implementing press upgrades · 2011-11-29 · implementing press upgrades press upgrade / retrofit...

MAURER SERVICES, © 2010

MAURER SERVICES UG

Implementing Press Upgrades

Cost control andRevenue

opportunities in newspaper

production

18 to 19 January 2010, New Delhi, India

Dr.-Ing. Andreas Maurer

WAN IFRA Seminar

MAURER SERVICES, © 2010 2

Implementing Press UpgradesPress Upgrade / Retrofit

AGENDA

1. Introducing MAURER SERVICES2. Press Upgrade – reasons for it3. Press Upgrade – what is possible3. Press Upgrade – what to think of4. Press Upgrade – one example


Implementing Press UpgradesIntroducing MAURER SERVICES

MAURER SERVICES

Completed with a service and trade department we are a

- designing- producing- installing- starting-up

Your and our ideas to improve and upgradeWeb-Offset and Rotogravure Machines

is …

full service partner for the printing industry

is producing

salt-less and chemical-freeReverse Osmosis Systems (RO)

for process water and drinking-water


Implementing Press UpgradesReasons for

• Make the press ready for new demands … make it ready for the future

- economical- technical

• Solve problems with the press

PRESS UPGRADE / RETROFITReasons for

Don’t want to invest in a new machine


Implementing Press UpgradeReasons for

• New needs for the newspaper• additional products for additional

production time of the printing press

• improving availability• improving reliability• improving stability of printing process• improving printing quality• reducing wasted paper• standardization (ensure repeatable conditions)• etc. Printing press

Peripheral equipment

Basic Considerations

Demands For / From Market

PRESS UPGRADE / RETROFIT – Ready for new demands / for the future




• improving availability• improving reliability• improving stability of printing process• improving printing quality• reducing wasted paper• standardization (ensure repeatable conditions)• etc.


• Electronic and control systems• changing single parts• upgrade of existing system• cross-grade to other supplier• register systems

• backup systems (f. e. additional folder)• single drives• spare parts running out

Printing Press



• improving availability• improving reliability• improving stability of printing process• improving printing quality• reducing wasted paper• standardization (ensure repeatable conditions)• spare parts running out • etc.


Peripheral Equipment

• modify CtP-System• invest in automatic ink supply• install a water treatment system• invest in inserting machines instead of using man power• etc.



Implementing Press UpgradeDemands For/From the Market

• New needs for the newspaper• additional products for additional

production time of the printing press

Demands For / From MarketPRESS UPGRADE / RETROFIT – Ready for new demands / for the future

• increase number of pages• increase number of colours• Semi-Commercial printing• cutting• trimming• folding possibilities• imprints• stitching• new / variable format size• etc


Implementing Press UpgradeWhat is possible

Basic ConfigurationPRESS UPGRADE / RETROFIT – Ready for new demands / for the future



Additional coloursPRESS UPGRADE / RETROFIT – Ready for new demands / for the future



Additional pages / full colourPRESS UPGRADE / RETROFIT – Ready for new demands / for the future



Semi-CommercialPRESS UPGRADE / RETROFIT – Ready for new demands / for the future



Back-Up-Folder to increase the availabilityPRESS UPGRADE / RETROFIT – Ready for new demands / for the future



in double-width machinesPRESS UPGRADE / RETROFIT – Reduction of web-width



in double-width machinesPRESS UPGRADE / RETROFIT – Reduction of web-width

by reducing the web width:

“quarter-line” movestowards to centre-line

Folder and folder superstructure:- formers has to be modified

Ribbons getting smaller:- driven rollers,- pins, - belt-systeminside the folder has to be modified

Modification of the Printing Unit:- ink boxes- rubber rollers- dampening unit (spraying, brushes)- plate cylinder (registration system, etc.)


