink generation 28 yen Per colour /1s
20% image
Electric power 131kw
Lamp consumption expense
2.2 times change per year
1,500hr life
Annual profit 30,291,281 Yen 4,132,733 gain
Considering Productivity + 20% and Sales Price +10%
H-UV Profitability - compared to Conventional printing
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H-UV ink Supplied by TOYO worldwide World-wide expansion with alternative ink suppliers Price comparable to regular UV Coverage 20% more than conventional ink Better colour hold-out (no dry back) Superior high gloss coatings
H-UV ink Supplied by TOYO worldwide World-wide expansion with alternative ink suppliers Price comparable to regular UV Coverage 20% more than conventional ink Better colour hold-out (no dry back) Superior high gloss coatings
H-UV INKS
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Classic UV Expensive installation and high running cost Produces ozone and heat (bad for m/c and environment)
LED-UV Overcomes a few of the issues with classic UV printing Expensive hardware, difficult to make a profit.
H-UV New printing technology using H-UV lamp and H-UV ink Lots of merit points compared with other UV processes. Superior printing quality and lowest production costs
Classic UV Expensive installation and high running cost Produces ozone and heat (bad for m/c and environment)
LED-UV Overcomes a few of the issues with classic UV printing Expensive hardware, difficult to make a profit.
H-UV New printing technology using H-UV lamp and H-UV ink Lots of merit points compared with other UV processes. Superior printing quality and lowest production costs
Summary
Copyright 2008 KOMORI Corporation. All Rights reserved.
KHS-AI + H-UV, adding Twenty MatchingKHS-AI + H-UV, adding Twenty Matching
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A system which matches a press sheet to a proof within 20 sheets of start-up
No change in quality after 20th sheet
A system which matches a press sheet to a proof within 20 sheets of start-up
No change in quality after 20th sheet
Twenty Matching - System
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Commercial sector Based on target density standards Using international printing standards Factory with environment control H-UV or conventional process inks
Commercial sector Based on target density standards Using international printing standards Factory with environment control H-UV or conventional process inks
Twenty Matching – Target Segment
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And when we combine KHS-AI, H-UV and Twenty Matching
We get !
And when we combine KHS-AI, H-UV and Twenty Matching
We get !
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Offset-On-Demand New business model for offset printers Competes with digital (Print On Demand) Three 200 copy jobs in 15mins Only 20 sheets waste (20 matching) Instant finishing
New business model for offset printers Competes with digital (Print On Demand) Three 200 copy jobs in 15mins Only 20 sheets waste (20 matching) Instant finishing
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Offset-On-Demand Can be used on straight or perfecting m/c Can be used with almost any substrate More profitable than digital over 400sheets Combined with near-line finishing equipment Can be combined with web-to-print
Can be used on straight or perfecting m/c Can be used with almost any substrate More profitable than digital over 400sheets Combined with near-line finishing equipment Can be combined with web-to-print
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Thank-you for your attention,
(See you soon for the demonstration)
Thank-you for your attention,
(See you soon for the demonstration)