Implementing Press UpgradeWhat to think of

PRESS UPGRADE – Reduction of web-width

Plate cylinder

some 1/100 mm Plate Cylinders:

- refurbish plate cylinders

Plates:

using “old size” panorama plates:-registration system can stay

using “new size” panorama plates orsingle plates:-registration system has to be modified



Picture Source: IFRA Special Report 10.2008

Double-truck as posterPRESS UPGRADE – New products – quality of machine

critical era if machinewas running withside-wide plates overlong time

Plate cylinder

some 1/100 mm



Picture Source: Tolerans

PRESS UPGRADE – Skip SlitterTabloid insert in a Broadsheet



Picture Source: Vits

PRESS UPGRADE – Plow or pre-foldSuper-Panorama-Pages

Installations in India:- Times of India, Mumbai (MAN)- Hindustan Times, Mumbai (MAN)- DNA, Bangalore (KBA)- DNA, Ahmedabad (KBA)



jaw cylinder spider wheel

2nd longitudinal fold as stand-alone-systemPRESS UPGRADE – Magazine fold

• supplements• manuals• books• etc.

transfer drumA3 exit

New products



Flexo-ImprinterPRESS UPGRADE – Variable Imprints

• page-wide imprints• flexible usage

- inks- smelling inks- gloss paint- etc.



alternatingorder

Imprints on pages close toeach other




ordered in a row

registered Imprints witha change of the sujeton the fly

this means:without stopping the machine




ElectronicPRESS UPGRADE / RETROFIT – Ready for new demands / for the future

S5-115U Unit S7-ET200 UnitPicture Source: SIEMENS, MA




Control PC

new

Picture Source: SIEMENS, MA

old




Main Drive

Picture Source: SIEMENS, MA

oldnew

Dampener Drive

old

new



Some questions (non economical)


What do I want to modify on my press?

Do I need the complete machine for my daily production?

Who is the right partner to run the project?

Is it possible to upgrade my machine in daily production?

Fits the condition of my machine the production of the new product?

What do I want to produce? What do I have to modify?

Is my building suitable for upgrading my machine?

Who is my project team?


Implementing Press UpgradeOne Example

UPGRADE and RETROFIT PROJECT

6 I-Printing-Units, 4 Y-Printing-Units2 Foldersno Reel-Splicerno Register Control SystemBaumüller Control System with SIEMENS S5

Machine KBA, Compacta 213, cut-off 630 mm

before:

Basic configuration



UPGRADE and RETROFIT PROJECTBasic configuration – schematic view

un-winder



Project description



before:

after: 14 I-Printing-Units, 4 Y-Printing-Units2 Folders5 Reel-Splicer, webbing-up device Register Control for cut-off and colourSIEMENS Control System S7, Ink key, control desksmodem connection


• 2 additional web full colour• automation• independent production of the sections



Project description



before:


after: 14 I-Printing-Units, 4 Y-Printing-Units2 Folders5 Reel-SplicerRegister Control for cut-off and colourSIEMENS Control System S7, Ink key, control desksmodem connection

Our Job:

• Find suitable printing units and reel-splicer• Basic engineering work• Offer the project

• Detailed engineering work• Producing all needed mechanical parts• Scheduling the installation and start-up• mechanical and electrical installation

• Start-up

Conditions:

no possibility to change building

Machine was the only onefor regional daily newspaper

DAILY PRODUCTION NEEDED



UPGRADE and RETROFIT PROJECT – Installation Phase 1Steel platform

Installing the steel platforms



UPGRADE and RETROFIT PROJECT – Installation Phase 1Install “new” Printing Units

and additional control desk

Reel-Splicers

switchgears (not shown)single drives

transmitters

towers of cut-offregistration (not shown)



reel splicers90° acrossto centre lineof machine

switchgears



UPGRADE and RETROFIT PROJECT – Installation Phase 2Electrical Installation

Start-Up with additional control desk

Installing new printing units and

machine inproduction





modification ofcontrol desk No. 1

connectingnew andold machine

prepare forproductionin next step





modification ofcontrol desk No. 2

connectingnew andold machine

prepare forproductionin next step

take out additionalcontrol desl



UPGRADE PROJECT – Installation Phase 3Full production – Take over procedure

4 webs 4 over 42 webs 1 over 1

Register towersnot shown in sketch



UPGRADE PROJECT – Installation Phase 3Take over procedure


Implementing Press UpgradeFinish


Thank you for your attention

Dr.-Ing. Andreas MaurerMAURER SERVICESTiefenthaler Straße 14D - 67280 Ebertheim

http://[email protected]

implementing press upgrades · 2011-11-29 · implementing press upgrades press upgrade / retrofit...

Documents